MECHATRONICS

DIPLOMA 5^TH SEMESTER

PREPARED BY

Dr. Animesh Chhotray

DEPARTMENT OF MECHANICAL ENGINEERING G.I.E.T, BANIATANGI

Introduction to Mechatronics

What is Mechatronics?

• The word mechatronics is composed of “mecha” from mechanical and the “tronics” from electronics.

Mechanical + Electronics = Mechatronics

• The term “Mechatronics” was coined by Tetsuro Mori, a senior Japanese engineer at Yasakawa Company in 1969.

Introduction to Mechatronics

• Mechatronics is synergistic integration of mechanical engineering, electronics engineering, control engineering and computer science.
• Mechatronics can also be termed as replacement of mechanics with electronics or enhance mechanics with electronics.
• For example, in modern automobiles, mechanical fuel injection systems are now replaced with electronic fuel

injection systems. This replacement made the automobiles more efficient and less pollutant.

Introduction to Mechatronics

Introduction to Mechatronics

• Mechatronics concurrently employs the disciplines of mechanical, electrical, control and computer engineering at the stage of design itself.
• Mechanical discipline is employed in terms of various

machines and mechanisms, where as

• Electrical engineering as various electric prime movers viz. AC/DC, servo motors and other systems is used.
• Control engineering helps in the development of various electronics-based control systems to enhance or replace the mechanics of the mechanical systems.
• Computers are widely used to develop various softwares to control the control systems; product design and development activities; materials and manufacturing resource planning, record keeping, market survey, and other sales related activities.

Advantages of Mechatronics system

• It is cost effective and it can produce high quality products.
• Production of parts and products of international standards gives better reputation and return.
• It serves effectively for high dimensional accuracy requirements.
• It provides high degree of flexibility to modify or redesign the

systems.

• It provides excellent performance characteristics.
• It Results in automation in production, assembly and quality control.
• Mechatronic systems provide the increased productivity in manufacturing organization.
• Reconfiguration feature by pre supplied programs facilitate the low volume production.
• It provides higher level of flexibility required for small product cycles.
• It provides the possibility of remote controlling as well as centralized

monitoring and control. .

• It has greater extend of machine utilization.
• Higher life is expected by proper maintenance and timely diagnosis

of the fault.

Disadvantages of Mechatronics system

design and implementation.

• It needs highly trained workers to operate.
• Techno-economic estimation has to be done carefully in the

selection of mechatronic system.

• It has complexity in identification and correction of problems in the systems.

• The initial cost is high.
• Maintenance and repair may workout costly.
• Multi-disciplinary engineering background

is required to

Applications of Mechatronic system

• Mechatronic is widely used in our day to day lives. Be it in digitally controlled combustion engines, robots, automated guided vehicles or other machine tools, mechatronics is present everywhere.
• It is used in home appliances such as dish washer and washing

machines.

• It is used in laser optical systems. It is part of the image and sound processing devices such as sound operators and automatic focusing device.
• Mechatronic is also used in intelligent measuring devices like calibration devices, measuring and testing of sensors.

• Mechatronic is used in the medical field as well. Many applications such as magnetic resonance, ultrasonic

medical probes,

arthroscopic devices use mechatronics.

• It is used in automation like automatic air conditioning systems, security system, automatic door systems. It is also used in pressure, heat and position control systems.
• It is widely used in aeronautics engineerings for unmanned aerial vehicles and automatic pilots. In the defence industry it is used for automatically guided vehicles and mine detection robots.

Scope of Mechatronics in Industrial Sector

• Design and Modelling

Design and modelling are simplified to a large extent by the use of mechatronic systems. Basically, design involves drawing, analysis, and documentation. In earlier days, the processes of design were performed manually and it took weeks or months together. Now, the computer is used to complete processes of design faster. There are many designing tools such as AUTOCAD, Solid Works, CATIA,PROENGG, through which 2D or 3D drawings can be made. There are a number of tools to edit drawings at a faster rate. Analysis of the design involves working out the stress distribution, temperature distribution, weight analysis, and animations.

The drum plotter, x-y plotter, CD drive, printer, etc. are many mechatronic devices used to give complete documentation of design drawings.

• Software Integration

Different kinds of software are used in manufacturing, design, testing, monitoring, and control of the manufacturing process. Examples of such software include computer aided design (CAD), computer aided testing (CAT), computer aided engineering (CAE), and computer aided processing planning (CAPP).

Scope of Mechatronics in Industrial Sector

The integration of the packets of software leads to computer integrated manufacturing (CIM) or just-in-time (JIT) manufacturing. Software integration is not only used for manufacturing but also for communication networks, economic analysis, etc.

• Actuators and Sensors

Mechanical, electrical, hydraulic, and pneumatic actuators are widely used in the industry.

Switching devices, solenoid-type devices, and drives such as alternative current (ac) and direct current (dc) motors can be used as electrical actuators.

Hydraulic and pneumatic drives use linear cylinders and rotary motors as actuators.

sensor is used for an element which produces a signal relating to

the quantity being measured.

For example, an electrical resistance temperature device transforms the input of temperature into change in resistance.

Similarly, Transducers are defined as devices which when subject to some physical change experience a related change.

Scope of Mechatronics in Industrial Sector

• Intelligent Control

There are many industrial processes and machines which control many variables automatically.

Temperature, liquid level, fluid flow, pressure, speed, etc. are

maintained constant by process controllers.

In these areas, mechatronic systems are used for decision making and controlling the manufacturing environment.

• Robotics

A robot is a multifunctional reprogrammable machine used to handle materials, tools, or any special items to perform a particular task.

Manipulation robots are capable of performing operations, assembly, spot welding, spray painting, etc.

​

Service robots such as mail service robots, household servant robots, nursing robots in hospitals are being used nowadays.

Scope of Mechatronics in Industrial Sector

• Manufacturing

In the domain of factory automation, mechatronics has had

far-reaching effects in manufacturing.

Major constituents of factory automation include computer numerically controlled (CNC) machines, robots, automation systems, and computer integration of all functions of

manufacturing.

Low volume, more

variety, higher levels of flexibility,

reduced lead time in manufacture, and automation in manufacturing and assembly are likely to be the future needs of customers, and mechatronic systems will play an important role in this context.

Scope of Mechatronics in Industrial Sector

Components of a Mechatronic System

• Mechanical

​

• Electronics

​

• Sensors

​

• Actuators

​

• Control

​

• Computing

Model of a Typical Mechatronic System

Modules of a Mechatronic System

1. Sensing
1. Sensors
2. Signal Conditioning
3. Analog-to-Digital and Digital-to-Analog Conversion

​

• Control
• Open Loop
• Closed Loop Control

​

• Action
• Drive Circuits II.Actuators III.Motors

Modules of a Mechatronic System

Components of a Mechatronic System

• A mechatronic system has at its core a mechanical system which needs to be commanded or controlled by a controller.
• The controller needs information about the state of the system. This information is obtained from sensors.
• In many cases, the signals produced by the sensors are not in a form ready to be read by the controller and need some signal conditioning operations performed on them.
• The conditioned, sensed signals are then converted to a digital form by Analog-to-Digital Convertor (ADC) and are then sent to the controller.

Components of a Mechatronic System

• The controller is the „mind‟ of the mechatronic system, which processes user commands and sensed signals to generate command signals to be sent to the actuators in the system.
• Actuators are devices that can convert electrical energy to mechanical energy.
• The user commands are obtained from a variety of devices, including command buttons, graphical user interfaces (GUIs), touch screens, or pads.

Importance of Mechatronics in automation

• Today‟s customers are demanding more variety and higher levels of flexibility in the products. Due to these demands and competition in the market, manufacturers are thriving to launch new/modified products to survive.
• It is reducing the product life as well as lead-time to manufacture a product. It is therefore essential to automate the manufacturing and assembly operations of a product.
• There are various activities involved in the product manufacturing process. These are shown in figure. These activities can be classified into two groups viz. design and manufacturing activities.

Importance of Mechatronics in automation

Importance of Mechatronics in automation

• Mechatronics concurrently employs the disciplines of mechanical, electrical, control and computer engineering at the stage of design itself.
• Mechanical discipline is employed in terms of various machines

and mechanisms.

• Whereas electrical engineering enables how various electric prime movers viz. AC/DC, servo motors and other systems is used.
• Control engineering helps in the development of various electronics-based control systems to enhance or replace the mechanics of the mechanical systems.
• Computers are widely used to write various softwares to control the control systems; product design and development activities; materials and manufacturing resource planning, record keeping, market survey, and other sales related activities.

Importance of Mechatronics in automation

• During the conventional design-manufacturing process, the design assessment is generally carried out after the production of first lot of the products. This consumes a lot of time, which leads to longer (in months/years) product development lead- time.
• Using computer aided design (CAD) / computer aided analysis (CAE) tools, three-dimensional models of products can easily be developed.
• These models can then be analyzed and can be simulated to study their performances using numerical tools.
• These exercises provide an approximate idea about performance of the product/system to the design team at the early stage of the product development. Based on the simulation studies, the designs can be modified to achieve better performances.

Importance of Mechatronics in automation

• Use of CAD–CAE tools saves significant time in

comparison with that required in the conventional

sequential design process.

• CAD-CAE generated final designs are then sent to the production and process planning section.
• Mechatronics based systems such as computer aided

manufacturing (CAM): automatic process planning, automatic part programming, manufacturing resource planning, etc.

• Mechatronics based automated systems such as automatic inspection and quality assurance, automatic packaging, record making, and automatic dispatch help to expedite the entire manufacturing operation.

Importance of Mechatronics in automation

ensure a supply better reliable products in the

• These systems certainly quality, well packed and market.

• Automation in the machine tools has reduced the human intervention in the machining operation and improved the process efficiency and product quality.
• Therefore it is important to study the principles of mechatronics and to learn how to apply them in the automation of a manufacturing system.