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INTRODUCTION

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• 1969 -The ‘mechatronics’ word introduced by Tessturo Mori. He was a senior engineer of Japanese
company Yaskawa Electric Corporation.
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• 1971 – the company was granted the trademark rights on the word.

• 1971- 80- mostly the servo technology is used in mechatronics

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• 1981-90-IT introduced. Microprocessors were embedded in Mechanical system

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• 1991 -2000 – Communication technology was added. Remote
operation and robotics were developed .

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• 1996 – 1st journal IEEE on mechatronics was released.

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• After 2000, finds application in aerospace, defence, bio-mechanics,
automotive electronics, banking(ATM) etc.,
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DEFINITION

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•Mechatronics is “ the synergistic integration

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of mechanics and mechanical engineering,

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Electronics, computer technology, and IT to
produce or enhance products and system”
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Graphical representation of mechatronics

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Elements of mechatronics system
Actuators and

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sensors

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Signals and
conditioning

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jin Digital logic
systems
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Software and data
acquisition systems
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Computers and
display devices
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Elements of mechatronics system
• Actuators and sensors

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• Actuators – pneumatic & Hydraulic actuator, electromechanical actuators,
electrical motor such as DC motor, AC motor, stepper motor, servo motor & piezo
electric actuators

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• Sensors – linear and rotational sensor, acceleration sensor, force, torque and
pressure sensor, temperature sensor, proximity sensors, light sensors

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• Signals and conditioning
• Two types: input and output

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• Input signal conditioning devices: discrete circuits, amplifiers, analog to
digital(A/D) convertors, Digital to Analog (D/A) convertors.
• Output signal conditioning devices: amplifiers, Digital to Analog (D/A) convertors,

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display decoders (DD) convertors, power transistors.
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Elements of mechatronics system
• Digital logic systems
• Logic circuits, micro controllers, programmable logic controllers(PLC), sequencing

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and timing controls, control algorithm.

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• Software and data acquisition systems
•

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Data logger, computer with plug in boards

• Computers and display devices

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• LED, CRT, LCD, digital displays etc.,
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Examples of mechatronics systems
• NC and CNC machine tools, flexible manufacturing system, Prototyping

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& robots
• Photo copiers, laser printers & fax machines

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• Automatic washing machines automatic ovens

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• Automatic teller machine (ATM)
• Coin counter

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• Automatic/digital camera, digital watch
• CT scan system, automatic blood testing equipment
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• Automatic sliding door
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Advantages of Mechatronics systems
• Cost effective and good quality products

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• High degree of flexibility to modify or redesign

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• Very good performance characteristics
• Wide area of applications

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• Greater productivity in case of manufacturing organization
• Posibility or remote controlling as well as centralized monitoring and
control
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• Greater extend of machine utilization
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Disadvantages of Mechatronics systems

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• High initial cost

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• Multi-disciplinary engineering background required to design and
implementation

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• Need of highly trained workers
• Complexity in identification and correction of problem in the system

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System

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Measurement system

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Liquid level measurement system

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Control systems

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•A control system refers to a group of physical

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component connected or related in such a

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manner as to command direct or regulate
itself or another system.
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Cooling level control system

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Steering control system of an automobile

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Temperature and blood pressure control

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system of human body

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TYPES OF CONTROL SYSTEM

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•Open loop control system

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•Closed loop or feedback control system

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Open loop control system

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• Open loop system are systems in which the output of

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a system is not used as a variable to control the

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system.

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Element of open loop control systems

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Bread toaster (open loop ) control system

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Closed loop control system

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• Closed loop system uses on a feed back loop to control the operation of

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the system.

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Room heating (Closed loop) control system
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 Open loop system • Closed loop system
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• It does not uses feedback • It uses feedback system

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• It is less accurate • It is more accurate
• It is simple in construction
• It is complicated in

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• Presence of non-linearity causes
malfunctioning construction

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• It perform accurately even

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• The response is slow because in presence of non-
manual control linearity
• Easy maintenance because of no
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complex electronic circuit
• Cost is less
• It perform task faster than
open loop
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• It is difficult to maintain
and repair
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• Cost is more
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Sequential controllers

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• A sequential control involve sequential execution of well defined
operations.

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The working of modern automatic washing

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machine is

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• Step 1 : pre-wash cycle-(Cold water wash)

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• Step 2: main wash cycle- (Hot water wash)

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• Step 3: rinse cycle- (Number of preset time)

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• Step 4: spin cycle- (Drain the water from clothes)
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Block diagram of automatic washing machine system

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Elements of control system for an automatic camera

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Concept of mechatronic approach

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Emerging area of mechatronics

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• Machine vision
• Automation and robotics

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• Development of unmanned vehicles
• Design of subsystem for automotive engineering

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• Sensing and control system

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• Operation and maintenance of CNC machine
• Expert system and artificial intelligence

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• Industrial electronics and consumer products
• Medical mechatronics and medical imaging systems
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• Micro/nano mechatronics
• Computer integrated manufacturing (CIM) system
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Need for mechatronics

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• Dynamic market conditions

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• Producing next generation products

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• Integration of modern technologies in products
• Variety in product ranges

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• Batch production runs
• Change in design perspective

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• Product quality and consistency
• Ease of reconfiguration of the process
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• Demand for increased flexibility
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Classification of Mechatronics

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Working of a four stroke SI engine

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Elements of control system for an

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electronic engine management system

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UNIT II

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8085 MICROPROCESSOR AND
8051 MICROCONTROLLER
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MICROPROCESSOR
• It is a semiconductor component that incorporates the functions of a central

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processing unit (CPU) on a single integrated circuit (IC) . i.e., the central

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processing unit (CPU) built on a single IC is called microprocessor.

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MICROPROCESSOR
• It is multipurpose, programmable and clock driven,

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• Register based electronic device that reads binary instructions from a

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storage device called memory,
• Accept binary data as input, process the data according to the instruction

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and provides results as output.

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Functional Block diagram of Microprocessor

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ALU Register Array

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Control
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Microprocessor
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Functional Block diagram of Microprocessor

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• ALU (Arithmetic and Logic Unit)
•

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It carries out arithmetic and logic operations on 8 bit word.
• Arithmetic operation – addition, subtraction , multiplication , division etc.,

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• Logic operation - AND,OR,EX-OR
• The content of accumulator and temporary register are the input to the ALU.
• ALU output is stored in accumulator

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• Register is a storage unit within the microprocessor used to store the data,

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address of instruction of any program.
• Microprocessor contained 6 general purpose register it has 8- bit memory
• Registers are B,C,D,E,H and L
• To hold 16-bit data a combination of two 8-bit registers can be used.

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• The combination of two 8-bit registers is known as Register Pair (BC, DE and HL).
• These Registers are used to store data temporarily during execution of the

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program.

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• Control Unit
• The timing and control unit acts as the brain of a computer.

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• It controls all operations of the CPU.

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• It controls input, output and all other devices connected to the CPU.

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Evolution of Microprocessor

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• First generation Microprocessor
• 1st Microprocessor, Intel 4004, a 4 bit PMOS Microprocessor introduced in

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1971 by the Intel corporation, USA.45 instructions and 2300 transistors
• It has limited memory-simple aplications.

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• An enhanced version of Intel 4004 is Intel 4040.
• e.g., Toshiba’s 73472, Rockwell International’s PPS-4 National IMP-4 etc.,

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Evolution of Microprocessor

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• Second generation Microprocessor
• In 1972, Intel introduced 8- bit Microprocessor named as Intel 8008, which

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also uses PMOS technology.
• But this technology was slow and not compatible with TTL logic

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• In 1973, Intel introduced more powerful and fast 8- bit NMOS
Microprocessor called Intel 8080-3 power supplies.

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• 1975-Intel 8085 is the improved version of Intel 8080
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• Third generation Microprocessor
• In 1978 Intel introduced a 16- bit Microprocessor called Intel 8086.

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• Other 16- bit Microprocessor are Intel 80186, Intel 80286, zilog’s z8000,
Motorola’s 68000, 68010 etc.,

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• Forth generation Microprocessor
• In 1980-32bit-Iapx432-not popular
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• In 1985 Intel introduced a 32- bit Microprocessor called Intel 60386-desktop -
386MP
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• Fifth generation Microprocessor
• Intel i860 is a 64 bit RISC microprocessor
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Architecture of 8085

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• Three main section
• ALU

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• Timing and Control unit-

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• Set of register

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8085

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• ALU
• Addition, Subtraction, Logical AND,OR…etc

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• Timing and Control Unit

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• timing and control signals –execution of instructions
• Controls the entire operation of the microprocessor
• Register
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•
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1- 8 bit Accumulator….i.e.-register A (ACC)
6-8 bit general purpose register (B,C,D,E,H & L)
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• 1- 16 bit register –SP(Stack Pointer)
• 1 -16 bit –PC (Program Counter)
• Instruction register
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• Temporary register
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Flag register
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• Flag register
• Carry flag (CY) – it is set, If carry or borrow occurs during the arithmetic

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operation.
• Parity flag (P) – it is set, if the result has even number of it otherwise made 0.

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• Auxiliary carry flag (AC) – Binary coded decimal operations (BCD)
• Zero flag (z) – is set if the result becomes 0

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• Sign flag (S) – is set if the result becomes –ve, if +ve, it is set to 0
• 2 bit (don’t care )
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Pin diagram

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Signals in 8085
• 6 group of signals

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• Address bus (A15-A8)-
• unidirectional

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• Data bus (AD7-AD0)
• bi-directional both data and

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address
• Control and Status signals

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• ALE (Address Latch Enable)
• RD,WR,IO/M,S0,S1
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• Power supply and Clock frequency
• VCC +5
• VSS-Ground
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• X1,X2
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• CLK
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• Externally initiated signals
•

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INTR
• INTA

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• TRAP
• RST 7.5,RST6.5,RST 5.5
• READY
•
•
•
HOLD
RESET IN jin
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RESET OUT
• HLDA
• Serial I/O Ports
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• SID
• SOD
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ADRESSING MODES IN 8085

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• Direct addressing

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• Register addressing
• Register indirect addressing

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• Immediate addressing
• Implicit addressing

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• Direct addressing
• LDA 240H (Load register A with the contents of memory location 240FH)

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• STA 2400H (Store the content of the accumulator in the memory location
2400H)

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• Register addressing
• MOV B, D (move the content of register D to register B)

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• INX H (increment the content of [H-L] register pair
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• Register indirect addressing
• LXI H, 2500H (Load H-L pair with 2500H)

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• MOV A, B (move the content of the memory location, whose address is in H-L
pair(H-L Pair) to accumulator)

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• HLT (halt)
• Immediate addressing

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• MVI A, 05 (Move 05 in register A)
• 3E, 05 (the code format of an instruction)
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• Implicit addressing
•

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There are certain instruction which operate the content of the accumulator.
• Such instruction do not require the address of the operand

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• CMA
• RAL
• RAR

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Instruction sets 8085

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• Data transfer group

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• Arithmetic group
• Logical group

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• Branch group
• Stack, I/O and Machine control group

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Data transfer group

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• MOV r1,r2

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• MOV r, M (Move the content of memory to
register)

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• MOV M, r
• MVI r1, data (Move
• MVI M, data jin
Immediate DATA to register)
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• LDA data (Load accumulator direct)
• STA addr (store accumulator direct)
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• XCHG (exchange the content of H-L with D-E pair)

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• LHLD addr (Load HL pair direct)

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• SHLD addr (Store HL pair direct)
• STAX xp ( store accumulator Indirect)

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Arithmetic group

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• ADD r • INR r

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• ADD M • INR M
• ADI data • DCR r

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• ADC r • DCR M
• ADC M
• SUB r
• SUB M
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• SUI data
• SBB r
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• SBB M
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Logical group

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• ANA r • CMA (complement acc)

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• ANA M • CMC(complement carry)
• ANI data • CMP r (compare)

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• ORA r • CMP M
• ORA M • CPI data
• ORI data
• XRA r
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• RRC
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• XRA m • RAL
• XRI data • RAR
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Branch group

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• Two branch instruction

•Conditional

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•The conditional branch instructions
transfer the program to the specified

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label when certain condition is
satisfied
•Unconditional jin
•The Unconditional branch instructions
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transfer the program to the specified
label when certain condition is not
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• Conditional jumb addr (label)
• If the condition is true and the program jumps to the specified label, the

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execution of a conditional jump takes 3 machine cycles and 10 states
• If the condition is not true, only two machine cycles and 7 states are required

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for the execution of the instruction.

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• JZ addr (label) [jump if the result is zero]

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[PC] address (label), jump if z=0

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Machine cycle – 2/3
States – 7/10

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Addressing mode – Immediate
Flags - None
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• JNZ addr [ jump if the result is not zero]
[PC] address (label), jump if z=1

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• JC addr [ jump if there is a carry ]

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[PC] address (label), jump if CS = 1

[PC] jin
• JNC addr [ jump if there is no carry ]
address (label), jump if CS = 0
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• JP addr [ jump if the result is plus)
[PC] address (label), jump if S = 0

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• JM addr [ jump if the result is minus)

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[PC] address (label), jump if S = 1
• JPE addr [ jump if even parity)
[PC]
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address (label), jump if P = 0
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[PC] address (label), jump if P = 1

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•CALL addr (label)
• Call the subroutine identified by the operand

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• CC addr (call subroutine if carry status CS=1)
• CNC addr (call subroutine if carry status CS=0)

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• CZ addr (call subroutine if result is zero)
• CNZ addr (call subroutine if result is not zero)

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• CP addr (call subroutine if result is plus)
• CM addr (call subroutine if result is minus)
• CPE addr (call subroutine if even parity)
•
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CPOE addr (call subroutine if odd parity)
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• Unconditional
• RET(Return from Subroutine)

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• CALL addr

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• RSTn (Restart)

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Stack ,I/O and Machine control Group

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• PUSH rp [push the content of register pair to stack)

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• PUSH PSW [push the program status to word]
• POP rp [pop the content of register pair which was saved from the

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stack]
• POP PSW
• IN PORT
• OUT PORT
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• EI (enable interrupts)
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• DI(disable interrupts)

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• HLT (halt)
• NOP( notion oper)

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• RIM(read interrupts mask)
• SIM (set interrupts mask)

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SIM(Set Interrupts Mask)

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RIM (Read Interrupts Mask)

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Timing diagram of 8085

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• Opcode fetch cycle (4T or 6T)

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• Memory Read cycle (3T)
• Memory write cycle (3T)

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• I/O read cycle (3T)
• I/O write cycle (3T)

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• Interrupt acknowledge (6T or 12T)
• Bus idle cycle (2T or 3T)
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Opcode fetch cycle

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Memory Read cycle

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Memory write cycle

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I/O read cycle

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I/O write cycle

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Microcontroller

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• A Microcontroller is a small computer on a single integrated circuit
containing a processor core, memory and programmable

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input/output peripherals.

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Features Microcontroller

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• 8 bit CPU

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• On chip oscillator
• 4Kb of ROM

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• 128 bytes of RAM
• 21 special functions register
• 32 I/O lines
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• 64 KB address space for external data memory
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• 64 KB address space for program memory
• 2 16-bit timer/counter
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Block diagram of 8051

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UNIT 3

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PROGRAMMABLE PERIPERAL INTERFACE

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Content

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• Introduction

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• Architecture of 8255
• Keyboard interfacing

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• LED display –interfacing
• ADC and DAC interface
• Temperature Control
• Stepper Motor Control
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• Traffic Control interface
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Introduction
• To communicate with the outside world, microprocessor use peripherals
(I/O devices)

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• Input devices – Keyboards, A/D converters etc.,

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• Output devices – CRT, Printers, LEDs etc.,
• Peripherals are connected to the microprocessors through electronic

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circuit known as interfacing circuits.

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Microprocessors unit with I/O devices

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Input Output
Micro
devices devices
(keyboard) jinprocessors
(LED)
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Input Output
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• Some of the general purpose interfacing devices
•

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I/O ports
• Programmable peripherals interface (PPI)

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• DMA controllers
• Interrupt controller

• CRT controller
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• Some of the special purpose interfacing devices
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• Keyboard
• Display
• Floppy Disc controllers
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Peripheral interfacing Chips are used

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generation of I/O ports

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• Programmable peripherals interface Inter 8255 (PPI)
• Programmable Interrupt controller (PIC) Intel 8259

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• Programmable communication interface (PCI) Intel 8251
•

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Keyboard display Controller Intel 8279
• Programmable counter /Inverter timer Intel 8253
• A/D and D/A Converter Interfacing

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Advantages

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• To perform specific functions by giving a control word to the internal
register.

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• Control word –instructions informs the peripheral about various

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functions to perform.
• Format (CW) specified by the manufacturer.

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Microprocessors unit with I/O devices

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Input
Micro Output
devices PPI 8279
proce device
(key
board)
8255
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(LED)
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Peripheral Display
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Interface Interface
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Address Space Partitioning

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• The Microprocessors uses 16 bit wide address bus for addressing
memories and I/O devices.

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• Using 16 bit wide address bus, it can access 216 = 64k bytes of

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memory and I/O devices
• Two schemes for the allocation of addresses to memories and I/O
devices
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• Memory mapped I/O
• I/O mapped I/O
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Memory mapped I/O

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• It has only one address space

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• Address space is defined as the set of all possible addresses that a
microprocessor can generate

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• Some addresses assigned to memories and Some addresses to I/O
devices

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• Memory locations are assigned with addresses from 8000 to 84FF
• I/O devices are assigned with addresses from 8500 to 85FF
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I/O mapped I/O scheme

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• In this scheme, addresses assigned to memories locations can also be
assigned to I/O devices

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• Since the same address may be assigned to memories locations or an

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I/O devices
• The microprocessor has a signal to distinguish whether the address
on the address bus is for memories locations or an I/O devices
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I/O mapped I/O scheme

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• When signal is high, then address on the address bus is for an I/O
devices

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• When signal is low, then address on the address bus is for memory

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locations
• Two extra instruction IN and OUT are used to address I/O devices.

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• The IN instruction is used to read the data of an input devices.
• The OUT instruction is used to send the data of an input devices.
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• This scheme is suitable for a large system.
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PROGRAMMABLE PERIPHERALS INTERFACE INTER
8255 (PPI)

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Operating mode of 8255

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• Bit Set Reset (BSR) Mode

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• I/O Mode

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Bit Set Reset (BSR) Mode

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BSR control word format

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I/O Mode

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• The 8255 has the following 3 modes of operation
• Mode 0 – Simple Input/output

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• Mode 1 – Input / Output with the Handshake or strobed

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• Mode 2 – Bi-directional I/O

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I/O Mode

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Mode 0 – Simple Input/output
• Port A and port B are used as two simple 8-bit I/O port

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• Port C as two 4-bit port

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• Features
• Outputs are latched
• Inputs are buffered not latched

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• Ports do not have handshake or interrupt capability
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I/O Mode
• Mode 1 – Input / Output with the Handshake
• Input or output data transfer is controlled by handshaking signals.

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• Handshaking signals are used to transfer data between devices whose data
transfer speeds are not same.

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• Port A and Port B are designed to operate with the Port C.
• When Port A and Port B are programmed in Mode 1, 6 pins of port C is used for

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their control.

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I/O Mode
• D0-D7 data bus
– bi directional, tri state data bus line

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– It is used to transfer data and control word from 8085 to 8255
• RD (Read)

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– When this pin is low, the CPU can read data in the port or status word through

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the data buffer
• WR (write)
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– When this pin is low, the CPU can write data in the port or in the control register
through the data buffer
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I/O Mode
• Mode 2 – Bi-directional I/O

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• Port A can be programmed to operate as a bidirectional port.

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• The mode 2 operation is only for port A

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• When port A is programmed in Mode 2, the Port B can be used in either
Mode 1 or Mode 0.
• Mode 2 operation the port a is controlled by PC3 to PC7 of port C.
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PIN DIAGRAM
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PROGRAMMING and OPERATION of 8255

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• Programming in MODE 0

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• D7 –set to 1
• D6,D5,D2- all set to 0 –MODE 0

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• D4,D3,D1 and D0- determine weather the corresponding ports are to
configured as input or output

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GROUP B
D4 D3 D1 D0 PORT A PORTC U PORT B PORT C L

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0 0 0 0 OUT OUT OUT OUT
0 0 0 1 OUT OUT OUT IP

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0 0 1 0 OUT OUT IP OUT

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0 0 1 1 OUT OUT IP IP
0 1 0 0 OUT IP OUT OUT

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0 1 0 1 OUT IP OUT IP
0 1 1 0 OUT IP IP OUT
0
1
1
0
1
0
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0
OUT
IP
IP
OUT
IP
OUT
IP
OUT
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1 0 0 1 IP OUT OUT IP
1 0 1 0 IP OUT IP OUT
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1 0 1 1 IP OUT IP IP
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1 1 0 0 IP IP OUT OUT
1 1 0 1 IP IP OUT IP
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1 1 1 0 IP IP IP OUT
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Programming in MODE 1

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• IBF- input buffer full

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• INTR- interrupt request
• INTE-interrupt enable

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• OBF-output buffer full

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• INTR-interrupt request
• INTE-interrupt enable
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Programming in MODE 2

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Interfacing cable

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Basic Key operation

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2 X 2 Key operation
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Keyboard Microprocessor Interface software Flowchart

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INTERFACING-keyboard

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LED Operation

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Microprocessor interface to LED (Common

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anode)

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Microprocessor interface to 7 segment

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LED (Parallel)

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Microprocessor interface to 7 segment LED

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(serial)

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Serial interface of 7

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segment LED to
Microprocessor
software flowchart
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INTERFACE-LED display

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ADC INTERFACE

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BLOCK diagram of ADC 0808

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PIN diagram of ADC 0808

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DAC INTERFACE

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Pin diagram of DAC

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Pin diagram of DAC

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INTERFACING diagram for DAC

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TEMPERATURE CONTROL

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• Temperature sensor –convert temp to electrical signal by thermistor

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• Transducer convert physical data into electrical signal
• Physical data –temp, light, flow, speed etc…

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• LM34 & LM35 –temperature sensor by NATIONAL SEMICONDUCTOR
CO-OPERATION

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• LM34 • LM35

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• Output voltage is linearly • Output voltage is linearly
proportional to Fahrenheit temp proportional to Celsius temp
• No external calibration • No external calibration

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• 10mV for each degree of • 10mV for each degree of

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Fahrenheit temp Centigrate temp

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STEPPER MOTOR CONTROL interface
• Digital motor used to translate electrical pulse into mechanical

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movement
• Center tap winding connected to 12 V supply

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• Motor can be excited by grounding four terminals of the two windings

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• ROTOR-Stepper motor has permanent magnet rotor .It is also known as
shaft
• STEP ANGLE-It is minimum degree of rotation associated with a single
step
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Stepper Motor Interface

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Excitation Table

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Step X1 X2 X3 X4

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1 0 1 0 1

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2 1 0 0 1
3 1 jin 0 1 0
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4 0 1 1 0
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1 0 1 0 1
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Traffic Light Control System
• Allow traffic from W to E and E to W transition for 20 seconds

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• Give transition period of 5 seconds (yellow bulbs ON)
• Allow traffic from N to s and S to n for 20 seconds

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• Give transition period of 5 seconds (yellow bulbs ON)

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• Repeat the process

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Traffic Light Control System

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Interfacing diagram for Traffic Light Control

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System

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UNIT 4

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PROGRAMMABLE LOGIC CONTROLLER

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Content

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• Introduction

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• Basic structure
• Input and output processing

pa
• Programming
• Mnemonics

jin
• Timers, counters and internal relays
• Data handling
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• Selection of PLC
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PROGRAMMABLE LOGIC CONTROLLER

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• A Programmable Logic Controller(PLC) is a digital computer used for
automation of typically industrial electromechanical processes, such

ul
as control of machinery on factory assembly lines, amusement rides
or light fixtures.

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Applications

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• Automated manufacturing process equipment and machinery

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• Packaging and filling equipment
• Chemical mixing

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• Conveyor systems and distillation etc.,

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Features and specification
• They are rugged and designed to withstand vibration, temperature,

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humidity and noise
• The interfacing for inputs and outputs is inside the controller.

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• They are easily programmed and have an easily understood
programming language.

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• Programming is primarily concerned with logic and switching operation.

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Hardwired motor circuit

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Hardwired motor circuit with PLC

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Basic structure

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• PLC is designed as a replacement for the hardwired relay and timer
logic, where PLC provides ease and flexibility of control based on

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programming and executive logical instruction.

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• The internal functions such as timers, counter and shift registers
making sophisticated control possible using even the smallest PLC.

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• PLC capable of performing function such as
• counting,
• logistics,

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• numerical application,
• comparing and processing of signals.

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• A PLC is divided in to 4 parts. They are

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• Input/output module (I/O)
• Central processing Unit (CPU)
• Memory
• Programming unit
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i) Input/output module (I/O)

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• It is used to transfer the data between external devices and CPU
• It is incorporated into PLC in two ways

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I. Fixed I/O – it is a small unit that comes in one piece with processor i.e., the
I/O terminals cannot be changed in fixed I/O

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II. Modular I/O – it is packed together i.e., there are several compartment of
I/O module are plugged together.

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Central processing Unit (CPU)

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• It is consisting of a microprocessor which interrupts the input signal and
carries out the control actions according to the program stored in the
memory, communicating the decision as an action signal to the output.

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• It scan the total information package stored in the memory and input and
output devices continuously.

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• During the scan the CPU executes instruction based on input data, sends
appropriate output responses to the output devices, updates data

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acquisition systems and indicate condition changes

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• Scan time for larger unit depends on the size of the memory and
configuration of the system

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• Power supply unit is needed to convert the AC voltage to the low DC

pa
voltage necessary for the processor and to supply power to other
circuit in the input and output interface module.

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Memory Unit

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• The memory in PLC stores the digital control logic, the process
program and the necessary instruction to operate the system.

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• The memory used in PLC are

pa
• Non-volatile memory
• Volatile memory

jin
• According to purpose of usage
• RAM –volatile memory
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• ROM- permanent storage
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Programming unit

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• It is used to enter the required program into the memory of the
processor

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• There are normally 3 approaches followed by the program

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• Use of hand held programmer
• Terminal with video display unit
• PC with appropriate software

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• Buses
• Data buses – it is used for communicating data b/n elements

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• Address buses-it is used to read the address of locations for accessing stored
data

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• Control buses- it is used for internal control action carried by the CPU
• System buses- it is used for communication b/n Input/output ports and

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input/output units

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• Memory
• RAM

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• ROM

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• PROM
• EPROM
• Electrically EPROM

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Optoisolator

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• Electrical connection from the external world is usually by means of
optoisolator

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• When a digital pulses passes through the LED, a pulse of Infrared

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radiation is produced.
• This pulses is detected by the phototransistor and gives rise to a
voltage in that circuit.
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Optoisolator

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Input channel with optoisolator

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• Common input voltage is 5V and 24V

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• Output voltage is 24V and 240V
• Output are often specified as being of

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• Relay type
• Transistor type
• Triac type
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Relay type of output

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The relay type output is used for both ac and dc switching

Relay are slow to operate
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Transistor type output

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The transistor type output is used for dc switching

This give faster switching action
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Triac type of output

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The triac type output is used for switching AC voltages

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Programming

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• The programming of PLC is based on the ladder diagram.

ul
• Ladder diagram involve writing a program in a similar maner to
drawing a switching circuit.

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Switch Control
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e.g., solenoid valve

open to allow water
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to enter a vessel
Temperature Control System www.rejinpaul.com

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Logic functions

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An AND System

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An OR System
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NOT System

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NOR System
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NAND System

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XOR System
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Cylinder Sequencing

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A+, B+, A- and B-

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List of Mnemonics used for the Mitsubishi f

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Series PLC

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Mnemonics for Logic system

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Mnemonics for Logic system

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Timer

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Timer circuit programmed to cause an output to go

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ON for 0.5s, then OFF for 0.5s, then OFF for 0.5s and
so on

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cycle timer
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Internal relay

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Counter

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Master control relay

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JUMP Instruction

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Data handling

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• Data movement

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• Data comparison
• Arithmetic operation

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• Code conversion

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Data Movement

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Controlling the speed of motor

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Selection of PLC
• System definition

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• Choosing the I/O hardware
• I/O timing consideration

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• Analog I/O module –resolution, voltage level

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• Conversion speed
• Analog closed control
• Communication
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• Counter, encoders and positioning
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• Selecting suppliers
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.c
UNIT 5

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ACTUATORS AND MECHATRONICS SYSTEMS DESIGN

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CONTENT

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❖Types of stepper and servo motors – construction, working principle
❖Design process - Stages in designing mechatronics system

ul
❖Traditional and mechatronic design concept
❖Possible design solution

pa
❖Case studies of mechatronics systems
❖Pick and place robot

jin
❖Engine management system
❖Automatic car park barrier
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Stages in designing mechatronics system

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Need for design

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Analysis of problem

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Preparation of specification

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jin
Generation of possible solution
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Evaluation
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Production of detailed design

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Production of working drawing

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Implementation of design
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Traditional design

.c
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A mechanical system

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Mechanical jinHydraulic Electrical
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linkages , drives and motors,
etc., pneumatic switches
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actuators etc.,
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Mechatronic design

.c
A

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mechanical
system

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Hydraulic
Mechanical
linkages ,
drives etc.,
jin and
pneumatic
Electrical
motors,
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switches
actuators etc.,
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Electronic
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components,
computers & IT
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systems
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Comparison of traditional and mechatronics

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design

.c
ul
Traditional design Mechatronics design
• It is based on a traditional • It is based on mechanical,

pa
systems such as mechanical, electronics, computer
hydraulic and pneumatic technology and control
systems engineering.
• Less flexible
• Less accurate
jin • More flexible
• More accurate
.re
• More complicate mechanism in • Less complicate mechanism in
design design
w

• It involve more components • It involve fewer components

and moving parts and moving parts
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w
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Possible design solution

.c
• Timer switch

ul
• Windscreen wiper motion
• Weighing scales

pa
jin
.re
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Timer switch

.c
ul
pa
jin
.re
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Possible solution for timer switch

.c
ul
pa
jin
.re
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 www.rejinpaul.com

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Windscreen wiper motion

.c
ul
pa
jin
.re
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 www.rejinpaul.com
Possible solution for Windscreen wiper

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motion

.c
ul
pa
jin
.re
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 www.rejinpaul.com

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Weighing scales

.c
ul
pa
jin
.re
w
w
w

Weighing Scales Weighing Scales mechanism

 www.rejinpaul.com

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.c
ul
pa
jin
.re
w
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Wheatstone bridge arrangement with ADC

w
 www.rejinpaul.com

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.c
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pa
jin
.re
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Wheatstone bridge with microcontroller

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 www.rejinpaul.com

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Case studies

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• Pick and place robot

ul
• Autonomous mobile robot
• Wireless surveillance balloon

pa
• Engine management system
• Automatic car park barrier

jin
.re
w
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 www.rejinpaul.com

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Pick and place robot

.c
ul
pa
jin
.re
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 www.rejinpaul.com

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.c
ul
pa
jin
.re
w
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Gripper mechanism of a robot

w
 www.rejinpaul.com

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.c
ul
pa
jin
.re
w
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Microcontroller circuit for pick and place robot

 www.rejinpaul.com

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Autonomous mobile robot

.c
ul
pa
jin
.re
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Elements of autonomous mobile robot

.c
ul
pa
jin
.re
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Wireless surveillance balloon

.c
ul
pa
jin
.re
w
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 www.rejinpaul.com

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Applications of wireless surveillance Ballon

.c
• Border security (TARS) in military

ul
• Enhancing battle field situational awareness
• Coastal surveillance

pa
• Platform for mounting telecommunication, television, radio
transmitters etc.,

jin
• Aerial platform for scientific instrument testing
.re
w
w
w
 www.rejinpaul.com
Engine Management System

om
.c
ul
pa
jin
.re
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Basic components
• Electronic control unit
• Fuel delivery system

.c
• Ignition system

ul
• Various sensors
•

pa
Throttle position sensors
• Exhaust gas oxygen sensors
• Manifold absolute pressure sensors
•
•
•
Temperature sensors
jin
Engine speed/Timing sensors
Exhaust gas regulation sensors
.re
• Mass sir flow sensors
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.c
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pa
jin
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Interfacing of sensors with controller in Automatic car park barrier