UNIT VI:

APPLICATIONS IN MECHATRONICS

Importance of Mechatronics in automation

FIG: Operations involved in design and manufacturing of a product

Todays 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.
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 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.

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 numerical tools are being continuously updated or enriched with the real-life performances of
the similar kind of products. 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. 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. Use of CADCAE 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. uses the design data provided by the design team. Based these inputs, various
activities will then be planned to achieve the manufacturing targets in terms of quality and quantity with in a
stipulated time frame.
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. These systems certainly
ensure a supply better quality, well packed and reliable products in the 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.

Mechatronics: products and systems in manufacturing

Mechatronics has a variety of applications as products and systems in the area of manufacturing automation. Some
of these applications are as follows:
1. Computer numerical control (CNC) machines
2. Tool monitoring systems
3. Advanced manufacturing systems
a. Flexible manufacturing system (FMS)
b. Computer integrated manufacturing (CIM)
4. Industrial robots
5. Automatic inspection systems: machine vision systems
6. Automatic packaging systems

1. Computer numerical control (CNC) machines

CNC machine is the best and basic example of application of Mechatronics in manufacturing automation. Efficient
operation of conventional machine tools such as Lathes, milling machines, drilling machine is dependent on operator
skill and training. Also a lot of time is consumed in workpart setting, tool setting and controlling the process
parameters viz. feed, speed, depth of cut. Thus conventional machining is slow and expensive to meet the challenges
of frequently changing product/part shape and size.

Computer numerical control (CNC) machines are now widely used in small to large scale industries. CNC machine
tools are integral part of Computer Aided Manufacturing (CAM) or Computer Integrated Manufacturing (CIM)
system. CNC means operating a machine tool by a series of coded instructions consisting of numbers, letters of the
alphabets, and symbols which the machine control unit (MCU) can understand. These instructions are converted into
electrical pulses of current which the machines motors and controls follow to carry out machining operations on a
work piece. Numbers, letters, and symbols are the coded instructions which refer to specific distances, positions,
functions or motions which the machine tool can understand. CNC automatically guides the axial movements of
machine tools with the help of computers. The auxiliary operations such as coolant on-off, tool change, door openclose are automated with the help of micro-controllers. Figure 1.2.1 shows the fundamental differences between a
conventional and a CNC machine tool. Manual operation of table and spindle movements is automated by using a
CNC controllers and servo motors. The spindle speed and work feed can precisely be controlled and maintained at
programmed level by the controller. The controller has self diagnostics facility which regularly alarms the operator
in case of any safety norm violation viz. door open during machining, tool wear/breakage etc. Modern machine tools
are now equipped with friction-less drives such as re-circulating ball screw drives, Linear motors etc.

Advanced Manufacturing Systems:

Flexible Manufacturing System Nowadays customers are demanding a wide variety of products. To satisfy this
demand, the manufacturers production concept has moved away from mass to small batch type of
production. Batch production offers more flexibility in product manufacturing. To cater this need, Flexible
Manufacturing Systems (FMS) have been evolved.
As per Rao, P. N. [3], FMS combines microelectronics and mechanical engineering to bring the economies of the
scale to batch work. A central online computer controls the machine tools, other work stations, and the transfer of

components and tooling. The computer also provides monitoring and information control. This combination of
flexibility and overall control makes possible the production of a wide range of products in small numbers.
FMS is a manufacturing cell or system consisting of one or more CNC machines, connected by automated material
handling system, pick-and-place robots and all operated under the control of a central computer. It also has auxiliary
sub-systems like component load/unload station, automatic tool handling system, tool pre-setter, component
measuring station, wash station etc. Figure 1.2.4 shows a typical arrangement of FMS system and its constituents.
Each of these will have further elements depending upon the requirement as given below, Joint initiative of IITs and
IISc Funded by MHRD Page 14 of 17
A. Workstations
o CNC machine tools
o Assembly equipment
o Measuring Equipment
o Washing stations
B. Material handing Equipment
o Load unload stations (Palletizing)
o Robotics
o Automated Guided Vehicles (AGVs)
o Automated Storage and retrieval Systems (AS/RS)
C. Tool systems
o Tool setting stations
o Tool transport systems
D. Control system
o Monitoring equipments
o Networks
It can be noticed that the FMS is shown with two machining centers viz. milling center and turning center. Besides it
has the load/unload stations, AS/RS for part and raw material storage, and a wire guided AGV for transporting the
parts between various elements of the FMS. This system is fully automatic means it has automatic tool changing
(ATC) and automatic pallet changing (APC) facilities. The central computer controls the overall operation and
coordination amongst the various constituents of the FMS system.

Video attached herewith gives an overview of a FMS system

Figure 1.2.4 A FMS Setup

The characteristic features of an FMS system are as follows,

1. FMS solves the mid-variety and mid-volume production problems for which neither the high production rate
transfer lines nor the highly flexible stand-alone CNC machines are suitable.
2. Several types of a defined mix can be processed simultaneously.
3. Tool change-over time is negligible.
4. Part handling from machine to machine is easier and faster due to employment of computer controlled material
handling system.
Benefits of an FMS
Flexibility to change part variety
Higher productivity
Higher machine utilization
Less rejections
High product quality
Reduced work-in-process and inventory
Better control over production
Just-in-time manufacturing
Minimally manned operation
Easier to expand

3.2Computer Integrated Manufacturing (CIM)

In the last lecture, we have seen that a number of activities and operations viz. designing, analyzing, testing,
manufacturing, packaging, quality control, etc. are involved in the life cycle of a product or a system (see Figure
1.1.4). Application of principles of automation to each of these activities enhances the productivity only at the
individual level. These are termed as islands of automation. Integrating all these islands of automation into a single
system enhances the overall productivity. Such a system is called as Computer Integrated Manufacturing (CIM).
The Society of Manufacturing Engineers (SME) defined CIM as CIM is the integration of the total manufacturing
enterprise through the use of integrated systems and data communications coupled with new managerial
philosophies that improve organizational and personal efficiency.
CIM basically involves the integration of advanced technologies such as computer aided design (CAD), computer
aided manufacturing (CAM), computer numerical control (CNC), robots, automated material handling systems, etc.
Today CIM has moved a step ahead by including and integrating the business improvement activities such as
customer satisfaction, total quality and continuous improvement. These activities are now managed by computers.
Business and marketing teams continuously feed the customer feedback to the design and production teams by using
the networking systems. Based on the customer requirements, design and manufacturing teams can immediately
improve the existing product design or can develop an entirely new product. Thus, the use of computers and
automation technologies made the manufacturing industry capable to provide rapid response to the changing needs
of customers.

ROLE OF CONDITION MONITORING SYSTEMS:

The machining process is either continuous, such as turning or drilling, or intermittent, such as the milling operation.
Continuous operations are performed with single cutting edge, removing material from one spindle revolution to the
next. Intermittent operations involve one or more cutting edges, removing material from one tooth to the other. In
both cases, material is removed from the work piece under the generation of chips. The machining operations are
controlled by various parameters, such as the spindle speed, depth of cut and feed rate, etc.
If the correct machining parameters are set, the machining operation is expected to perform well and the final
produced part will meet the final requirements given in the part specification. Depending on the machining process
characteristics, the cutting tool may have a short or long life time. For cost effective production, the number of tool
changes should be kept at minimum and the cutting tool inserts must be used close to the limiting tool life without
violating the overall machining system. This requires in-depth knowledge about the tool wear rate and maximizes
tool life for the actual machining setup and machining conditions.
In well behaved machining processes, the tool life can be more or less accurately determined and the tool change
interval may therefore be optimize during some tool wear criterion, such as the maximum flank wear. The simple
case will however require almost a gradual tool wear. For more complex materials and demanding machining
processes, tool wear may become excessive and sudden events, such as tool chipping and breakage, will most likely
occur. The monitoring of the tool condition may therefore be very difficult since such unexpected events occur
within a relatively short time interval.
The behavior of the machining process is also dependent on the workpiece material, cutting tool material and
geometry, actual machining process parameters and the condition of the overall machining system. Hardness
variations in the workpiece material, which can be traced back to the manufacturing of the workpiece material itself,
is another factor which may increase the unpredictability of the machining process, leading to drastically shorter tool
life ,tool chipping and tool breakage.

The cutting tool can be regarded as the limiting component of the machining process and is the main reason why
machining process condition monitoring as the spindle speed, depth of cut and feed rate, etc. is mostly concerned
with the actual state of the cutting tool.

Figure 2.1 Role of condition monitoring systems.

When the cutting tool is worn the cutting force and vibration amplitudes tend to increase and the machining process
may become unstable. The main task of the condition monitoring system, CMS, is to collect relevant data from the
machining process, then process and analyze the data to detect symptoms of troubles, but also to signal a control
function to adjust the machining process parameters to a more stable machining region. Within the stable region
,optimization can be performed to meet some criterion, such as maximizing the material removal rate, minimizing
the production cost, etc., see Figure 2.1.Process instabilities are often recognized as increased vibration amplitudes,
which may cause unexpected events such as tool failures, which can be harmful l to the workpiece and machine tool.
To meet the increasing demands on higher productivity and high quality of the produced parts, vast amount of
research has been invested in the development of CMSs in order to prevent failures and compensate for faults. A
various number of sensors have been used for the monitoring of the state of the cutting tool. A review on the use of
external sensors for monitoring of the state of the cutting tool has been presented by Byrne
The difficulties in designing reliable TCMs can be related to the complexity of the machining process itself, which
may have one or more of the following characteristics, apart from the changes of the machine tool itself .
1. complex to chaotic behaviour due to non-homogeneities in workpiece material,
2. sensitivity of the process parameters to cutting conditions, and
3. nonlinear relationship of the process parameters to tool wear.

Sensorless condition monitoring:

Sensorless condition monitoring is about monitoring of the machining process by utilizing the existing sensors and
signals in the machine tool without using external sensors, such as force sensors and accelerometers. The main
advantage is that the additional complexity is kept to a minimum while reducing the cost of the condition monitoring
system. Two types of internal signals are considered, i.e. internal drive signals and encoder signals.

Internal drive signals

Internal drive signals, such as the spindle motor current and feed drive current ,can be measured with a non-intrusive
Hall effect sensor Measuring of the current signal from the servo drive motors and spindle motors has been widely
used as a means of indirect measuring of the cutting force to avoid the impracticability of force dynamometers.
However, the observed current signal from the servo drive motor contains additional components related to
acceleration and deceleration of the work table, friction force in the guide way, feed direction change, etc. Thus, to
obtain a reliable estimation of the cutting force, the undesired components in the current signals must first be
removed, which can be accomplished using special pre-processing methods. The cutting force estimation method
presented by Kim et al. also makes use of the internal feed rate signals to generalize the cutting force estimation to
multi-axis machining. utilized the spindle power consumption signal and feed drive current signals to estimate tool
wear in high-speed milling.
Internal signals may also be accessed directly from diagnostics sockets (DACoutputs) on the drive modules.
However, these signals may have limited use due to the relatively low internal sampling rate (a few milliseconds)
and distortions due to internal digital-to-analogue conversion. The internal sensor may also be located far away from
the component to be monitored. Internal drive signals also represent a sum of signals originating from different
sources From a condition monitoring point of view, the use of the internal drive signals may be inappropriate due to
the relatively low sampling rate and internal delays ,which in turn may result in poor and incorrect results and
assumptions. A TCM system that utilizes the existing spindle speed and spindle load signalshave been reported by
Amer et al.

Encoder signals
The machine tool manufacturer have several options to achieve high position accuracy. The most popular way is to
use position encoders due to their high reliability and sensitivity. Linear and angular position encoders are integral
parts of the machine tool and used internally to close the position control loops. These encoders measure the position
along the feed axes rotating axes(spindle and turn table) respectively. Encoders have been used in the pas research.
Kaye et al. used the change in spindle speed (measured with an optical encoder) to detect tool wear in turning. Jang
et al. used the pulse signal from a rotary encoder to perform once-per-revolution sampling ofthe vibration signal.
Plapper and Weck found that backlash in the drive chain manifests itself as an increased difference between the
position from the motor encoder and the encoder of the direct position when the axis movement is reversed. Verl et
al. used the output signals from the position encoders to quantify the wear of the ball screw drive. They concluded
that the accuracy of positioning is a key factor to initiate maintenance. Klocke et al. took a step towards positionoriented process monitoring by utilizing all position encoder signals from a 5-axis milling machine for an in-depth
analysis of a free form milling operation. A complete measurement chain was also presented, allowing
synchronization of the position signals with other type of signals, such as cutting force and vibration signals.

POSITION ENCODERS IN CNC MACHINE TOOLS:

Various types of position encoders are available, such as linear or rotary encoders. The encoder may be either an
absolute or an incremental encoders. Encoders are also based on different physical principles, such as light,
magnetism or induction. Rotary encoders are mounted directly on the motor shaft to measure the angular position
and linear encoders are mounted on along the feed axes, which gives a direct measuring of the position. Linear
position can also be measured indirectly using a rotary encoder on the driving shaft. In the latter case the pitch of the
lead screw must be known to get the position. For high precision measuring of the position using encoders the direct
measuring principle is preferred.

The 5-axis multitask machine tool1 used in the experimental work in this thesis, is equipped with an rotary encoder2
to measure the angular position of the spindle shaft and turn tables, and linear encoders3 to measure the position
along the feed axes. The physical structure of the 5-axis multitask machine tool and available position encoders is
illustrated in Figure 2.2.The position accuracy of machine tools is strongly dependent on the type of position
encoders used. Modern machine tools are equipped with so called Sin/Cos-encoders, which give continuous
sinusoidal outputs instead of square waves as is the case for incremental optical encoders. Position estimation from
the signals is mainly based on interpolation. The main advantage with continuous output signals is that the signals
may be interpolated to an arbitrary resolution to achieve the desired accuracy.

MICRO-ELECTROMECHANICAL SYSTEMS (MEMS)

Micro-electromechanical systems (MEMS) is a process technology used to create tiny integrated devices or systems
that combine mechanical and electrical components. They are fabricated using integrated circuit (IC) batch
processing techniques and can range in size from a few micrometers to millimetres. These devices (or systems) have
the ability to sense ,control and actuate on the micro scale, and generate effects on the macro scale.
MEMS, an acronym that originated in the United States, is also referred to as MicrosystemsTechnology (MST) in
Europe and Micromachines in Japan. Regardless of terminology, the uniting factor of a MEMS device is in the way

it is made. While the device electronics are fabricated using computer chip IC technology, the micromechanical
components are fabricated by sophisticated manipulations of silicon and other substrates using micromachining
processes. Processes such as bulk and surface micromachining, as well as high-aspect-ratio micromachining
(HARM) selectively remove parts of the silicon or add additional structural layers to form the mechanical and
electromechanical components. While integrated circuits are designed to exploit the electrical properties of silicon,
MEMS takes advantage of either silicons mechanical properties or both its electrical and mechanical properties.

Figure 1. Schematic illustration of MEMS components.

In the most general form, MEMS consist of mechanical microstructures, microsensors, microactuators and
microelectronics, all integrated onto the same silicon chip. This is shown schematically in Figure1.Microsensors
detect changes in the systems environment by measuring mechanical, thermal, magnetic, chemical or
electromagnetic informationor phenomena. Microelectronics process this information and signal the microactuators
to reactand create some form of changes to the environment. MEMS devices are very small; their components are
usually microscopic. Levers, gears,pistons, as well as motors and even steam engines have all been fabricated by
MEMS (Figure2). However, MEMS is not just about the miniaturization of mechanical components or making
things out of silicon (in fact, the term MEMS is actually misleading as many micro machined devices are not
mechanical in any sense). MEMS is a manufacturing technology; a paradigm for designing and creating complex
mechanical devices and systems as well as their integrated electronics using batch fabrication techniques.

Figure 2. (a) A MEMS silicon motor together with a strand of human hair [1], and (b)
the legs of a spider mite standing on gears from a micro-engine [2 Sandia National

Labs, SUMMiT *Technology, http://mems.sandia.gov].

MEMS has several distinct advantages as a manufacturing technology. In the first place, the interdisciplinary nature
of MEMS technology and its micromachining techniques, as well as its diversity of applications has resulted in an
unprecedented range of devices and synergies across previously unrelated fields (for example biology and
microelectronics). Secondly, MEMS with its batch fabrication techniques enables components and devices to be
manufactured with increased performance and reliability, combined with the obvious advantages of reduced physical
size, volume, weight and cost. Thirdly, MEMS provides the basis for the manufacture of products that cannot be
made by other methods. These factors make MEMS potentially a far more pervasive technology than integrated
circuit microchips .However, there are many challenges and technological obstacles associated with miniaturization
that need to be addressed and overcome before MEMS can realize its overwhelming potential.

Established MEMS Applications:

i) Automotive airbag sensor
Automotive airbag sensors were one of the first commercial devices using MEMS. They are in widespread use today
in the form of a single chip containing a smart sensor, or accelerometer, which measures the rapid deceleration of a
vehicle on hitting an object. The deceleration is sensed by a change in voltage. An electronic control unit
subsequently sends a signal to trigger and explosively fill the airbag. Initial air bag technology used conventional
mechanical ball and tube type devices which were relatively complex, weighed several pounds and cost several
hundred dollars. They were usually mounted in the front of the vehicle with separate electronics near the airbag.
MEMS has enabled the same function to be accomplished by integrating an accelerometer and the electronics into a
single silicon chip, resulting in a tiny device that can be housed within the steering wheel column and costs only a
few dollars (Figures 4 and 5). The accelerometer is essentially a capacitive or piezo resistive device consisting of a
suspended pendulum proof mass/plate assembly. As acceleration acts on the proof mass ,micro machined capacitive
or piezoresistive plates sense a change in acceleration from deflection of the plates. The sense plates can be seen
inFigure 4.

Figure 4. (a) The first commercial accelerometer from Analog Devices (1990); its size is less than 1
cm2 (left) [12], and (b) capacitive sense plates, 60 microns deep (right) [13].

Figure 5. Modern day MEMS accelerometer (left), andthe fully packaged device (right) [12].
The airbag sensor is fundamental to the success of MEMS and micromachining technology. With over 60 million
devices sold and in operation over the last 10 years and operating in such a challenging environment as that found
within a vehicle, the reliability of the technology has been proven. An example of this success is todays vehicles
the BMW 740ihas over 70 MEMS devices including anti-lock braking systems, active suspension, appliance and
navigation control systems, vibration monitoring, fuel sensors, noise reduction, rollover detection, seatbelt restraint
and tensioning etc. As a result, the automotive industry has become one of the main drivers for the development of
MEMS for other equally demanding environments. Some of the leading airbag accelerometer manufacturers include
Analog Devices, Motorola, Sensor Nor and Nippondenso. Accelerometers are not just limited to automotive
applications. Earthquake detection, virtual reality video games and joysticks, pacemakers, high performance disk
drives and weapon systems arming are some of the many potential uses for accelerometers.

Medical pressure sensor :

Another example of an extremely successful MEMS application is the miniature disposable pressure sensor used to
monitor blood pressure in hospitals. These sensors connect to a patients intravenous (IV) line and monitor the blood
pressure through the IV solution. For a fraction of their cost ($10), they replace the early external blood pressure
sensors that cost over $600 and had to be sterilized and recalibrated for reuse. These expensive devices measure
blood pressure with a saline-filled tube and diaphragm arrangement that has to be connected to an artery with a
needle.

Figure 1 Schematic illustration of a piezoresistive pressure sensor

The disposable sensor consists of a silicon substrate which is etched to produce a membraneand is bonded to a
substrate (Figure 1). A piezoresistive layer is applied on the membrane surface near the edges to convert the
mechanical stress into an electrical voltage. Pressure corresponds to deflection of the membrane. The sensing
element is mounted on a plastic orceramic base with a plastic cap over it, designed to fit into a manufacturers
housing (Figure2). A gel is used to separate the saline solution from the sensing element.
As in the case of the MEMS airbag sensor, the disposable blood pressure sensor has been one of the strongest
MEMS success stories to date. The principal manufacturers being Lucas Novasensor, EG & G IC Sensors and
Motorola with over 17 millions units per year. More recently, the technology from the blood pressure sensor has
been taken a step further in the development of the catheter-tip pressure sensor. This considerably smaller MEMS
device is designed to fit on the tip of a catheter and measure intravascular pressure (its size being only 0.15 mm x
0.40 mm x 0.90 mm).Pressure sensors are the biggest medical MEMS application to date with the accelerometer
MEMS a distant second. Although the majority of these accelerometer applications remain under development,
advanced pacemaker designs include a MEMS accelerometer device that measures the patients activity. The
technology, similar to that found in the airbag sensor ,enables the patients motion and activity to be monitored and
signals the pacemaker to adjust its rate accordingly.

Figure 2. (a) Disposable blood pressure sensor connected to an IV line [14], (b) disposable blood pressure
sensors (as shipped) [15], and (c) intra cardial catheter-tip sensors for monitoring blood pressure during
cardiac catheterisation, shown on the head of a pin [13].

FUZZY LOGIC IN MECHATRONICS APPLICATIONS:

Fuzzy Logic Rice Cooking System :

As we know a rice cooker or rice steamer is a device that used primarily for cooking rice. The preparation of ricehas
traditionally been a cooking process which requires attention to ensure the rice is cooked properly. FUZZY based
rice cookers simplify the process by automatically controlling the heat and timing, and at the same time freeing up a
heating element on the range