UNIT – I INTRODUCTION

MECHATRONICS:

It field of study that implies the synergistic integration of electronic engineering, electrical
engineering, control engineering and computer technology with mechanical engineering for the
design, manufacture, analyse and maintenance of a wide range of engineering products and
processes".

SYSTEM:

A system may be defined as a black box which has an input and an output. System
concerned only with the relationship between the input and output and not on the process going
inside the box.
 Here, the input is the electric power and the output after processed by the system is
rotation. The system is motor.
MECHATRONIC SYSTEM:

Actuators: Solenoids, voice coils, D.C. motors, Stepper motors, Servomotor, hydraulics,
pneumatics.
Sensors: Switches, Potentiometer, Photoelectrics, Digital encoder, Strain gauge,
Thermocouple, accelerometer etc.
Input signal conditioning and interfacing: Discrete circuits, Amplifiers, Filters, A/D,
D/D.
Digital control architecture: Logic circuits, Microcontroller, SBC, PLC, Sequencing and
timing, Logic and arithmetic, Control algorithm, Communication.
Output signal conditioning and interfacing: D/A D/D, Amplifiers, PWM, Power
transistor, Power Op - amps.
Graphical displays: LEDs, Digital displays, LCD, CRT
The actuators produce motion or cause some action;
The sensors detect the state of the system parameters, inputs and outputs;
Digital devices control the system;
Conditioning and interfacing circuits provide connection between the control circuit and the
input/output devices;
Graphical displays provide visual feedback to users.

MEASUREMENT SYSTEM:

A measurement system can be defined as a black box which is used for making
measurements. It has the input as the quantity being measured and the output as a measured
value of that quantity.
Example:

Elements of Measurement Systems:

Measurement system consists of the following three elements.

a) Sensor b) Signal conditioner c) Display System
Sensor:

A sensor consists of transducer whose function is to convert the one form of energy into
electrical form of energy. A sensor is a sensing element of measurement system that converts
the input quantity being measured into an output signal which is related to the quantity

Example:
Temperature Sensor – Thermocouple
Input – Temperature
Output – E.M.F (Electrical Parameter).

Signal Conditioner:
A signal conditioner receives signal from the sensor and manipulates it into a suitable
condition for display. The signal conditioner performs filtering, amplification or other signal
conditioning on the sensor output.
Example:
Temperature measurement – Single Conditioner function (Amplifier)
Input – Small E.M.F value (From sensor)
Output – Big E.M.F Value (Amplified).
Display System:
A display system displays the data (output) from the signal conditioner by analog or
digital. A digital system is a temporary store such as recorder.

Example:
Display – L.E.D (or) Number on scale by pointer movement
Input – Conditioned Signal (from signal conditioner)
Output – Value of the quantity (Temperature)
Temperature Measurement System:

CONTROL SYSTEM:

A black box which is used to control its output in a pre-set value

OPEN LOOP CONTROL SYSTEM:

 If there is no feedback device to compare the actual value with desired one.
 No control over its input
CLOSED LOOP CONTROL SYSTEM:

 If there is feedback device to compare the actual value with desired one

Elements of Closed Loop System:

The elements of closed loop control system are

 Comparison Unit
 Control Unit
 Correction Unit
 Process Unit
 Measurement Device
EXAMPLES:
System of Controlling Room Temperature
Controlled Variable : Room temperature
Reference Variable : Required Room temperature (pre-set value)
Comparison Element : Person compares the measured value with required value
Error Signal : Different between the measured and required temperatures.
Control Unit : Person
Correction Unit : The switch on the fire
Process : Heating by the fire
Measuring Device : Thermometer
System of Controlling Water Level
Controlled variable : Water level in the tank
Reference variable : Initial setting of thc float and lever position
Comparison Element : The lever
Error signal : Difference between the actual & initial setting of the lever
positions
Control Unit : The pivoted lever
Correction Unit : The flap opening or closing the water
Process supply : The water level in the tank
Measuring device : The floating ball and lever

Automatic Speed Control of Rotating Shaft

Potentiometer - To set the reference value (Voltage to be supplied to
differential amplifier)
Differential amplifier - To compare amplify the difference between the reference
and feedback values
 Tachogenerator - To measure the speed of the rotating shaft and is connected
to the rotating shaft by means of a pair of level gears

SEQUENTIAL CONTROLLERS:
It is used to control the process that are strictly ordered in a time or sequence

DOMESTIC WASHING MACHINE:

Pre Wash Cycle:

Pre-wash cycle may involve the following sequence of operations.
 Opening of valve to fill the drum when a current is supplied
  Microprocessor is used to operate the switch for opening closing the valve.
 Closing the valve after receiving the signal from a sensor when the required
level of
water is filled in the washing drum.
 Stopping the flow of water after the current is switched off by the
microprocessor.  Switch on the motor to rotate for stipulated time.
 Initiates the operation of pump to empty the water from
the drum.  Pre-wash cycle involves washing the clothes in
the d m by cold water.
Main Wash Cycle:
Main wash cycle involves washing the clothes in the drum by hot water and
the sequence of operations in main wash is as follows:
 Cold water is supplied after the Pre-wash cycle is completed.
 Current is supplied in large amount to switch on the heater for heating
the cold water.  Temperature sensor switches off the current after the
water is heated to required
temperature.
 Microprocessor or cam switch ON the motor to rotate the drum
 Microprocessor or cam switches on the current to a discharge pump to

empty the drum. Rinse Cycle:

Rinse cycle involves washing out the clothes with cold water a number of
times and the sequence of operations in a Rinse cycle are as follows:
 Opening of valve to allow cold water into the drum when the
microprocessor are given signals to supply current after the main wash
 cycle is completed.
 Switches off the supply current by the signals from
microprocessor  Operation of motor to rotate the drum
 Operation of pump to empty the drum and respect this sequence a

number of times. Spinning Cycle

Spinning cycle involves removing of water from the clothes and the sequence
of operations is
 Switching on the drum motor to rotate it at a higher speed than a rinsing
cycle.

AUTOMATIC CAMERA:
ENGINE MANAGEMENT SYSTEM:
SENSORS Transducers:
It is an element which is subjected to physical change experience a
related change. Example: Tactile Sensors.
Sensors:
It is an element which is not subjected to physical change experience a
related change. Example: LVDT
PERFORMANCE

TERMINOLOGY: Static

Characteristics:

Range and Span:

 The range of a transducer defines the limits between which the input can
vary.
 The difference between the limits (maximum value - minimum value) is
known as span.  For example a load cell is used to measure force. An input
force can vary from 20 to 100
N. Then the range of load cell is 20 to 100 N. And the span of load cell is 80
N (i.e., 100-20)
Error:
 The algebraic difference between the indicated value and the true value of
the measured parameter is termed as the error of the device.
 Error = Indicated value — true value
 For example, if the transducer gives a temperature reading of 30°C
when the actual temperature is 29° C, then the error is + 1°C. If the actual
temperature is
 3 1° C, then the
error is — 1°C.

Accuracy:
 Accuracy is defined as the ability of the instrument to respond to the true
 value of the measure variable under the reference conditions.
 For example, a thermocouple has an accuracy of ± 1° C. This means that
reading given by the thermocouple can be expected to lie within + 1°C (or) —
1°C of the true value.  Accuracy is also expressed as a percentage of the
full range output (or) full scale
deflection.

 For example, a thermocouple can be specified as having an accuracy of ±4

% of full
range output. Hence if the range of the thermocouple is 0 to 200°C, then
the reading
given can be expected to be within + 8°C (or) — 8°C of the
true reading.
Sensitivity:
 The sensitivity is the relationship showing how much output we can get
per unit input.  sensitivity = Output / Input
Precision:
 It is defined as the degree of exactness for which the instrument is intended

to perform. Hysteresis error:

 When a device is used to measure any parameter plot the graph of output
Vs value of measured quantity.
 First for increasing values of the measured quantity and then for decreasing
values of the measured quantity.
  The two output readings obtained usually differ from each other.
Repeatability:
 The repeatability and reproducibility of a transducer are its ability to
give the same
output for repeated applications of the same
input value.

Reliability:
 The reliability of a system is defined as the possibility that it will perform
its assigned functions for a specific period of time under given conditions.
Stability:
 The stability of a transducer is its ability to give the same output when used
 to measure a
constant input over a

period of time. Drift:

 The term drift is the change in output that

occurs over time. Dead band:

 There will be no output for certain range of input values. This is known
as dead band. There will be no output until the input has reached a particular
value.
Dead time:
 It is the time required by a transducer to begin to respond to a change in

input value. Resolution:

 Resolution is defined as the smallest increment in the measured value
that can be detected.
 The resolution is the smallest change in the input value which will produce
an observable change in the input.
Backlash:
 Backlash is defined as the maximum distance (or) angle through which
any part of a mechanical system can be moved in one direction without
causing any motion of the attached part.
 Backlash is an undesirable phenomenon and is important in the precision
design of gear trains.