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DEPARTMENT OF MECHANICAL ENGINEERING

IV YEAR / VII SEMESTER

ME3791 – MECHATRONICS AND IOT

Mr. M. IDHAYACHANDRAN
Assistant Professor / ECE
Nadar Saraswathi College of Engineering & Technology,
Vadapudupatti, Annanji (po), Theni – 625531.
UNIT - 5 – MECHATRONIC SYSTEM
DESIGN
Design Stages of Mechatronic System

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Stage 1- Need for Design:
 The design process begins with a need. Needs are usually arise from dissatisfaction with an existing
situation. Needs may come from inputs of operating or service personal or from a customer through
sales or marketing representatives.
 They may be to reduce cost, increase reliability or performance or just change because of public has

become bored with the product.

Stage 2- Analysis of Problem:
 Probably the most critical step in a design process is the analysis of the problem i.e., to find out the
true nature of the problem.
 The true problem is not always what is seems to be at the first glance. Its importance is often
overlooked because this stage requires such a small part of the total time to create the final design.
 It is advantageous to define the problem as broadly as possible. If the problem is not accurately
defined, it will lead to a waste of time on designs and will not fulfill.

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 Case Study – Pick & Place Robot
Mechatronic system are widely used in industries
This robot has three axes about which the motion occur.
The following movements are as follows,
a) Clockwise & Anticlockwise rotation of a robot unit on its base.
b) Linear movement of Arm horizontally. (extraction or contraction).
c) Up & Down movement of the arm
d) Open & Close movements of Gripper

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 The above movements can be obtained by pneumatic cylinders, operated by
solenoid valve with limit switches.
 Limit switch – motion completed or not.
 Clockwise rotation – obtained by piston & cylinder arrangement (forward
movement of the piston).
 Counter clockwise rotation – obtained by piston & cylinder arrangement
(backward movement of the piston).
 Upward movement of Arm - forward movement of the piston in the cylinder.
 Downward movement of Arm - backward movement of the piston in the cylinder.
 Gripper opens - forward movement of the piston in the cylinder.
 Gripper closed - backward movement of the piston in the cylinder.

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 A microcontroller (M68HC11 type) is used to control the solenoid valves of
cylinders.
 TRIAC optoisolator – LED & TRIAC
Optoisolator – a semiconductor device used for transfer the signal
TRIAC – (Triode for Alternating Current) - used in power control and switching
applications
 LED input is 1, TRIAC is glowed & activate the current to the solenoid valve
 Then the DCV opens its o/p port to conduct the compressed air to actuate the
(extension / retraction) of the piston in the cylinder.

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 Case Study - Engine Management System
An Electronic EMS is made up of sensors, actuators & wirings which are integrated
in to a central processor called microprocessor or microcomputer.
Gather number of data’s from various sensors and adjust the fuel supply &
injection time.
So this helps to minimize the emissions & maximize the fuel efficiency at any
workload.

Basic components – Electronic Control Unit (EUC), fuel delivery system, Ignition
system & various sensors.

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Electronic Control Unit (EUC)
Sensor provide feedback to ECU to indicate how the engine is running.
It makes necessary adjustments for the operation of FDS & Ignition system.
Fuel Delivery System (FDS)
A high pressure fuel pump is mounted near the fuel tank.
A fuel line from the pump passes through the fuel filter to the fuel rail.
At the end of the fuel rail, a regulator is placed to regulate the pressure.
Ignition System
It consist of ignition coil, distributed spark plug which are connected with ECU to
receive signal for proper timed operation.

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Various Sensors
Engine sensors are classified in to following 5 groups.
 Throttle Position Sensor
 Exhaust gas Oxygen Sensor
 Manifold Absolute Pressure Sensor
 Temperature Sensor
 Speed Sensor
All these functions are centrally controlled by microcontroller.
Throttle Position Sensor:
Sends a signal to ECU about TP & force applied by driver. Then ECU
controls the FD & SI time. Potentiometer & Hall effect sensors are used.

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Exhaust Gas Oxygen (EGO) Sensor:
It is placed in engine exhaust system. The amount of O2 in indicates the ECU to
provide proper air-fuel ratio. Else entire system will suffer.
Manifold Absolute Pressure Sensor:
They measure the degree of vaccum in the engines intake which depends on
throttle opening & engine speed. Here piezoelectric & variable capacitor sensors are used
Temperature Sensor:
Send a signal to ECU to activate or deactivate the cooling fans in water cooled engine. Usually
thermistors & thermodiodes are used.
Engine Speed Sensor:
Send a signal to ECU to regulate engine speed & crank position. It also ensure that the engine
speed does not cross the safety limits.

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 Case Study - Automatic Car Park Barrier
 An ACP barrier operated by coin inserted.
 This system uses PLC for its operation.
 Two barriers – In barrier & Out barrier.
 In barrier – when correct money is inserted
 Out barrier – detection of car infront of it.
 This ACP barrier system consists of pivoted at the end, two solenoid 3/2 DCV A & B
and piston cylinder arrangement.
 A connecting rod connects the piston & barrier.
 Solenoid actuated DCV used to control movement of piston.
 Solenoid A is used to move piston upward & Solenoid B is used to move piston
downward.
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Principle:
When the current flows through solenoid A, the piston move
upward and cause the barrier to turn & rise about its pivot to allow the car.
When the barrier hits the limit switch, it turn on the timer for
certain delay.
Then the solenoid B is activated for the downward movement of
piston in the cylinder.

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 Case Study - Wireless Surveillance Balloon
 Surveillance generally refers to monitoring or observing a person or a group of people
from a certain distance.
 Surveillance equipment is typically used in warfare and/or incounter-insurgency
operations to monitor the activities of an enemy from a distance thereby reducing the
risk of confrontations which may result in injury and possible death to friendly
personnel,
 Surveillance equipment may also be used to monitor hazardous situations from
 a distance, such as for example, as may-be associated with chemical hazards,

Explosive hazards

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 Wireless surveillance balloon is an Aerostats or Tethered balloons which carry surveillance
cameras high-up-in the air to obtain a broader perspective view of the target area.
 It is useful for both military and civil operations.
 These surveillance balloons are essentially robots
 they become a socially interactive multiple robot system.
Elements
 image sensors,
 thermal sensors
 audio sensors
 location sensors,
 altitude sensors
 a compass, and
 motion sensors
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Applications:
 border security (TARS) in military
 enhancing battlefield situational awareness
 coastal surveillance
 platform for mounting telecommunication, television, radio transmitters and
 broadband equipment
 aerial platform for scientific instrument testing
 aerial platform for weather prediction instruments

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THANK YOU