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Unit I: An Introduction to Mechatronics

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MECHanical + elecTRONICS
6ME3A: Mechatronics

An Introduction to A philosophy in which there is a coordinated and concurrently

Mechatronics developed, integration of mechanical engineering with electronics
and intelligent computer control in the design and manufacture of
Tarun Kr. Aseri
Asst. Prof.
products and processes.
Mechanical Engineering
Govt. Engineering College Ajmer
Barliya Chouraha, NH-8,
Ajmer-305001, India
A multidisciplinary approach
Email: tarunaseri@gmail.com

1 2

Electrical Control Results:

Engineering Engineering

Mechanical Computer
Automated data
Much greater
Engineering Engineering Ease in redesign Reprogrammable collection and
flexibility,
reporting
Mechatronics

3 4
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Juice filling and packing machine Video

F:\Subjects\Mechatronics\Juice filling and sealing machine.mp4

•Sequential approach
Design
•Cocurrent approach

5 6

Pick and Place, chip shooter video Automotive Assembly line video

F:\Subjects\Mechatronics\Essemtec - Cobra - High speed Pick and Place F:\Subjects\Mechatronics\Skoda Octavia Production (1)
Product Video HD.mp4

Mechanical Engineering Department

Govt. Engineering College Ajmer 7 8
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With the help of microelectronics and sensor technology, mechatronics systems are Design Feasibility study Design
Analysis

Design Process
Design need with collecting conceptu-
specifications information alization model
providing high levels of precision and reliability.

It is now possible to move (in x – y plane) the work table of a modern production
Design Design
machine tool in a step of 0.0001 mm. Design
documentatio analysis, Design
evaluation
n optimization
By employment of reprogrammable microcontrollers/microcomputers, it is now easy
to add new functions and capabilities to a product or a system.

Manufacturing Process
Design
Today’s domestic washing machines are “intelligent” and four-wheel passenger Process Production Order NC, CNC, DNC
procurement
planning planning material programming
automobiles are equipped with safety installations such as air-bags, parking of new tools

(proximity) sensors, antitheft electronic keys etc.

Quality
Marketing Shipping Packaging Production
control
9 10

Automated Manufacturing Systems Three Type of Automation

► Operates in the factory on the physical product A=?

► Automated operations:
B=?
► Processing, Assembly, Inspection. Material Handling
C=?
A
Product
► Automated: Reduced level of Human intervention Variety
B
► 3 Basic Types:
► Fixed Automation C
► Programmable Automation
► Flexible Automation 100 10k 10t
Production Quality

11 12
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Three Type of Automation Human & Machines

Flexible Automation Relative strength of Human and Machine

A=?
B=? Programmable Automation
C=? Fixed Automation
A
Product
Variety
B

100 10k 10t

Production Quantity

13 14

Human & Machines Human & Machines

Relative strength of Human and Machine Relative strength of Human and Machine

Aoccdnig to a rscheearch at Cmabrigde According to a research at Cambridge University,

Uinervtisy, it deosn’t mttaer in waht oredr the
ltteers in a wrod are, the olny iprmtoant tihng
is taht the frist and lsat ltteer be at the rghit
pctae. The rset can be a toatl mses and you
can sitll raed it wouthit porbetm. Tìhs is
bcuseae the huamn mnid deos not raed ervey
lteter by isttef, but the wrod as a wlohe.
15
it doesn’t matter in what order the letters in a
word are, the only important thing is that the first
and last letter be at the right place. The rest can
be total mess and you can still read it without
problem. This is because the human mind does
not read every letter by itself, but the word as a
whole.
16
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Human & Machines Mechatronics

Relative strength of Human and Machine
HUMANS
 Sense unexpected Stimuli
 Develop new solutions to problems
 Adapt to changes
 Cope with abstract problems
 Generalize from observations
 Learn from experience
 Make difficult decisions based on
incomplete data
Engineering Mechanics of Machine Elements
MACHINES ► Kinematics
 Perform repetitive tasks • Position
 Store large amount of data • Velocity
 Retrieve data from memory
• Acceleration
 Perform multitasks simultaneously
► Kinematics Analysis
 Apply high forces & power
• Impact (due to change in momentum)
 Perform simple computations quickly
• Jerk (due to change in acceleration)
 Make routine decisions quickly

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Mechatronics Mechatronics

Engineering Mechanics of Machine Elements Electronics Engineering

► Dynamics ► Measurement systems
• Torque • Sensors, Signal conditions and display units
• Force ► Actuators
► Dynamic Analysis ► Power Electronics
• Friction ► Microelectronics
• Inertia

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Mechatronics: Informatics/Information System
Automation
Software design
Artificial intelligence
Tools/Devices Programmable logic
control (PLC)
Microcontroller
Personal Computers
Informatics/
Information System Reduce human errors
Solve complex
engineering problems
Communication system
Output Finance system
Virtual modelling
Data storage
Access/Retrieved data
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Flexible Manufacturing System
• Flexible Manufacturing Systems (FMS) is a manufacturing philosophy
based on the concept of effectively controlling material flow through a
network of versatile production stations using an efficient and versatile
material handling and storage systems.
• FMS is a system that consists of numerous programmable machine
tools connected by an automated material handling system.
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Assignments
• Assignment 1: Study the product life cycle diagram and elaborate
the various design and manufacturing activities for a product: four-
wheel automobile (a passenger car) or a mobile cell phone.
• Assignment 2: Identify a mechatronics system being used by you in
your daily routine. Analyze its elements and state its importance in
the functioning of that system.
22
Flexible Manufacturing System
• Shorter lead times, meeting demand fluctuations, handling volume and
variety, reduction in space and people and obtaining better control due
to automation.
• The main disadvantage is that the initial installation cost and
operational costs are high and it is necessary to have enough volumes
to the use of FMS.
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Flexible Manufacturing System Flexible Manufacturing System

Classified into: There are three levels of manufacturing flexibility.

─Flexible Manufacturing Cell (FMC), 1-Basic Flexibilities

─Flexible manufacturing System (FMS) and Machine flexibility - the ease with which a machine can process various operations

─Flexible manufacturing Line (FML)
FMCs have high flexibility but handle less volume while FML have less
flexibility but can handle very large volumes.
Material handling flexibility -a measure of the ease with which different part types
can be transported and properly positioned at the various machine tools in a system
Operation flexibility - a measure of the ease with which alternative operation
sequences can be used for processing a part type

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Flexible Manufacturing System Flexible Manufacturing System

2-System flexibilities: 3-Aggregate flexibilities
Volume flexibility Program Flexibility
Expansion flexibility Production Flexibility
Routing flexibility Market Flexibility
Process flexibility
Video of FMC
Product flexibility

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Applications
Micro-
1) Design and Modelling
2) Software Integration Electro-
3) Actuator and Sensors
Mechanical
4) Intelligent Control
5) Robotics System
6) Manufacturing
7) Motion Control
8) Vibration and Noise Control
9) Optics An introduction to MEMS Technology

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MEMS: Micro-Electro-Mechanical System

• MEMS has been identified as one of the most promising technologies Videos
for the 21st Century and has the potential to revolutionize both
industrial and consumer products by combining silicon-based
microelectronics with micromachining technology. Its techniques
and microsystem-based devices have the potential to dramatically
affect of all of our lives and the way we live.
• Fabricated using micromachining technology
• Used for sensing, actuation or are passive micro-structures
• Usually integrated with electronic circuitry for control and/or
information processing
• Components Size between 1 to 100 micrometres in size (i.e. 0.001 to
0.1 mm)

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Why MEMS?
• Miniaturization with no loss of functionality,
• Integration to form a monolithic system,
• Improved reproducibility, reliability and accuracy,
• Low power consumption,
• Fast actuation techniques,
• Improved selectivity and sensitivity

MEMS may be the ONLY solution

33 34

35 36
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MEMS – Micro-electro-mechanical-systems
Micro-Probing
Micro-Fluidics Micro-Optics

Micro
Nano- Pressure,
Force, Inertial,
Bio-MEMS
World Sound, etc.

Micro-Scale
Actuation and RF-MEMS
Motion

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Microprocessor -based controllers and Microelectronics
• Programmable Logic Devices (PLD) are programmable systems and
are generally used in manufacturing automation to perform different
control functions, according to the programs written in its memory,
using low level languages of commands.
Microprocessor -based controllers and Microelectronics
There are following three types of PLDs are being employed in
mechatronics systems.
1. Microprocessor
It is a digital integrated circuit which carries out necessary digital functions to
process the information obtained from measurement system.
2. Microcomputer
It uses microprocessor as its central processing unit and contains all functions of
a computer.
3. Programmable Logic Controller (PLC)
It is used to control the operations of electro-mechanical devices especially in
tough and hazardous industrial environments.

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Microprocessor -based controllers and Microelectronics Components

1. Processor, which processes the information collected from measurement
system and takes logical decisions based on the information. Then it sends
this information to actuators or output devices.
2. Memory, it stores
a. the input data collected from sensors
b. the programs to process the information and to take necessary
decisions or actions. Program is a set of instructions written for
the processor to perform a task. A group of programs is called
software.
3. Input/output devices: these are used to communicate with the outside
world/operator.

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Microprocessor
• It is a multi-purpose, programmable device that reads binary
instructions from a storage device called memory, processes the data
according to the instructions, and then provides results as output.
• In common practice it is also known as CPU (central processing unit).
CPU can be referred as complete computational engine on a single
chip.
• First Microcontroller, Intel 4004 was launched in 1971. It was able to
process just 4 bits. It started a new era in electronics engineering.
• Microprocessor chip was one of the important inventions of the 20th
century.

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PIC18FXXXX

45 46

Microprocessor Microprocessor
Applications of microprocessors are classified primarily in two Microprocessor works or operates in binary digits i.e. 0 and 1, bits.
categories:
These bits are electrical voltages in the machine, generally 0 - low
1. Reprogrammable Systems : Micro computers
voltage level, and 1 -high voltage level. A group of bits form a ‘word’.
2. Embedded Systems : photocopying machine, Digital camera
In general, the word length is about 8 bits. This is called as a ‘byte’. A
word with a length of 4 bits is called as a ‘Nibble’.
Microprocessor processes the ‘commands in binary form’ to accomplish
a task. These are called as ‘instructions’. Instructions are generally
entered through input devices and can be stored in a storage device
called memory.
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Microprocessor: Configuration Microprocessor: Working 53 54 55

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Microprocessor: Functions of components Microprocessor: Function of components

The functions of each element are as follows:
1. ALU: ALU stands for Arithmetical Logical Unit. As name indicates it has two parts:
a. Arithmetical unit which is responsible for mathematical operations like addition,
subtraction, multiplication and division,
b. Logical unit which is dedicated to take logical decisions like greater than, less than,
equal to, not equal to etc. (Basically AND/OR/NOT Operations)
2. Register Array: Registers are small storage devices that are available to CPU or
processors. They act as temporary storage for processing of intermediate data by
mathematical or logical operations.
3. Control: This part of CPU is dedicated to coordinate data flow and signal flow through
various types of buses i.e. Data Bus, Control Bus, and Address Bus etc. It directs data flow
between CPU and storage and I/O devices.
4. Memory: There are two different types of memory segments being used by the
CPU. First is the ROM which stands for Read Only Memory while other is R/W
which stands for Read and Write Memory or Random Access Memory (RAM).
a. ROM: From this memory unit, CPU can only read the stored data. No writing
operations can be done in this part of memory. Thus it is used to store the programs
that need no alteration or changes like Monitor Program or Keyboard driver etc.
b. R/W: As name indicates it is opposite to ROM and used for both reading and
writing operations. In general User’s program and instruction are stored in this
segment of memory unit.

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Microprocessor: Functions of components Microprocessor: Functions

5. Input Devices: Input devices are used to enter input data to
microprocessor from Keyboard or from ADC which receives data from
sensors/signal conditioning systems.
6. Output Devices: These devices display the results/conclusions coming
out from ALUs either in soft copy (Monitor) or in Hard Copy (Printer).
Various functions of microprocessor are as follows:
• Microprocessor performs a variety of logical and mathematical
operations using its ALU.
• It controls data flow in a system and hence can transfer data from one
location to another based on the instructions given to it.
• A microprocessor can take necessary decisions and jump to a new set of
instructions based on those decisions.

53 54

Microprocessor: Elements Figure Microprocessor: Elements Figure

A simple microprocessor consists of following basic elements: • Reset Line is used to restart execution and reset the processor to zero.

• Data Bus: Through data bus, the data flow between • Address Latch is a register which stores the addresses in the memory.
• Program Counter: It is a register which can increment its value by 1 and keeps the record of
a. various storage units number of instructions executed. It can be set to zero when instructed.
b. ALU and memory units • Test Register: It is a register which stores intermediate or in-process data of ALU operations.
• Address Bus: It controls the flow of memory addresses between ALU and For example it is required to hold the ‘carry’ while ALU is performing ‘addition’ operation. It
also stores the data which can be accessed by Instruction decoder to make any decision.
memory unit.
• 3-State Buffers: These are tri-state buffers. A tri-state buffer can go to a third state
• RD (read) and WR (write) lines set or obtain the addressed locations in the in addition to the states of 1 and 0.
memory. • The instruction register and instruction decoder are responsible for controlling the
• Clock line transfers the clock pulse sequence to the processor. operations of all other components of a microprocessor.

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Microprocessor: Elements Figure Microcontroller Central Processer

There are following control lines present in a microprocessor, which are used to
Microcomputer
communicate instructions and data with the instruction decoder.
 Microcomputer is a microprocessor Memory
• Instruct the A register to latch the value currently on the data bus. based system.
• Instruct the B register to latch the value currently on the data bus.  It is a data processing system that
 employs a microprocessor as its I/O Ports
• Instruct the C register to latch the value currently output by the ALU.
central unit.
• Instruct the program counter register to latch the value currently on the data bus.  Based on the input it takes decisions.
• Instruct the address register to latch the value currently on the data bus.  These decisions are further used to
MicroController
control a system or to actuate an action
• Instruct the instruction register to latch the value currently on the data bus.
or operation.
• Instruct the program counter to increment.

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Microcontroller Microcontroller-Applications
 It is a microprocessor-based system.  Microcontrollers find applications in
 Automobiles,
 It implements the functions of a computer and a controller on a single
 Aircraft,
chip.
 Medical Electronics
 Generally microcontroller is programmed for one specific application  Home Appliances.
and it is dedicated to a specific control function.  They are small in size and can be embedded in an electromechanical
system without taking up much space. Thus we can have a system with its
functions completely designed into a chip.
 However microcontrollers have very little user programmable memory.
 Various types of microcontroller chips available in market are: Motorola
68HC11, Zilog Z8 and Intel MCS51 and 96 series.

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Mechatronics-Applications
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 Thank You
2. Tool monitoring systems
For
3. Advanced manufacturing systems
a. Flexible manufacturing system (FMS) Your Attention
b. Computer integrated manufacturing (CIM)
4. Industrial robots
5. Automatic inspection systems: machine vision systems
6. Automatic packaging systems

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