Course Material

Name of the Course : Mechatronics

Name of the Unit : Introduction to Mechatronics Systems

Name of the Topic : Concept and Components of Mechatronics systems

and Importance of Mechatronics in automation

Objectives: To understand the various definitions and concept of the mechatronics and
also to impart knowledge about the various components of mechatronics
which are very much essential to understand the emerging field of
automation.

Outcomes: Upon successful completion, the student should be able to understand the
principles of the basic components and implement their ideas to ddemonstrate
the basic structure of mechatronics system.

Pre-requisites: To have a basic knowledge of various measurement systems and

working principle of different electrical systems.

1. The spring material used in a spring control device should have the following
property.

(A) Should be nonmagnetic

(B) Most be of low temperature coefficient
(C) Should have low specific resistance
(D) All of the above

2. A galvanometer has

(A) Air friction damping

(B) Fluid friction damping
(C) Eddy current damping
(D) Spring coil damping
3. The resistance can be measured most accurately by

(A) Voltmeter-ammeter method

(B) Bridge method
(C) Multimeter
(D) Megger

4. To measure the flux, devices used are based on

(A) Voltaic effect

(B) Piezo-electric effect
(C) Hall effect
(D) Photo-voltaic effect

5. Wagner earthing device is used to eliminate errors due to

(A) Electrostatic coupling

(B) Electromagnetic coupling
(C) Both A and B
(D) None of the above

6. The repeat accuracy of an instrument can be judged from its

(A) Static error

(B) Linearity error
(C) Dynamic error
(D) Standard deviation of error

7. An instrument to be used for measurement and control should preferably have

(A) Dead zone and dead time

(B) Linear output and fast response
(C) Non-linear output
(D) A highly damped response
8. Which instrument has identical calibration for AC as well as DC values?

(A) Hot wire type

(B) Moving coil type
(C) Induction type
(D) Moving iron type

9. The thermocouple instruments do not have

(A) High sensitivity

(B) Absence of frequency error
(C) Independence of ambient temperature
(D) High degree of measuring accuracy

10. The advantages of moving coil permanent magnet type instrument are

(A) Low power consumption

(B) No hysteresis loss
(C) Efficiency eddy current damping
(D) All of the above

1. Definitions of the term Mechatronics

(i) T. Mori (1969) expressed the word ‘mechatronics’ that it is composed of mecha
from mechanics and tronics from electronics. In other words, technologies and
developed products will be incorporating electronics more and more into
mechanisms, intimately and organically, and making it impossible to tell where
one ends and the other begins.
 (ii) W. Bolton (1995) expressed the term mechatronics that is the Integration of
electronics, control engineering, and mechanical engineering.

(iii) D. M. Auslander and C. J. Kempf (1996) defined as it is the application of

complex decision making to the operation of physical systems.

(iv) F. Harshama, M. Tomizuka, and T. Fukuda (196) expressed as, it is the

synergistic integration of mechanical engineering with electronics and intelligent
computer control in the design and manufacturing of industrial products and
processes.

(v) It is the synergistic use of precision engineering, control theory, computer

science, and sensor and actuator technology to design improved products and
processes defined by S. Ashley (1997).

(vi) It is the field of study involving the analysis, design, synthesis, and selection of
systems that combine electronics and mechanical components with modern
controls and microprocessors by D. G. Alciatore and M. B. Histand (1998).

2. Mechatronics-based Product Realization

• Systems engineering allows design, analysis, and synthesis of products and

processes involving components from multiple disciplines.

• Mechatronics exploits systems engineering to guide the product realization

process from design, model, simulate, analyze, refine, prototype, validate, and
deployment cycle.

• In mechatronics-based product realization: mechanical, electrical, and computer

engineering and information systems are integrated throughout the design
process so that the final products can be better than the sum of its parts.
 Mechatronic Design Process

3. Concept of Mechatronics design

4. Evolution Level of Mechatronics
i. Primary Level Mechatronics
This level incorporates I/O devices such as sensors and actuators that integrates
electrical signals with mechanical action at the basic control levels.
Examples: Electrically controlled fluid valves and relays
ii. Secondary Level Mechatronics
This level integrates microelectronics into electrically controlled devices.
Examples: Cassette players
iii. Third Level Mechatronics
This level incorporates advanced feedback functions into control strategy thereby
enhancing the quality in terms of sophistication called smart system.
Examples: Control of Electrical motor used to activate industrial robots, hard disk,
CD drives and automatic washing machines.
iv. Fourth Level Mechatronics:
This level incorporates intelligent control in mechatronics system. It introduces
intelligence and fault detection and isolation (FDI) capability systems

5. Basic structure
The basic structure of the mechatronic system which carries the sensors, actuators,
and devices for information processing. The surrounding environment, in which the
mechatronic system operates, is also important. A diagram of this structure is shown
in Figure. The system has usually a mechanical, electro mechanical or hydraulic
structure or it is a combination of these structures. It means that a given physical
system can be generally understood as a respective system that can be represented by
a hierarchically structured mechatronic system. A task of sensors is to determine a
chosen state variable value of the system.
 In this case, the sensors can be physically represented by the measured values or
software sensors so called observers. The sensors supply input variables for the
information processing, at present usually digital, i.e. discrete in terms of values and
time. The information processing is usually done by a microprocessor although it can
be also done by a fully analog electronics or combined (hybrid) analog/digital
electronics. The information processing determines actions needed to affect
appropriately the state variables of the system. An implementation of the actions is
directly in the system by actuators.

The goal of the mechatronic system is a spatial integration with other functional
elements in the area of sensors as well as in the area of actuators. It would create an
intelligent unit, i.e. an intelligent sensor (integration of a measured values sensor, an
analog/digital converter and a microprocessor) and an intelligent actuator (an
integration of a digital/analog converter, an adapter circuit or a power amplifier, or
even a microprocessor). The intelligent sensor measures analog physical quantities,
for example pressure, temperature, velocity, it digitalizes 8 measured values and
transfers the signal – suitably adjusted – to information processing devices. The
intelligent actuator is directly activated by the digital signal coming from the
corresponding information processing device.
 Signals are converted to analog variables, amplified and then handed over, e.g. to
create force or movement. A closer look at relations between the system, the sensors,
the information processing and the actuators shows that a description of the relations
using flows is useful.

In principle, there are three different types of flows:

(i) material flow, (ii) energy flow, and (iii) information flow.

The mechatronic system, shown in above Figure which consists of units connected
by three types of flows. The most visible are energy and material flows. Flows
connecting the base system and environment with sensors and actuators have a
character of energy flow as well as information flow – energy flows for measurement
requirements (sensors) as well as for action execution (actuators) but energy is
transferred as well – control signals of actuators and measurement signals of sensors.
Tools for information processing use the information flow from sensors and also
generate the information flow for the actuators. One main energy flow affecting,
directly or indirectly, the system can be noticed in case of energy flows.
Communication with a human or a system user is usually realized by a special
human-machine interface. The connection is represented by the information flow in
both cases.

6. Modularization and hierarchization

Complex mechatronic systems are usually made by synergetic integration of
different mechatronic modules, i.e. elements of system or components connected to
groups, jointly executing a certain function. It is not recommended to make the
integration at one level but it is necessary to separate the configuration according to
the principle of hierarchization because the modules contain and constitute different
functions. A higher-level system is made if more basic modules are connected
together by its functional mechatronic structure and mechanic supporting structure.
 At this higher level, the other tasks are realized according to the events monitored
by a sensor system and evaluated by the information - processing unit. A target value
for the subordinate basic mechatronic modules is generated at this level of hierarchic
structure as well as error diagnosis and algorithm monitoring. Another hierarchic
level, at which the basic modules and already grouped systems are simply connected
by the information processing units, is suitable if the mechatronic system would do
other tasks, for example process of learning or adaptation.

A sample of mechatronic system’s hierarchical structure is shown in the above

Figure. The basic modules at the first level (e.g. a spring unit with wound spring and
telescopic damper) are connected to the second level (e.g. car) by the information
processing. The created systems are connected together by information processing
(e.g. crossway control) at the third level. A spatial integration of related equipment is
also an important task as well as functional integration of the mechatronic modules.
Modules of equipment have to be integrated through defined interfaces to create a
whole system with individual hierarchical levels (mechatronic units). A simultaneous
considering of both integration tasks leads to the optimally constructed mechatronic
systems.
7. Basic Elements of Mechatronics System

The various elements in typical mechatronic systems are shown in Figure.

(i) Sensors and actuators

Sensors and actuators mostly come under mechanical systems. The actuators
produce motion or cause some action. The sensors detect the state of the system
parameters, inputs, and outputs. The various actuators .used in the mechatronic
system are pneumatic and hydraulic actuators, electro-mechanical actuators,
electrical motors such as DC motors, AC motors, stepper motors, servomotors, and
piezoelectric actuators. The various types of sensors used in the mechatronic system
are linear arid rotational sensors, acceleration sensors, force, torque and pressure
sensors, flow sensors, temperature sensors, proximity sensors, light sensors.

(ii) Signals and conditioning

The mechatronic systems deal with two types of signals and conditioning such as -
input and output. The input devices receive input signals from the mechatronic
systems via interfacing devices and sensors. Then it is sent to the control circuits for
conditioning or processing. The various input signal conditioning devices used in the
mechatronic system are discrete circuits, amplifiers, Analog-to-Digital (A/D)
converters, Digital-to-Digital (DZD) convertors. The output signals from the system
are sent to output/display devices through interfacing devices. The various output
signal conditioning devices used in the mechatronic system are Digital-to-Analog
(D/A) converters, Display Decoders (DD) converters, amplifiers, power transistors,
and power op-amps.
(iii) Digital logic systems
Digital logic devices control overall system operation. The various digital logic
systems used in the mechatronic system are logic circuits, microcontrollers,
programmable logic controllers, sequencing and timing controls, and control
algorithms.

(iv) Software and data acquisition systems

The data acquisition system acquires the output signals from sensors in the form
of voltage, frequency, resistance etc. and it is inputted into the microprocessor or
computer. Software is used to control the acquisition of data through DAC board.
The data acquisition system consists of a multiplexer, amplifier, register, and control
circuitry and DAC board. The various data acquisition systems used in the
mechatronic system is data loggers, computer with plug-in boards, etc.

(v) Computers and display devices

Computers are used to store a large number of data and process further through
software. Display devices are used to give visual feedback to the user. The various
display devices used in the mechatronic system are LEDs, CRT, LCD, digital
displays, etc.
8. Fields of application

i. High-speed laser cutting and engraving systems of extreme accuracy,

ii. Measuring systems with optical and mechanical scanning,
iii. Micro-assembly systems,
iv. Wafer inspection and machining.
9. Real life applications of Mechatronics

i. In Health Care

Robotic surgery has been around since 2000, when the da Vinci Surgical System
was approved by the FDA. The robot includes a camera on one arm and surgical
equipment on the other. Using a robot to perform surgery has many benefits,
including being less invasive, which leads to faster recovery and less risk of
infection.

New surgical robots are being developed for eye surgery, targeting lung cancer,
knee surgery, and laparoscopic surgeries. One robot, called CorPath, is enabling
surgeons to perform procedures from a distance. In December 2018, CorPath was
used by a surgeon to conduct an elective procedure on a patient that was 20 miles
away. Read more about this revolutionary procedure.

ii. Around the House

Refrigerators that can order milk when you are running low. Washers that text
you when the load is ready for the dryer. Vacuums that carry cats around the house
while they clean your hardwood floors. All of these devices are available due to
mechatronics. And, of course, who is ever without their smart phone? A cell phone’s
camera, for example, uses mechatronics to take cute pictures and videos of your cat
riding that robotic vacuum.
iii. In the Car

Mechatronics engineering has saved thousands of lives through the advent of anti-
lock brakes and stabilization, air bag inflation, and fully autonomous vehicles. The
U.S. Postal System is even testing autonomous trucks to deliver the mail.

iv. In Manufacturing

The manufacturing process has become largely automated, and that is frequently
due to integration of mechatronics. Industrial robots perform consistently and
quickly, enabling manufacturers to keep up with demand while reducing costs. Like
many other areas, manufacturing has adopted smart technology to ensure efficiency.

v. For Exploration

The Mars rovers Spirit and Opportunity provided a view of the red planet that
had never been seen, sending to Earth a combined 342,432 pictures. Some proposed
uses for mechatronics in space exploration include robotic arms on the International
Space Station, development of life-sustaining systems on the moon or otherwise
uninhabitable planets, or flying robots to examine planets’ surfaces.
 Test after completion

1. Which of the following are characteristics of mechatronic products and systems?

(A) Functional interaction between mechanical, electronic and information

technologies
(B) Spatial interaction of subsystems in one physical unit
(C) Intelligence related to the control functions of the mechatronics system
(D) All of the above

2. A group of components which can complete certain tasks or achieve certain desired
results in a desired manner while working together is called as_____

(A) Output system

(B) Sequence system
(C) Control system
(D) All of the above

3. In which system does the output not affect the process in any way?

(A) Open loop system

(B) Closed loop system
(C) Both a. and b.
(D) None of the above

4. Which of the following cannot be an input that is given to the PLC?

(A) Manual switches

(B) Relays
(C) Sensors
(D) None of the above

5. On-off Control is also called as ________.

(A) One position control

(B) Two position control
(C) Four position control
(D) Half position control
 Conclusion
• The various definitions and concepts of mechatronics system are thoroughly
studied to impart and develop the new mechatronics design.

• The working principle and various stages of the elements of mechatronics

components are discussed in stage by stage.

• Mechatronics consists of integration of mechanical engineering with electronics,

computer systems, and advanced controls to design, construct, and operate
products and processes.

• In the industry is currently an increasing demand to acquire the core skills of

mechanical engineers and electrical engineers as well as management and
business.

• Their knowledge enables them to solve a wide range of mechanical, electrical and
software problems, allowing them to participate in and lead multidisciplinary
design teams.

• The knowledge gained from the fundamentals of the various mechatronic systems
on the real life applications.

Demo Videos
https://www.youtube.com/watch?v=4Eaou2pOGGo

https://www.youtube.com/watch?v=bVD2w2drhaU

https://www.youtube.com/watch?v=3WBdpbhR4AU

References
1. W. Bolton, “Mechatronics”, Pearson Education, 3rd Edition, 2007.

2. Michael B. Histand and David G. Alciatore, “ Introduction to Mechatronics and

Measurement Systems”, McGraw-Hill International Editions, 2007. 3rd Edition