UNIT I PART - A

1) Define Mechatronics? Mechatronics is the synergistic combination of precision Mechanical engineering, electronic control and system thinking in the design of products and manufacturing products. 2) What are the needs for Mechatronics? a) b) c) d) e) Globalization Increased integration and automation Computer integration and automation Greater focus on service System integration

3) How Mechatronics has been classified? a) b) c) d) Manufacturing mechatronics Automobile mechatronics Medical Mechatroncs Mechatronics for office automation

4) What are the elements of mechatronics? a) b) c) d) electronics devices Mechanical system Measuring devices rotary linear Programmable Logic Controller (PLC)

5) What are the advantages of manufacturing machatronics? To improve quality and quantity Scrap reduction/zero quantity Poke-yoke application Better maintenance capabilities Flexibility in production line Profitability

6) What are the industrial applications of Mechatronics? Washing machine Computer disk drive Robotics Servo-technology NC/CNC machine Automobile 7) Compare the domain for mechatronics with human body?
Human Body Parts Muscles : Provide force and energy to do work Elements of Mechatronics Mechanical Engg : Proves analysis of Mechanism,

Brain : To think and take decision

motion planning, energy transformation etc. Micro processor / Computer : To take decision Speedy processing of data

Nervous System : Linking and coordinating various parts of body including brain.

Repeative processing Information Technology : Communication Data Processing

Integration of all parts, nervous system and brain in necessary for proper functioning of human body.

Linking various modules of the system Integration of mechanical engineering, Micrpropcessor / Computer, Electronics, and Control and Information Technology is necessary for synergistic effect in mechatronics.

8) What are the activities of manufacturing mechatronics?

Engineering design and Analysis Manufacturing Operations Data acquisition and Analysis

9) Define a System? A system can be taught of as a box, which has an input and an output, and where we are not concerned with what goes on inside the box but only the relationship between the output and the input. 10) Define a measurement system? A measurement system can be thought of as a black box, which used for making measurements. It has as its input the quantity being measured and its output the value of that quantity. 11) Define a control system? A control system can be though of as a black box which is used to control its output to some particular value or particular sequence of values.

12) Give a block diagram of a measurement system?

13) What is the purpose of using signal conditioner? A signal conditioner takes the signal from the sensors and manipulates it into a condition which is suitable for either display or in the case of a control system, for use to exercise control. 14) Why display systems are used in mechatronics system? They are used to display the output from the signal conditioner. 15) What is correction element in the mechatronics system? The correction element produces a change in the process to correct or change the controlled condition. 16) Define Transducers? It is defined as a device which, when actuated transforms energy from one form to another. Generally, any physical parameters are converted into electrical form. 17) What are the two types of transducers? Electrical and Mechanical transducer. 18) Write notes on electrical transducer? It is a sensing device by which a physical, mechanical or optical quantity to be measured is transformed directly by a suitable mechanism into an electrical, voltage/current proportional to the input measured. 19) Name the parameters that dictate the transducer capability? They are linearity, repeatability, resolution and reliability. 20) Define sensitivity? It is defined as the electrical o/p unit change is the physical parameters. High sensitivities generally desirable for a transducer. 21) What are the advantages of electrical transducer? a) Electrical amplification and attenuation can be done easily even with static devices. b) The effects of friction and mass-inertia are minimized. 22) Classify electrical transducers? Active and passive

23) Name the two parts of a transducer? They are sensing element and transduction element. 24) Mention the factors considered while selecting a transducer? Operating range, Sensitivity, Accuracy, usage and ruggedness and Electrical parameters. 25) What are resistive transducers? Resistive transducers are those in which the resistance changes due to a change in some physical phenomenon. The change in the value of the resistance with a change in the length of the conductor can be used to measure displacement. 26) What is meant by POT? It is a resistance potentiometers used for the purpose of voltage division. It consists of a resistive element provided with a sliding contact called as wiper. 27) What is known as helipots? The POT uses translatory or rotational motions. But there are some POTs which use the combination of the two motions. (i.e.) translational as well as rotational. These POTs have a helix form of resistive element that is known as helipots. 28) List the merits of resistance potentiometer? a) They are inexpensive and simple to operate. b) Useful for the measurement of large amplitude of displacement. 29) List the demerits of resistance potentiometer? a) When using a linear potentiometer, a large force is required to move the sliding contacts. b) The sliding contacts can wear out become misaligned and generate noise 30) Explain the working principle of strain gauge? It works on the principle that the resistance of a conductor or a semiconductor changes when strained. This property can be used for measurement of displacement, force and pressure. 31) Name the different types of strain gauges? Unbounded metal strain gauges, Bonded metal wire strain gauges, Bounded metal foil strain gauge, diffused metal strain gauge. 32) List the advantages of semiconductor strain gauges? a) Hysterisis character is excellent. b) Frequency response is up to 1012 Hz. c) Their length ranges from 0.7 to 7mm. 33) What is meant by rosette?

It is a combination of strain gauges to a single element strain gauge. 34) What is an inductive electromechanical transducer? It is a device that converts physical motion into a change in inductance. 35) Give the three working principles of variable inductance transducers? Change of self inductance, change of mutual inductance and production of eddy currents. 36) Write notes on LVDT? It is a linear variable differential transformer, which is used to translate the linear motion into electrical signals. It consists of a single primary winding and two secondary windings. 37) List the advantages of LVDT? a) b) c) d) High range of displacement measurement. Friction and electrical isolation. Ruggedness Low hysterisis and low power consumption.

38) List the disadvantages of LVDT? a) The transducer performance is affected by vibrations. b) Relatively large displacements are required for appreciable differential input. 39) Write down the principle of operation of capacitive transducers? C = A/d = rO A/d Where A = overlapping area of plates in m2. D = distance between two plates in m r = relative permittivity o = permittivity of free space (8.85 x10-12 F/m) 40) List the advantages of capacitive transducers? a) They require extremely small forces to operate. b) They are extremely sensitive. c) Have good frequency response and require small power to operate them. 41) Give the expression for output voltage of piezo electric transducer? E = Q/CP Where Q = generated charge CP = shunt capacitances 42) Classify digital transducers?

Tachometer transducers, Incremental transducers and Absolute transducers. 43) What is digitizers? It is a digital encoding transducer that enables a linear or rotary displacement to be directly converted into digital form without intermediate forms of analog to digital conversion (A/D). 44) Give the uses of tachometer encoder? Used for the measurement of speed rather than displacement and in situation where the rotation never reverses. 45) What is bimetallic element? It is an element which consists of strips of two metals with differing co-efficient of thermal expansion, bonded or welded together to form a single piece. 46) What is fluidity? It is a term which is used to describe the property of fluids. 47) What is humidity? It is the measure of water vapour present in a gas. It is usually measured as absolute humidity, relative humidity or dew point temperature. 48) What is absolute humidity? It is the mass of water vapour present per unit volume. 49) What is the purpose of using Hygrometer? Hygrometer is used to directly measure the value of humidity. 50) Write the expression of Reynolds Number? Re = dPV/ Where d = Diameter of the pipe = dynamic viscosity P = mass density of the fluid.

UNIT II
ACTUATION SYSTEMS

PART A
1. What are the advantages of hydraulic actuators over electrical actuators? a. b. c. d. e. Compact size (i.e) higher power transmission for the same size. Less moving parts Less wear and fear and self lubricating. Controlled motion. Adaptability for automatic control

2. List components of a hydraulic system. Basic components of Hydraulic systems are : 1. 2. 3. 4. 5. 6. Reservoir to hold oil. Hydraulic pump normally positive displacement type. Electric motor to drive the pump. Actuator, which may be rotary or linear Control values for controlling flow, direction and pressure and Pipelines and fittings to transmit oil power.

3. Give application of pneumatic system. a. b. c. d. e. Hammer Press Riveting Chiseling Rotary grinding

4. What types of pumps are used for oil hydraulic system? a. Gear pump b. Vane pump c. Piston pump 5. What are the functions of control value? The functions of control values are the direction, flow and pressure. 6. What is a cam? A cam is a machine element which generally rotates at uniform speed and it is required to impart reciprocating or oscillatory motion to another machine element called follower by virtue of profile (or shape) of the cam making direct contact with the follower. 7. A cam profile is the ________ surface area of the cam. Ans. Total 8. Give an application of cam is a mechatronics system.

1. 2. 3. 4.

For operating the values in interval combustion engines. Textile machine tools Paper cutting machines Feed mechanism of automatic lathes, switches, etc.

9. What are the different types of Cams? 1. Radial (or) disc cams 2. Cylindrical cams 3. Translation cams 10. What are the different types of motions of the follower in cam rotates at a uniform angular velocity? 1. 2. 3. 4. Uniform velocity (or) uniform motion. Simple harmonic motion (SHM) Uniform acceleration and retardation. Cycloidal motion

11. Define mechanisms in actuators. Mechanical power from a prime moves (or) an electric motor or pneumatic / hydraulic actuators is to be transmitted to get a useful motion, which may be rotary or reciprocating (or) oscillating. Such devices are called Mechanisms. 12. What are different types of Gears? 1. 2. 3. 4. Helical gear Bevel gear Worm gear Spur gear

13. What is Gear? To transmit a definite power from one shaft to another shaft, the projections on one disc and recesses on another disc can be made which can mesh with each other. This leads to the formation of teeth on both discs and the discs with teeth on their periphery are known as Gears (or) Toothed wheel is called Gear.

14. What are the advantages of gear drive over other drives? Advantages of Gear drive 1. 2. 3. 4. 5. Gear drive is a positive drive (no slip). It can transmit very large power It has high transmission efficiency. It requires less space. It is reliable.

15. What are the disadvantages of gear drive over other drives? Disadvantages of gear drive 1. 2. 3. 4. Maintenance cost of gear drive is also high due to lubrication requirements. Manufacturing cost of gear is high. The error in cutting teeth may cause vibrations and noise during operations. It requires precise alignment of shafts.

16. What is the purpose of coupling? Couplings are used to connect two shafts. 17. What are the different types of couplings? Flange coupling rigid type. Tyre coupling. 18. What is the function of Clutch? Clutches are the devices for transmission of power between two shafts at will. The power between shafts will be transmitted either by mechanical function (or) electromagnetic coupling. Positive clutches are used only for slow speeds. 19. In a contactor what NO and NC stand for? NO Normally Open NC Normally Closed 20. What is the function of a relay? Normally relay is meant for carrying current upto 1A. For higher current, contactors, having bigger electromagnet are employed. The energizing coil of the contactor will be connected to overload protection. 21. Give some examples of solid state switches. Diodes Thyristor and triacs Bipolar transistor Power MOSFETS 22. Give a few application of solenoid in mechatronics system. a. Brakes b. Clutches 23. What is Triac? The triac is similar to thyristor and is equivalent to pair of thyristors in reverse parallel on the same clamp. These are used as rectifier, pulse with modulator for DC motor control and phase control. 24. What is Diodes? Flexible flange coupling. Gear coupling.

Diodes allows current in one direction for forward potential and does not allow in the other direction for reversed potential. 25. What is Thyristors (or Silicon controlled rectifiers)? Thyristor switch operation is controlled by gate current. For eg. When gate current is zero, the thyristor breakdown voltage may be 300V and on breakdown, the voltage will come down to 12V, there by increasing current through thyristor. If gate current is given, the breakdown voltage will come down or firing will take place earlier. 26. What is MOSPET? MOSFETS (Metal-Oxide Field Effect Transistors) is similar to bipolar transistors except that no current flows into the gate to exercise the control. The gate voltage is the controlling signal. With MOSFETs, very high frequency switching is possible upto 1 mHZ. 27. Classify electric motors for mechatronics system. a. b. c. d. AC motors DC motors Servo motor Stepper motor

28. What is the advantage of slipring motor over squirrel case induction motor? a. Simple in construction b. Rugged characteristic and are widely used for driving machine tools, pumps, compressors. 29. What is Servo motor? Servo motor is a 2 phase motor used for control application. It consists of two phases, reference phase (phase m) and control phase (phase a) both drawn from a same source. Control phase voltage is shifted in phase by 90 from reference phase by means of phase shifting networks. 30. What is stepper motor and give its merits? Stepper motor consists of sets of electromagnets in stator and a permanent magnet in rotor. The stepper motor having 4 poles. This consists of two magnets (4 poles) whose polarity can be changed and they can be switched on and off. 31. Give specification of a stepper motor. The stepper motor will be specified by the following:a. b. c. d. e. Phase Step angle Holding torque Pull in torque Pull out torque

UNIT III

10

PART A
1. In the avenue of mechatronics define a system A system is defined as a group of properly arranged elements those when act together. Provides the desired output with respect to available inputs. Evidently, a systems takes some inputs and provides some outputs while satisfying the law of conservation of energy. 2. What is system modeling? System modeling is about solving practical problems by creating mathematical models, called model equations which can be manipulated and optimized during the process of system design. 3. Spring elements _________ potential energy Ans: Stores 4. The element possessing inertance is known as _________ Ans: inertor 5. Define fluid capacitor An elements in which the stored energy is a function of fluid pressure is defined as fluid capacitor. 6. What are the various ways of classifying the basic engineering systems? 1. 2. 3. 4. Mechanical system Electrical system Fluid system Thermal system (or) Fluid system.

7. What are the analysis and design procedure in mechatronics system? 1. 2. 3. 4. 5. Identification for description Formulation of a mathematical model Analysis of the model Interpretation conformation are verification Practical behaviour study.

8. Distinguish between physical and mathematical model? Modeling is nothing but a mathematical description of the physical system. It governs the fundamental physical laws associated with the system. During the design process, the laws interns of mathematical model are exploited to meet the desirable design specification.

9. What are the three basic modeling elements are embarked for the mechanical system?

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a. Spring b. Damper c. Mass / Inertia 10. Define Damper element (or) dashpot Damper elements does not store any energy. It consumes energy, which cannot be recovered. Other name of the damper is dashpot that symbolizes resistance, more appropriately mechanical resistance. 11. What are the basic models of heat transfer? a. Conduction b. Convection c. Radiation 12. What are the basic modeling elements of electrical systems?
a. An b. A c.

Inductor (spring potential energy) resistor (Damper loss) A capacitor (mass / inertia kinetic energy).

13. Define mass / Inertia elements? Mass elements refers to translational movement where as inertia element corresponds to rotational movement. Both mass and inertia elements govern the law in terms of storing kinetic energy. 14. What are the three basic modeling elements in fluid system? a. Inertance b. Fluid resistance c. Fluid capacitance 15. Define fluid resistance? A fluid resistor dissipates energy. A flow of fluid through a fluid system gives rise to a pressure drop analogous to voltage drop across an electrical resistance element. The drop signifies loss. 16. Define fluid capacitor? An element in which the stored energy is a function of fluid pressure is defined as fluid capacitor. 17. What are the basic modeling elements of thermal system? a. Thermal capacitance b. Thermal resistance 18. What is lumped parameter? System model based on the elements such as spring damper and mass/inertia is referred

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to as lumped. Parameter model due to the reason that each element is basic and independent of others. 19. Define Dynamic System? When the system parameter change with respect to time it is called dynamic system. 20. What is the pneumatic actuator in its basic nature? The pneumatic actuator in its basic nature is simply a local consisting of a point mass and a dashpot with damping constant. 21. What is the method to control the speed of a D.C motor? The speed of a DC motor can be controlled either by changing the armature voltage, the magnetic flux, the armature resistance (or) combinations of these. 22. Pure thermal neither characterizes loss nor stores any energy? Resistance. 23. What are the factors need to be considered for selecting a microcontroller? a. b. c. d. e. Number of input / output pins Interfaces required Memory requirements The no of interrupts required Processing speed required

24. What are the components of closed loop process control systems? a. Process equipment b. Control equipment 25. What are the components consists of control equipment? 1. 2. 3. 4. 5. Controller The measuring unit The comparator The actuator The power unit.

26. What are the various types of control in mechatronics system? a. b. c. d. e. f. On off control During adjusting control or time proportionate control Proportional control Integrate control (or) proportional speed sloshing control (or) reset action control. Derivative control (or) rate control Programme control.

27. What is ON OFF control?

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When the control value (or) the final control element has only two positions fully closed (or)fully open, as actuated by the controller, the control scheme is known as on-off control. 28. What is PID controller? Combining all three models of control (proportional integral and derivative) enables a controller to be produced which has no offset error and reduces the tendency for oscillations. Such a controller is known as a three model controller (or) PID controller. 29. What is the purpose of closed loop control system? A closed loop control systems a controller is used to compare the output of a system with the required condition and convert the error into a control action designed to reduce the error. 30. Explain the term PLC? The term programmable logic control (PLC) is used for a simple controller based on a microprocessor and operates by examining the input signals from sensors and carrying out logic instructions which have been programmed into the memory. 31. What are the various types of control modes? The various types of control modes (is the ways in which controllers can react to error signals) are: 1. Two step mode 2. proportional mode 3. derivative mode 4. integral mode 5. Combinations of modes PD, PI, & PID. 32. What are the advantages of microprocessors as controller over analog controllers? 1. The form of controlling action (eg. Proportional or laree mode) can be changed by purely a change in the computer software. 2. No alteration in hardware or electrical wiring in required. 3. Where as with analog control separate controllers are required for each process being controlled, however, with a microprocessor many separate processes can be controlled by sampling processes with a multiplexer. 33. What criteria should be considered while selecting a PLC? 1. Types of inputs / outputs required such as: - Isolation - Out board power supply for inputs / outputs - Signal conditioning 2. Input / output capacity required 3. size of memory required 4. Speed and power required for CPU. This is linked to the number of types of instructions that can be handled by a PLC. UNIT IV
PROGRAMMING LOGIC CONTROLLER

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PART - A 1. What are the advantages of relay output switching? a. b. c. d. Contacts for giving to a temporary overload. Immune to false trips from electrical noise. Little voltage drop across contacts. No restrictions when connecting in serial or parallel configurations.

2. What are the limitations of relay output switching? Mechanical switching is slower Mechanical life is limited. Subject to contact bounce and cannot be completely sealed.

3. What are the advantages of solid state switching? Fast switching speed. High reliability Infinite life Low power required to energize No contact arcing Little or no switching noise.

4. What are the limitations of solid state switching? Switch may be destroyed by an overload. Tends to fail in the ON state Heat dissipation Expensive and possibility of false trips from electrical noise.

5. What are the advantages of PLC? Flexibility Maintainability Connectivity Ruggedness and reliability.

6. What is meant by ladder logic? Ladder logic is a language that differs from most other computer languages in that it is a graphic language. The programmer simply draws a schematic diagram of 16 logic on the screen. It resembles the elementary diagrams used in the hand wired relay logic systems. The instruction set consists of coils normally open contacts, normally closed contacts and other familiar symbols. The symbols represent the function of the component. 7. What are the advantages of a smart, handheld programming terminal? 1. Easy transfer of the PLC program to the HHT for editing or trouble shooting. 2. Easy transport of a program to the field to update a current machines program

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3. 4. 5. 6. 7. 8.

Rugged and industrially hardened for the factory environment. Cheaper than a laptop computer. Easy to use and easy to learn; no software required. Compact size. Some will fit in a pocket. Program storage Monitor resident PLC program for trouble shooting.

8. What are the limitations of HHT? 1. Not all CPUs in a manufactures PLC will support handheld programming. 2. An HHP will hold only one program at a time whereas a lap top or desktop personal or industrial computer can hold many programs on hardware. 3. Documentation not displayed. 4. If the battery life is over, a program stored in memory will be lost. 9. What are the advantages of software programming? 1. 2. 3. 4. 5. Personal computer monitor can display multiple rungs of logic. Data table can be easily monitored. Personal computer software offers cut and paste features for easy editing. Programs can be stored on it computers hard drive. Programs can be transferred from the hard drive to a floppy drive and then it can be transported.

10. Draw various Ladder symbols. Input as contacts not closed until input Input as contacts which are closed Unit input Output

Special Instruction

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UNIT V
DESIGN AND MECHATRONICS SYSTEM

PART A
1. Name the various stages in designing mechatronics system? 1. 2. 3. 4. 5. 6. 7. Need for design. Analysis of problem Preparation of specification Generation of possible solution Selection of suitable solution or Evaluation Production of detailed design Production of working drawing

2. Mention any four statements about the problem definition. Mass and dimensions of design. Type and range of motion required. Accuracy of the element Input and output requirements of elements.

3. Generation of possible solution stage is called us --------------Conceptualization stages. 4. Compare traditional and mechatronics design. Sl. No.
1 2 3 4 5

Traditional design
It is based on traditional system such as mechanical, hydraulic and pneumatic Less flexible Less Accurate More complicate mechanism in design Components and moving parts

Mechatronics design
It based on mechanical, electronics, computer technology and control engineering More flexible More accurate Less complicate mechanism design It involves fewer compounds and moving parts.

5. What are the requirements satisfied before starting the timer? Start the pulse applied. Check the timer whether it is ON or OFF condition The timer should be in OFF condition before triggering 6. How can be delay varied in a simple program? DELAY LOOP LDX DATA DEX BNE LOOP RTS

7. What are the advantages of PLC system?

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In PLC system, the time duration can be easily adjusted by changing the timer preset values (i.e., DATA) in the program whereas the traditional system requires various sizes of the cams. 8. What is a windscreen wiper? Windscreen wiper is a device which is used to clear the front glass of the cars, buses, train etc., during raining days. 9. What are the configurations in operating stepper motor? 1. Full step configuration. 2. Half-step configuration 10. Write the basic steps of the program to run a stepper motor. Step1: Advance a step by applying a data. Step2: Call time delay routine to complete a step. Step3: Repeat step and step2 until the required number of steps Step4: To reverse the direction of stepper motor, the same steps given above are repeated in the reverse order data. 11. What is the function of decoder? Decoder is used to convert the data from micro controller into seven segment data to glow the LED segments. 12. What are the various movements of robots? 1. 2. 3. 4. Clock wise and anticlockwise rotation of the robot unit on its base. Linear movement of the arm horizontally i.e., extension or contraction of arm. Up and down movement of the arm and Open and close movement of the gripper.

13. Name the two barriers used in automatic car parking system and state its uses. There are two barriers used namely in barrier and out barrier. In barrier is used to open when the correct money is inserted while out barrier open when the car is detected in front of it. 14. List the various sensors contained in engine management system. Temperature sensor hot wire anemometer oil and pressure sensor oxygen sensor.

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