AN

INDUSTRIAL TRAINING REPORT

ON
CAR MECHATRONICS

Submitted in Partial fulfillment for the award of the Degree of

Bachelor of Engineering
in
MECHANICAL ENGINEERING_

To

RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA

BHOPAL (M.P)

Industrial Training Undertaken at

Centre for Research and Industrial Staff Performance
Shyamla Hills,Bhopal-462002

Submitted By
Abhishek Chouksey
(0105ME151010)

Department of Mechanical Engineering

Oriental Institute of Science and Technology, Bhopal
Session: 2019-2020
Industrial Training Certificate
(Color Copy)
 (i)
ABSTRACT

A large share of automotive innovations consists of significant improvements

in formerly pure mechanical systems which are made possible using integrated
electronics together with complex information processing. Such mechatronic systems
require a concurrent design of mechanical, electronical, and information processing
subsystems
in order to reach the cost requirements of the automotive industry. The
motivation for the use of mechatronics is discussed, as well as the most important
technological challenges of the mechatronical approach.

Mechanical engineering is one of the most professional branches which experience a surge
growth in early 19th century, as it was the backbone of industrial growth and revolution. But
with the passage of time leading to advancement in technology and enhancement in
productivity, mechanical found difficult to fulfill the demands, whims and fancies .Therefore
it employed electronics engg, giving birth to the most blockbuster and stupendous branch of
engineering which we calling as mechatronics.Mechatronics is a synergetic integration of
mechanical, electrical, computer science .Mechatronics is everywhere such as automobiles,
robotics, pumps and many more.
Our presentation lays emphasis on how Mechatronics proved to be a boon in the world
of car.
Modern vehicle design is driven by the need for increased comfort, safety and security. As a
result automobiles are becoming intelligent and increasingly reliant on electronics by
offering compact, highly advanced components and modules used in communication, safety,
information power train systems, radio frequency and sensing technologies. With growing
numbers of cars on roads and increasing technologies in modern automobiles, there is an
urgent need for automotive engineers with knowledge of technologically advanced, modern
engines.

“Car Mechatronics is a step to offer ready-to-market talent pool to support the growing
needs of the Indian automotive market.”

Keywords: Automotive industry, automotive control, control system design, chassis

control, engine control, man/machine interaction.
 ACKNOWLEDGEMENT

I take this opportunity to express my sincere gratitude to all those who have been helpful in
the successful completion of my Industrial Training. I would like to show my greatest
appreciation to the highly esteemed and devoted technical staff, supervisors of the Centre
for Research and Industrial Staff Performance, Shyamla Hills Bhopal.I am highly
indebted to them for their tremendous support and help during the completion my training.

My special thank goes to Sudhir viswakarma, Car mechatronics, CRISP Shyamla Hills
Bhopal for acceptance my request for providing Industrial Training and giving me an
opportunity to be a trainee of CRISP, Shyamla Hills .I would like to thank you to all those
people who directly or indirectly helped and guided me to complete my training, including
the following instructors and technical officers of various sections.

Nevertheless, I would like to place on record my deep sense of gratitude to Dr. K.G.
Sudhakar ,Director, Oriental Institute of Science and Technology, Bhopal who granted me
the permission of Industrial training. I also wish to extend my thanks to DR. Chitresh
Nayak, I would like to express my special gratitude towards my parents and friends for their
constant encouragement.

ABHISHEK CHOUKSEY
(0105ME151010)
 TABLE OF CONTENTS

Title Page No.

Abstract ……… …………………………………………….…………….…(i)

Acknowledgement ………………………………………………….…….…(ii)
Table of Contents…………………………………………………..……..… (iii)
Chapter 1: Introduction 1 - 10 (for example)
1.1 Introduction of the Training Organization 1
1.2 Administrative System the Organization
1.3 Business Functions of the Organization
1.4 Services Provided by the Organization
1.5 Benefits from the Training
Chapter 2: Car Mechatronics Introduction
2.1 Objectives
2.2 Analysis
2.3 Techniques
Chapter 3: Methodology
3.1 Introduction
3.2 Software and Tools Used
Chapter 4: Result &Analysis
4.1 Results
4.2 Scope
Chapter 5: Conclusion,Recommendations & Future Work
5.1 Results
5.2 Scope & Future Work
Bibliography…………………………………………………………….……iv
 INTRODUCTION
1.1 Introduction of the Organistaion.

Centre for Research and Industrial Staff Performance, (CRISP), Bhopal has been
established in the year 1997 as a Society under the Indo –German Technical Cooperation
agreement. Ministry of MSME, Government of India was the line ministry for this project
whereas the Department of Technical Education & Skill Development, Government of
Madhya Pradesh and German Technical Cooperation agency (GTZ) were the
implementation partners. It is headquartered in Bhopal with national & international
operations dedicated to human resource development & organizational development.
These activities are targeted at Government, Industries, Academic Institutions,
Developmental Organizations as well as the Civil Society.
The organization has excellent infrastructure in terms of sophisticated laboratories in the
field of Industrial Automation, Mechatronics, Production Technology, Information &
Communication Technology (ICT), Multimedia Technology etc. CRISP is one of the
most preferred service providers in the areas of Technical Vocational Education &
Training (TVET), Training Institution Management and Entrepreneurship development.
FEATURES OF THE ORGANISATION

A. A nodal Centre for Department of Technical Education & Skill Development

Government of Madhya Pradesh for technical and management staff capacity building.
B. More than 500 delighted clients from Industries, Central & State Government
Organizations, Academia, Developmental Organizations etc.
C. A role model for German Technical Co-operation Agency (GTZ) for replicating CRISP
like successful Project in India and other countries.
D. Practicing professional & management principles in our operations.
E. Facilitating applications of e-Governance for State Govt. of Madhya Pradesh.
F. A strong team of qualified & experienced employees (more than 150) capable of
handelling technical and educational projects within India & overseas.

AREA OF SPECIALIZATIONS
1. Manufacturing Technology (CNC Technology, CAD/CAM (Unigraphics, Pro-E, CATIA, Solid Works
& I-DEAS), AutoCAD.
2. Industrial Automation (PLC, Variable Frequency Drives, Field Instrumentation, MMI, Hydraulics,
Pneumatics).
3. Mechatronics: Mechanical, Electrical, Electronics, Instrumentation, IT.
4. Car Mechatronics.
5. Behavioral Sciences and Management (Leadership Development, Communication Skills, Team
Building etc.).
6. Information Technology (Application & Software Development, Hardware & Networking Training,
Web Designing etc.).
7. Vocational Education & Training (Design & development of curriculum & study materials, Train The
Trainers, Instructors Training, Trade identification survey, impact study etc).
8. Fashion, Interior & Graphic Designing
9. Multimedia (3D Animation, Non-Linear video editing, show reel development)
10. Entrepreneurship Development
 CAR MECHATRONICS
OBJECTIVES
• Define Mechatronics
• Locate and identity Electronics Controls in fuel System
• Locate and identify Electronics Controls in Alr
System
• Locate and identify Electronics Controls in Ignition System
• Locate and identify Electronics Control in Exhaust System
• Differentiate between Fuel Injection System and Non Fuel Injection
System (Carbureted based)
• State drawsbacks of Non Fuel Injection System
• List benefits of Fuel Injection System
• Define Mechanical Systems
• Describe controls in Fuel System
• Describe controls in Air System
• Describe controls in Ignition System
• Describe controls in Exhaust System
• Describe controls in Suspension System
• Describe controls in Steering System
• Describe controls in Brake System
• Describe controls in Safety System
• Define Electricity in terms of voltage, current and resistance
• Calculate Ohm's Law
• Measure Electricity
• Conduct test using a Multimeters
• Analyse Series and Parallel Circuit
• Describe Open and Short Circuit
• Performing Circuit Test
• Performing Component Test
• Describe material properties Conductivity and Non conductivity
• Describe auto electrical circuits and their symbols
• Define Sensors, Actuators & ECM
• Describe various types of sensors & Actuators
• Explain working principle of various types of sensors & Actuator
• Explain characteristics of various types of sensors & Actuators
• Draw and explain sensor flow diagrams
• Describe input/output of sensors & actuators
• Make visual inspection of Sensors, Actuators and Wiring Harness
• Conduct test on Sensors & various modules of ECM
• Describe input/output parameters of ECM
• Explain modules of ECM

“Mechatronics is the synergistic integration of sensors, actuators,

signal conditioning, power electronics, decision and control algorithms,
and computer hardware and software to manage complexity,
uncertainty, and communication in engineered systems.”
 “The term ‘mechatronics’ was first coined by the Japanese scientist
Yoshikaza in 1969. The trademark was accepted in 1972. Mechatronics
is a subject which includes mechanics, electronics, and informatics.”

Applications of Mechatronics

Mechatronics has a wide range of applications,

• Smart consumer products: home security, camera, microwave
oven,
toaster, dish washer, laundry washer-dryer, climate control units,
etc.
• Medical: implant-devices, assisted surgery, haptic, etc.
• Defense: unmanned air, ground, and underwater vehicles, smart
munitions, jet engines, etc.
• Manufacturing: robotics, machines, processes, etc.
• Automotive: climate control, antilock brake, active suspension,
cruise
control, air bags, engine management, safety, etc.
• Network-centric, distributed systems: distributed robotics,
telerobotics, intelligent highways, etc.

A methodology is a collection of practices, procedures and rules

by those who work in a particular branch of knowledge or
discipline. The familiar technological disciplines include
mechanical engineering, electrical engineering, and computer
science and information technology.

CHAPTER 3

Disciplinary Foundations of Mechatronics

• Mechanical Engineering
•Electrical Engineering
• Computer Engineering
• Computer/Information Systems

Multi-/Cross-/Inter-Disciplinary

• Products and processes requiring inputs from more than one discipline can be realized
through following types of interactions.
-Multi-disciplinary: This is an additive process of brining multiple disciplines together to
bear on a problem.

– Cross-disciplinary: In this process, one discipline is examined from the perspective of

another discipline.

– Inter-disciplinary: This is an integrative process involving two or more disciplines

simultaneously to bear on a problem.

Sequential/Concurrent Product Realization

• Sequential and discipline specific concurrent design processes for product

realization are at best multi-disciplinary calling upon discipline specialists to
“design by discipline.”

– Design mechanical system “plant.”

– Select sensors and actuators and mount on plant.

– Design signal conditioning and power electronics.

– Design and implement control algorithm using electrical, electronics,

microprocessor, microcontroller, or microcomputer based hardware.
 Mechatronics-based Product Realization

• Systems engineering allows design, analysis, and synthesis of products and

processes involving components from multiple disciplines.

• Mechatronics exploits systems engineering to guide the product realization

process from design, model, simulate, analyze, refine, prototype, validate, and
deployment cycle.

• In mechatronics-based product realization: mechanical, electrical, and computer

engineering and information systems are integrated throughout the design
process so that the final products can be better than the sum of its parts.
• Mechatronics system is not
– simply a multi-disciplinary system
– simply an electromechanical system
– just a control system.
Mechatronic Design Process
 Evolution of Mechatronics as a Contemporary Design Paradigm
• Technological advances in design, manufacturing, and operation of engineered
products/devices/processes can be traced through:

– Industrial revolution

– Semiconductor revolution

– Information revolution

MECHANICAL SYSTEMS
ANTILOCK BRAKES SYSTEM (ABS)
Antilock Brakes are essentially an enhanced or Improved version of ordinary brakes. Simply put, the
antilock brake system is designed to prevent the brakes from locking up and skidding when braking hard or
when braking on wet or slick surfaces. This adds a significant margin of safety for everyday driving by
preventing dangerous skids and allowing the driver to maintain steering control while trying to stop.
 AUTOMOTIVE STEERING
The means by which a motor vehicle is controlled about the vertical axis

Industrial Revolution

Allowed design of products and processes for energy conversion and transmission thus
allowing the use of energy to do useful work.

• Engineering designs of this era were largely mechanical

– e.g., operations of motion transmission, sensing, actuation, and computation were

performed using mechanical components such as cams, gears, levers, and linkages).

• Purely mechanical systems suffer from

– Power amplification inability.

– Energy losses due to tolerances, inertia, and friction.

 Elements of Mechatronics—Mechanical

• Mechanical elements refer to – mechanical structure, mechanism, thermo-fluid,

and hydraulic aspects of a mechatronics system.

• Mechanical elements may include static/dynamic characteristics.

• A mechanical element interacts with its environment purposefully.

• Mechanical elements require physical power to produce motion, force, heat, etc.

Elements of Mechatronics—Electromechanical
• Electromechanical elements refer to:
– Sensors

• A variety of physical variables can be measured using sensors, e.g., light using photo-resistor, level and
displacement using potentiometer, direction/tilt using magnetic sensor, sound using microphone, stress and
pressure using strain gauge, touch using micro-switch, temperature using thermistor, and humidity using
conductivity sensor
– Actuators

• DC servomotor, stepper motor, relay, solenoid, speaker, light emitting diode (LED), shape memory alloy,
electromagnet, and pump apply commanded action on the physical process • IC-based sensors and actuators
(digital-compass, -potentiometer, etc.).
IC-based sensors and actuators (digital-compass, -potentiometer, etc.).
 Elements of Mechatronics—
Electrical/Electronic

• Electrical elements refer to:

– Electrical components (e.g., resistor (R), capacitor (C), inductor

(L),transformer, etc.), circuits, and analog signals

• Electronic elements refer to:

– analog/digital electronics, transistors, thyristors, opto-isolators,

operationalamplifiers, power electronics, and signal
conditioning.

• The electrical/electronic elements are used to interface

electromechanical sensors and actuators to the control
interface/computing hardware elements
 Elements of Mechatronics—Control
Interface/Computing Hardware

• Control interface/computing hardware elements

refer to:

– Analog-to-digital (A2D) converter, digital-to-analog (D2A)

converter, digital input/output (I/O), counters, timers,
microprocessor, microcontroller, data acquisition and control
(DAC) board, and digital signal processing (DSP) board

• Control interface hardware allows analog/digital

interfacing:

– communication of sensor signal to the control computer and

communication of control signal from the control computer to
the actuator

• Control computing hardware implements a control

algorithm, which uses sensor measurements, to
compute control actions to be applied by the actuator.
Elements of Mechatronics—
Computer/Information System

• Computer elements refer to hardware/software

utilized to perform:
– computer-aided dynamic system analysis, optimization, design,
and simulation
– virtual instrumentation
– rapid control prototyping
– hardware-in-the-loop simulation
– PC-based data acquisition and control
 Elements of Mechatronics

• Typical knowledgebase for optimal design and

operation of mechatronic systems comprises of:
– Dynamic system modeling and analysis

• Thermo-fluid, structural, hydraulic, electrical, chemical, biological,

etc.
– Decision and control theory
– Sensors and signal conditioning
– Actuators and power electronics
– Data acquisition

• A2D, D2A, digital I/O, counters, timers, etc.

– Hardware interfacing
– Rapid control prototyping
– Embedded computing

Balance theory, simulation, hardware, and software

Key Elements of Mechatronics

 CHAPTER 4

Structural Control
 INTERNET OF THINGS

The Internet of things (IoT) is the inter-networking of physical

devices, embedded with electronics, software, sensors, actuators,
and network connectivity which enable these objects to collect
and exchange data.

IoT and mechatronics are complementary. Many of the smart

components associated with the Internet of Things will be
essentially mechatronic. The development of the IoT is forcing
mechatronics engineers, designers, practitioners and educators to
research the ways in which mechatronic systems and
components are perceived, designed and manufactured. This
allows them to face up to new issues such as data security,
machine ethics and the human-machine interface.[6]

Home Automation

• Using a computer:

– Turn on the lights at preset times

– Adjust brightness

– Turn on the heat at preset times or temperature

– Serve as a security system

 Robotics
Robotics & Mechatronics focuses on robotics and deals with modelling and
simulation of physical systems, intelligent control, robotic actuators and
embedded control systems.
 Future Trends in Mechatronic Engineering
A remarkable human ability is to learn from the results obtained from past acts so as to
perform better when executing similar tasks in the future. This learning ability provides
human beings with the ability to act as autonomous units. A further ability lies in
communicating with other human beings so as to undertake collective tasks. The above
description of human abilities provides a basis for understanding and trends in mechatronics
(see the right side of Figure 2). Note that task (v)⎯actuation, task (ii)⎯(signal
communication), and task (iv)⎯(signal processing and decision making) have already been
enabled (at least in part) by M, E, and C technologies respectively. Sensing and sensor fusion
(task ii) will be the next capability to be acquired by mechatronic systems. Already, many
mechatronic units possess rudimentary sensing abilities. For instance, modern air
conditioning units are able to sense air temperature and humidity through separate sensors
and fuse the signals through fuzzy logic reasoning. Likewise, sensors in the form of
transducers have long been used to enable feedback control in machines. However, there is
still a long way to go. Sensors produce copious amounts of data that need to be digested to
discover patterns of interest before control can be effected through the „actuators‟. Advances
in high-speed microcomputers and signal processing algorithms (such as those based on
wavelet theory) have now opened the door for the exploitation of sensors exploiting a wide
range of physical, chemical and, even, biological phenomena. While actuators are limited in
variety, the variety of possible sensors is almost unlimited. For instance cutting forces in
CNC machining and its consequences (e.g., tool fracture) can today be monitored and
controlled using commercially available devices capable of sensing 10 machining noise,
machine vibrations, acoustic emission, drive motor current [40], etc. Future mechatronic
engineers will have to possess deeper understanding of natural sciences so as to cope with
the growing variety of sensors. And they will have to learn to fuse these sensors using such
emerging techniques as fuzzy logic reasoning and artificial neural nets (ANN). Machine
learning: Intelligence means adapting to the environment and improving performance over
time [41]. Within the domain of mechatronic engineering, “there has been considerable
interest in learning through the use of ANN and fuzzy logic for applications in control and
robotics, autonomous guided vehicles (AGV), etc., that require mainly reflective intelligence
when performed by human operators and tasks, such as machine diagnostics, requiring
combinations of reflexive intelligence and low level reflective intelligence [39].” This
interest will continue well into the future. Autonomization refers to the development of the
ability to survive and perform robustly while the external environment changes. With
progress in sensor and learning technologies, tomorrow‟s mechatronic devices can be
expected to become progressively more autonomous. They will be able to reset their local
goals autonomously under changing external environments so as to meet the broad
systemlevel goals set by human beings. Modularization will be a consequence of
autonomization. Mechatronic sub-units will come in modular form, i.e., with all the abilities
required for local goal setting, control, and learning encapsulated within the sub-unit. Thus,
in time, every mechatronic sub-unit will be self-contained and intelligent. To the
mechatronic engineer, they will appear as black boxes. All (s)he has to do is to choose the
right combination of sub-units and build the desired system Miniaturization refers to the
trend towards mechatronic units of significantly smaller size. Progress in precision
engineering, newer materials (composites, diamond coatings, etc.), and nano-technologies
will contribute to this development Links to the Internet: The Internet will become
ubiquitous within the mechatronic world. Every autonomous mechatronic unit will be
connected via broadband and satellite networks to the rest of the world. Each mechatronic
device will be able to access the information and knowledge base available on the Internet so
as to optimize its own performance. At the same time, it will be able to communicate its
operational status to remote monitors. For instance, one would be able to query from one‟s
office the refrigerator at home about its contents and receive a fairly accurate answer.
Likewise, one can query a pillbox how many pills are remaining! Societies of devices: The
metaphor of society is very similar to that used by Minsky in his book „The Society of Mind
[42]‟. He says: “[M]ind is made up of many smaller processes. These we‟ll call agents. Each
mental agent by itself can only do simple things that need no mind or thought at all. Yet
when we join these agents and societies⎯in certain special ways⎯this leads to true
intelligence.” Once a mechatronic device has become autonomous, locally intelligent, and
able to communicate extensively via the Internet, it can join „societies‟ of devices with a
common purpose or interest. The implications of meachatronic devices developing social
relationships with other devices and human beings can be bewildering. Quoting from [39]:
“[I]magine that you are walking through a production facility. Your guide points to a
[mechatronic] work center and says “He is a baby. He still has to a lot to learn.” He then
walks to another and says “Ah! This guy is the smartest. He knows what he is doing. He is
11 correct 80% of the time.”” Note that, while we had started this article with an implicit
image of mechatronic devices as being inanimate, we are ending with a very animate (live)
image. Future mechatronic engineers will have to learn to cope with the immense
technological changes described above. Let us hope that educators of mechatronic engineers
will keep up.

CONCLUSION
After having a deep and crystal clear study of
Mechatronics, focusing all its details, we find that
it is like a blessing of science and technology on mankind
providing safety, security, whims and
fancies to life.

It is like a sea entangling mechanical, electrical, electronics

and computer science, thereby-:
“ESTABLISHING THE REGIN OF VIRTUE IN THE
WORLD AND IN THE CHAPTER OF SCIENCE AND
ENGINEERING”
 Bibliography

• WIKIPEDIA.COM
• GOOGLE.COM
• CAR MECHATRONICS(STUDY MATERIAL)