Mechatronics

Mechatronics is a concept of Japanese origin

(1970’s) and can be defined as the application of
electronics and computer technology to control
the motions of mechanical systems
Mechatronics: a multi-disciplinary approach

• It is a multidisciplinary approach
to product and manufacturing
system design.
• It involves application of
electrical, mechanical, control and
computer
engineering to develop products,
processes and systems with
greater flexibility, ease in redesign
and ability of reprogramming.
• It concurrently includes all these
disciplines
Key Elements of Mechatronics Systems
Key Elements of Mechatronics Systems
 Evolution of Mechatronics / Levels of Mechatronics
• Primary Level : Integrates electrical signaling with mechanical action
at the basic control level for e.g. fluid valves and relay switches

• Secondary Level : Integrates microelectronics into electrically

controlled devices for e.g. cassette tape player

• Tertiary Level : Incorporates advanced control strategy using

microelectronics, microprocessors and other application specific
integrated circuits for e.g. microprocessor based electrical motor
used for actuation purpose in robots.

• Quaternary Level : This level attempts to improve smartness a step

ahead by introducing intelligence ( artificial neural network and fuzzy
logic ) and fault detection and isolation ( F.D.I.) capability into the
system.
 Measurement Characteristics of Mx

The performance characteristics of an instrument are mainly

divided into two categories:

i) Static characteristics

ii) Dynamic characteristics

 Static characteristics
The set of criteria defined for the instruments, which are used to
measure the quantities which are slowly varying with time or mostly
constant, i.e., do not vary with time, is called ‘static characteristics’. The
various static characteristics are:

i) Accuracy ii) Precision

iii) Sensitivity iv) Linearity
v) Reproducibility vi) Repeatability
vii) Resolution viii) Threshold
ix) Drift x) Stability
xi) Tolerance xii) Range or span
 Dynamic characteristics:

The set of criteria defined for the instruments, which are changes
rapidly with time, is called ‘dynamic characteristics’. The various static
characteristics are:
i) Speed of response ii) Measuring lag
iii) Fidelity iv) Dynamic error

Speed of response:
It is defined as the rapidity with which a measurement system responds
to changes in the measured quantity.

Measuring lag:
It is the retardation or delay in the response of a measurement system
to changes in the measured quantity. The measuring lags are of two
types: Retardation Type and Time Delay Lag
a) Retardation type:
In this case the response of the measurement system begins immediately after
the
change in measured quantity has occurred.

b) Time delay lag:

In this case the response of the measurement system begins after a dead time
after
the application of the input.

Fidelity:
It is defined as the degree to which a measurement system indicates changes
in the measured quantity without dynamic
error.

Dynamic error:
It is the difference between the true value of the quantity changing with time
& the value indicated by the measurement system if no static error is assumed.
It is also called measurement error.
Mx System Design Approach
Phases of Mechatronics Design Process
Washing Machine
Digital Camera
Digital Camera
CD Player
 Mechanical System Elements
• Spring
• Mass
• Dashpot
 Spring
• Spring represent stiffness of a system
•The stiffness of a spring is described by:
F=k.x
• The object applying the force to stretch the spring is also acted on
by a force (Newton’s third law), this force will be in the opposite
direction and equal in size to the force used to stretch the spring
 Dashpot
• It is a type of forces when we push an object through a fluid
or move an object against friction forces

c – damping coefficient
 Mass
• The acceleration experienced by mass m under the action of
instantaneous force F is given as –

m – mass
 Gears
• Gears transmit power / motion between two shafts by meshing without any
slip.
• In any pair of gears, the smaller one is called pinion and the larger one is
called gear immaterial of which is driving the other.

• When pinion is the driver –

It results in step down drive in which the output speed decreases and the
torque increases.

• When the gear is the driver -

It results in step up drive in which the output speed increases and the torque
decreases
Types/Classification of Gears
 Spur Gears
• Spur gears have their teeth parallel to the axis and are used
for transmitting power between two parallel shafts.
• They are simple in construction and easy to manufacture
• They have highest efficiency and excellent precision rating.
• They are used in high speed and high load application in all
types of trains and a wide range of velocity ratios.
• Hence, they find wide applications right from clocks,
household gadgets, motor cycles, automobiles, and railways
to aircrafts
 Helical Gears
• Helical gears have teeth inclined to the axis
• teeth are longer than spur gears and have higher load
carrying capacity.
• Contact ratio is higher than spur gears and they operate
smoother and quieter than spur gears.
• Their efficiency is slightly lower than spur gears.
• These gears find wide applications in automotive
gearboxes
 Double Helical Gear
• They have opposing helical teeth with or without a gap
• Two axial thrusts oppose each other and nullify.
• Applications are limited to high capacity reduction drives
like that of cement mills and crushers
• Manufacturing difficulty makes them costlier
 Rack and Pinion Gears
• Rack is a segment of a gear of infinite diameter
• This type of gearing is used for converting rotary motion
into translatory motion or visa versa.
• The tooth can be spur or helical

Spur tooth rack and pinion Helical tooth rack and pinion
 Bevel Gears
• This is a gear in which the teeth have tapered conical
elements that have the same direction as the pitch cone
base line (generatrix).
• The straight bevel gear is both the simplest to produce and
the most widely applied in the bevel gear family.
 Worm Gears
• Worm and worm gear pair consists of a worm, which is very
similar to a screw and a worm gear, which is a helical gear.
• The sliding action prevalent in the system while resulting in
quieter operation produces considerable frictional heat.

• Efficiency of these gears is low anywhere from 90% to 40 %.

• Need good lubrication for heat dissipation and for
improving the efficiency.
• Applications - Automatic door system, Automotive steering
systems
Worm Gears
 Servomechanism
A servomechanism, sometimes shortened to servo, is an automatic
device that uses error-sensing negative feedback to correct the
performance of a mechanism and is defined by its function. It usually
includes an in built encoder.

The term correctly applies only to systems where the feedback or error-
correction signals help control mechanical position, speed or other
parameters.

For example, an automotive power window control is not a

servomechanism, as there is no automatic feedback that controls
position—the operator does this by observation. By contrast a car's
cruise control uses closed loop feedback, which classifies it as a
servomechanism.
 Servomechanism
Uses of Servo-Mechanism
Position Control - Any difference between the actual and wanted
values (an "error signal") is amplified (and converted) and used to drive
the system in the direction necessary to reduce or eliminate the error.

Speed Control - Varying the speed of motor and load according to an

externally set program of values. This is also called set point (or
reference) tracking.
 Servomechanism
Advantages of Servo Control System
• Intermediate motor and control costs
• Continuous duty
• Reversible.
• Speed is proportional to the applied voltage
• Torque is proportional to the current
• Very efficient
• No power required to hold a static load in position
• Flat speed-torque curve
• Peak torque available for short periods of time
• Smooth rotation at low speeds
• Good up to 3,000 RPM
Working of Servomechanism
Design of Coin Counter/Coin Separator
Case study of Coin Counter
Mechanical Design:
Case study of Coin Counter
Electronic Design:

Controller Unit
 Case study of Coin Counter
Electronic Design:
Photodiode:

Operates in Reverse Biased

 Counter circuit using photodiode
• A photo-diode can be used to count items on
a conveyor belt.