1. ME407 MECHATRONICS SUKESH O P Assistant Professor Dept. of Mechanical Engineering JECC 10/16/2018 1 SUKESH O P/ APME/ME407- MR-2018

2. ME407 MECHATRONICS  Course Objectives:  To introduce the features of various sensors used in CNC machines and robots  To study the fabrication and functioning of MEMS pressure and inertial sensors  To enable development of hydraulic/pneumatic circuit and PLC programs for simple applications 10/16/2018 2 SUKESH O P/ APME/ME407- MR-2018

3. Expected outcome: The students will be able to i. Know the mechanical systems used in mechatronics ii. Integrate mechanical, electronics, control and computer engineering in the design of mechatronics systems ME407 MECHATRONICS 10/16/2018 3 SUKESH O P/ APME/ME407- MR-2018

4. Expected outcome: The students will be able to i. Know the mechanical systems used in mechatronics ii. Integrate mechanical, electronics, control and computer engineering in the design of mechatronics systems ME407 MECHATRONICS 10/16/2018 4 SUKESH O P/ APME/ME407- MR-2018

5. SYLLABUS  Introduction to Mechatronics, sensors, Actuators, Micro Electro Mechanical Systems (MEMS), Mechatronics in Computer Numerical Control (CNC) machines, Mechatronics in Robotics-Electrical drives, Force and tactile sensors, Image processing techniques, Case studies of Mechatronics systems. 10/16/2018 5 SUKESH O P/ APME/ME407- MR-2018

6. MODULE-I  Introduction to Mechatronics: Structure of Mechatronics system. Sensors - Characteristics - Temperature, flow, pressure sensors. Displacement, position and proximity sensing by magnetic, optical, ultrasonic, inductive, capacitive and eddy current methods. Encoders: incremental and absolute, gray coded encoder. Resolvers and synchros. Piezoelectric sensors. Acoustic Emission sensors. Principle and types of vibration sensors. 10/16/2018 6 SUKESH O P/ APME/ME407- MR-2018

7. MODULE-1 Introduction to Mechatronics : Structure of Mechatronics system. 10/16/2018 7 SUKESH O P/ APME/ME407- MR-2018

8. 10/16/2018 8 SUKESH O P/ APME/ME407- MR-2018 Introduction to Mechatronics  The term “Mechatronics" was first assigned by Mr. Tetsuro Mori, a senior engineer of the Japanese company Yaskawa, in 1969.  The word "mechatronics" was registered as trademark by the company in Japan with the registration number of "46-32714" in 1971.

9. Mechatronics  Mechatronics is a multidisciplinary field of science that includes a combination of mechanical engineering, electronics, computer engineering, telecommunications engineering, systems engineering and control engineering.  It specifically refers to multidisciplinary approach to product and Manufacturing system design. 10/16/2018 9 SUKESH O P/ APME/ME407- MR-2018

10. Mechatronics - definition  Mechatronics basically refers to mechanical electronic systems and normally described as a synergistic integration of mechanical engineering, electronics and intelligent computer control in design and manufacture of products and processes.  In other words : synergistic integration of mechanical engineering, electronic engineering, computer technology and control engineering in development of electromechanical products, through an integrated design approach. 10/16/2018 10 SUKESH O P/ APME/ME407- MR-2018 Synergistic – means various parts

11. 10/16/2018 11 SUKESH O P/ APME/ME407- MR-2018

12. Mechatronics 10/16/2018 12 SUKESH O P/ APME/ME407- MR-2018

13. Introduction to Mechatronics systems Advantages of Mechatronics systems Cost effective and Very good quality. High degree of flexibility. Greater productivity. Higher quantity and producing reliability. Greater extent of machine utilisation. Maintenance cost is less. Machining of complex designs can be done. 10/16/2018 13 SUKESH O P/ APME/ME407- MR-2018

14. Introduction to Mechatronics systems Disadvantages of Mechatronics systems  High initial cost.  Skilled worker is required.  Fault detection s complex.  Complicated design and system 10/16/2018 14 SUKESH O P/ APME/ME407- MR-2018

15. Introduction to Mechatronics systems Features/Characteristics of Mechatronics systems  High quality product.  High reliability and Safety.  Low coast.  Portable.  Produced quickly.  Serviceability, maintainability and upgradability. 10/16/2018 15 SUKESH O P/ APME/ME407- MR-2018

16. Introduction to Mechatronics systems Applications of Mechatronics systems  Automotives.  Flexible manufacturing systems(FMS).  Measurement systems.  Cd/DVD and setup boxes.  Robots employed in inspection and welding operations.  Scanners/photocopier/fax.  Automatic washing machines.  Air conditioners, elevator controls. 10/16/2018 16 SUKESH O P/ APME/ME407- MR-2018

17. Introduction to Mechatronics systems Scope of Mechatronics systems  Better design of products.  Better process planning.  Reliable and quality oriented manufacturing.  Intelligent process and production control.  Manufacturing of complex parts.  More Accurate and more precision of jobs. 10/16/2018 17 SUKESH O P/ APME/ME407- MR-2018

18. Components of a Mechatronics system 18 Structure of a Mechatronics system Electrical systems Controllers 10/16/2018SUKESH O P/ APME/ME407- MR-2018

19. Components of a Mechatronics system 1. Actuators: Produce motion or cause some action. DC motor, Stepper motors, servomotors, hydraulics, pneumatics 2. Sensors: detect the state of the system parameters, inputs and outputs. Switches, Potentiometer, Strain gauge, Thermocouple, digital encoder 3. Input signal conditioning and interfacing: provide connection b/w the control circuits and the I/P Discrete circuits, Amplifiers, Filters, A/D,D/D 4. Digital control architectures: Control the system. Logic circuits, microcontroller, PLC 5. Output signal conditioning and interfacing : provide connection b/w the control circuits and the O/P D/A, D/D, Amplifiers, Power transisters. 6. Graphical Display : Provide visual feedback to users.LEDs, Digital displays, LCD, CRT 10/16/2018 19 SUKESH O P/ APME/ME407- MR-2018

20. Modules In Mechatronic system  IM – Interface Module  ASM – Assembly Module  PM- Processor Module.  EM- Environment Module  CM- Communication Module  MM- Measurement Module  AM- Actuation Module  SM- Software Module 10/16/2018 20 SUKESH O P/ APME/ME407- MR-2018

21. Modules In Mechatronic system Environment module This module is concerned with the parameter like forces, temperature, speed and their effect on boundary of the system. This also deals with the dynamics and existence of the system and the function. Assembly Module Manufacturing mechanical and structural realization, part and system integration are the activities in this module. Input information is received from actuation module and output is given to measurement module. 10/16/2018 21 SUKESH O P/ APME/ME407- MR-2018

22. Modules In Mechatronic system Measurement Module Sensors and micro devices, transducers are the some components of this module, which supply information output to communication module. Gathers information about system status. Actuation Module Hydraulic, pneumatic and electric actuators, piezo- electric devices, microcontrollers are the systems identified few in this module. This module recieves information from the communication module for execution. 10/16/2018 22 SUKESH O P/ APME/ME407- MR-2018

23. Modules In Mechatronic system Communication Module this is concerned with transmission of information b/w modules within the system. The input and output information's reveal the nature of signal and distance over which it has to be transmitted and operating environment. This module mainly interacts with the processor module. Processor Module This is formed by micro processors, embedded and electronic circuits. This extracts information from communication module about measurement parameters, demand settings system parameters to be processed. This module interacts with interface module and the software module for information processing. 10/16/2018 23 SUKESH O P/ APME/ME407- MR-2018

24. Modules In Mechatronic system Software Module this module contains instructions for opening, defined algorithms, operation control programs of processor module. The nature and forms of instruction are linked to associate and interact with procesor module. Interface Module Between various levels in the system, are interfaced for transfer of information with interaction with processor module and the system representing the world. This provides man-machine interface for user information. The information is classified by nature od i/p x o/p. 10/16/2018 24 SUKESH O P/ APME/ME407- MR-2018

25. Levels of mechatronics system 1. Stand-alone systems, for ex: washing machine, compact disk player, auto focus camera, boat auto pilot, etc. 2. Systems with high level of distributed Sensor- microcontroller-relationships, for ex: wire aircraft. 3. A large factory system that is also a distributed system but which links a number of major subsystems such as machining centers, robots for part handling, automated inspection stations etc, 4. A system that incorporates intelligent control or artificial intelligence, for ex: humanoid robot. 10/16/2018 25 SUKESH O P/ APME/ME407- MR-2018

26. System 10/16/2018SUKESH O P/ APME/ME407- MR-2018 26  System is a group of physical components combined to perform a specific function. All mechatronics devices consist of systems. A system can be considered as a box that has an input and an output.  A control system can be considered as a device that is used to control the output of the system to a desired value. Ex: domestic air-conditioning

27. System 10/16/2018SUKESH O P/ APME/ME407- MR-2018 27 Electric Generator OutputInput Mechanical rotation Electric power

28. Measurement systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 28 Digital Tachometer OutputInput Rotation of a shaft Number on the LED display SUKESH O P/ APME/ME407- MR-2018

29. Introduction to Measurement systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 29 Elements of measuring system  1. Transducer : is a sensing that converts a physical input into output, usually voltage.  2. Signal processor: performs filtering and amplification functions.  3. Recorder: records or displays the output of signal processor. Transducer Signal Processor Recorder

30. Functions of Instruments and Measurement systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 30 1. Indicating function: 1. Indicating function: Examples :- (1) A pressure gauge is used for indicating pressure. (2) The deflection of a pointer of a speedometer indicates the speed of the automotive at that moment. 2. Recording function 2. Recording function: Examples :- (1) A potentiometer type of recorder used for monitoring temperature records the instantaneous values of temperatures on a strip chart recorder. 3. Controlling function: 3. Controlling function: This is one of the most important functions specially in the field of industrial control processes.

31. Applications of Measurement Systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 31 1. Monitoring of processes and operations: Example : (1) A voltmeter indicates the value of current or voltage being monitored(measured) at a particular instant. (2)Water and electric energy meters. 2. Control of processes and operation: Example : (1) Typical refrigeration system which employs a thermostatic control. (2) A temperature measuring device senses the room temperature thus providing the information necessary for proper functioning of the control system.

32. Applications of Measurement Systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 32 3. Experimental engineering analysis: (1) Determination of system parameters, variables and performance indices. (2) Testing the validity of theoretical predictions. (3) Solutions of mathematical relationships with the help of analogies. SUKESH O P/ APME/ME407- MR-2018

33. Measurement system performance 10/16/2018SUKESH O P/ APME/ME407- MR-2018 33 1. Static characteristics a. Accuracyb. sensitivity c. Reproducibility d. Static error. 2. Dynamic characteristics a. speed of response b. Measuring lag. c. Fidelity d. Dynamic error

34. Control systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 34  A control system is an arrangement of physical components connected or related in such a manner as to command, direct or regulate itself or another system. The basic functions of control systems are: - to minimize the error b/w the actual and the desired output. - to minimize the time response to load changes in the system.

35. Requirements of a control system 10/16/2018SUKESH O P/ APME/ME407- MR-2018 35 1. Stability : for any change in the input signal, the output of the system reads or makes its response at reasonable value. 2. Accuracy : the closeness of the measured value to the true value is known as accuracy. 3. Response : the quickness with which an instrument responds to a change in the output signal is known us response.

36. Examples of control system applications 10/16/2018SUKESH O P/ APME/ME407- MR-2018 36 1. Steering control of automobile. 2. Printwheel control system. 3. Industrial sewing machines. 4. Sun-tracking control of solar collectors. 5. Speed control systems. 6. Temperature control of an electric furnace.

37. Elements of a control system 10/16/2018SUKESH O P/ APME/ME407- MR-2018 37 1. Control variable The quantity or condition of the controlled system which can be directly measured and controlled is called Controlled variable. 2. Indirectly controlled variable The quantity or condition related to controlled variable, but cannot be directly measured is called Indirectly controlled variable

38. Elements of a control system 10/16/2018SUKESH O P/ APME/ME407- MR-2018 38 3. Command : 3. Command : The input which can be independently varied is called Command. 4. Reference input: 4. Reference input: A standard signal used for comparison in the close-loop system. 5. Actuating signal: 5. Actuating signal: The difference between the feedback signal is called Actuating signal 6. Disturbance: 6. Disturbance: Any signal other than the reference which affects the system performance is called disturbance. 7. System error: 7. System error: The difference between the actual value and ideal value is called System error.

39. Types of Control Systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 39 1. Open-loop control systems or Non-feedback control systems. 2. Closed-loop control systems or Feedback control systems.

40. Open-loop Control Systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 40

41. Advantages and Disadvantages of OLS 10/16/2018SUKESH O P/ APME/ME407- MR-2018 41 ADV: Simple construction. Easy maintenance. Less cost. Has better reliability and stability. LIMITATIONS Presence of non-linearities causes malfunctioning. The error cannot be corrected. The control action depends upon input command. Its not suitable for rough works.

42. Closed-loop Control Systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 42

43. Advantages and Disadvantages of CLS 10/16/2018SUKESH O P/ APME/ME407- MR-2018 43 ADV More accurate Control action basically depends upon feedback. Change in system component is automaticaly taken care of. DISADV: The system is complicated and expensive. The system may become unstable. SUKESH O P/ APME/ME407- MR-2018

44. Some examples: Washing machine The electric switch Microwave oven Air conditioner Liquid level control Feedforward control system Feedback control system 10/16/2018 44 SUKESH O P/ APME/ME407- MR-2018

45. 1. Less accurate 2. Generally build easily 3. Stability can be ensured. 4. The control adjustment depends upon human judgment and estimate. 5. Any change is system component cannot be taken care of automatically. 1. More accurate. 2. Generally complicated and costly 3. May become unstable at times. 4. The control adjustment depends on output and feedback element. 5. Change in system component is automatically taken care of. 10/16/2018 45 SUKESH O P/ APME/ME407- MR-2018 Open-loop Closed-loop

46. Feed back principle 10/16/2018SUKESH O P/ APME/ME407- MR-2018 46  The required level of control in open-loop systems depends only on human judgment. So, the performance of a control system can be improved by upgrading the skill of the operator and the nature of the measurement. Only with experience is one able to predict the results obtained.  Ex: Ironbox

47. Basic elements of a Feedback System 10/16/2018SUKESH O P/ APME/ME407- MR-2018 47 1. Forward path: 1. Forward path: The forward path consist of 1. Error-detecting device: 1. Error-detecting device: it is a device that receives the output signal and compares it with a standard value. It also gives the command o/p signal at each &every instant. 2. Amplifier : 2. Amplifier : it amplifies the o/p signal to a suitable/ required scale. 3. Compensating network: 3. Compensating network: it improves the overall performance of the system.

48. Basic elements of a Feedback System 10/16/2018SUKESH O P/ APME/ME407- MR-2018 48 2. Feedback system: This is the path that sends the information about the o/p signal at each and every instant to the error-detecting device.

49. Classification of feedback control systems 10/16/2018 49 1. Regulatory systems. 2. Follow-up system. 3. Servo-mechanism systems. 4. Continuous data feedback systems. 5. Sampled or discrete data control systems. SUKESH O P/ APME/ME407- MR-2018

50. Classification of feedback control systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 50 1. Regulatory systems: 1. Regulatory systems: this feedback control system is used when the input signal is constant, for ex: Refrigerator, Iron box 2. Follow-up system: 2. Follow-up system: this feedback control system is used when the input signal changes at each and every instant and where the output follows the input signal closely, Ex: Cam and follower mechanism 3. Servo mechanism system: 3. Servo mechanism system: This feedback control system is used where the mechanical quantity output with time derivatives is used.

51. Classification of feedback control systems 10/16/2018SUKESH O P/ APME/ME407- MR-2018 51 4. Continuous data feedback systems: 4. Continuous data feedback systems: This feedback control system is used where the input signal has functions of the continuous time variable. Ex: Potentiometers. 5. Sampled or discrete data control systems: 5. Sampled or discrete data control systems: This feedback control system is mainly used in input signals that have pulses or have numerical codes. Ex: A/D converter and Digital to Analog(D/A) converter. SUKESH O P/ APME/ME407- MR-2018