UNIT - 1

AUTOMATION
Automation is the technology by which a process or procedure is accomplished without
human assistance. Automation is a technology concerned with the application of
mechanical , electronic and computer based systems to operate & control the production.

AUTOMATION INCLUDES :-

1. Automatic machine tools to process the parts

2. Automatic assembly machines
3. Industrial robots
4. Automatic material handling & storage systems
5.Automatic inspection systems for Q.C(Quality control).
6. Feed back control and computer process control
7. Computer systems for planning, data collection & decision making to support
manufacturing activities.
NEED OF AUTOMATION

1.High cost of labour in industrial society the cost of labour has been increasing
2. Shortage of labour especially in advanced nations
3.To increase the productivity : automation increases the out put per hour
4.labour trend towards service sector: large number of people think that the industrial
work is tedious , dirty & under standard.
5. Safety:by automation the operator is transferred from the active part to supervisory
part. so more safety is offered to the operator
6. High cost of material: automation minimise the wastage of material
7. Improved quality of product.
8. Automation reduces manufacturing lead time and in process inventory
9. High cost of not automating.

ADVANTAGES OF AUTOMATION
(ARGUMENTS IN FAVOUR OF AUTOMATION)

1. Automation decreases the average number of working hours to workers – offers greater
leisure
2. Automation offers lower price & good quality products
3. Automation provides more safety to workers
4. Growth of automation offers more employment opportunity
5. Automation increases the standard of living.

DISADVANTAGES OF AUTOMATION
(ARGUMENTS AGAIST AUTOMATION)

1.Automation will subjugate (overcome) the human being by machine: Automation reduces
the need of skilled workers. The main works are performed by the automatic machines
 and menial works such as loading, unloading etc are performed by the workers. ie:
Automation degrade the factory work .

2. Automation leads to unemployment: Automation increases the production so it

replaces workers by machines. The creation of new job by automation will not
be fast enough to take up the displaced workers.
3. Automation reduces the purchasing power: As automation increases the unemployment ,
people will not be able to purchase the articles.Production stops and again unemployment
increases.

TYPES OF AUTOMATION

Automated manufacturing systems can be classified as

1. Fixed automation
2. Programmable automation
3. Flexible automation.

FIXED AUTOMATION

Fixed automation is a system in which sequence of processing (or assembling) is fixed by

equipment configuration. only one or two products – special purpose machines are
arranged according to the sequence of operations .
Suitable for mass production.
No flexibility.
example :- 1. machining transfer lines.
2. automated assembly lines.

PROGRAMMABLE AUTOMATION

In programmable automation, production equipment is designed so that it is capable to

change the sequence of operation by changing the program.
large variety of products can be done.
Most suitable for batch production (can also be used for job order) to change the product,
change the program, jigs , fixtures and tool settings.
General purpuse machines are used.
example:- NC machines, Industrial robots, PLC etc.

FLEXIBLE AUTOMATION

Flexible automation is an extension of programmable automation.

A flexible automation system is capable of producing a variety of products with no time
loss for change over from product to product changing of tools, jigs, fixtures etc are also
programmed & no time loss in change over. Flexibility is less than the programmable
automation. but time for changeover is zero. Suitable for continuous production of variable
mixture of products. example:- FMS (Flexible Manufacturing system).
 PROGRAMMABLE
FIXED AUTOMATION AUTOMATION FLEXIBLE AUTOMATION

GENERAL PURPUSE
GENERAL PURPUSE
1 CUSTOM ENGINEERED MACHINES ARE USED
MACHINES ARE USED
MACHINES ARE USED
VOLUME OF PRODUCTION IS
HIGH VOLUME OF LESS VOLUME OF INBETWEEN FIXED &
2
PRODUCTION PRODUCTION PROGRAMMABLE
AUTOMATIONS
HIGH FLEXIBILITY BUT A
HIGH FLEXIBILITY -
NO FLEXIBITY - ONLY 1 OR LITTLE BIT LESS COMPARED
3 LARGE VARIETY OF
2 PRODUCTS WITH PROGRAMMABLE
PRODUCT
AUTO:
A CONSIDERABLE TIME
CHANGE OVER IS NOTIS CONSUMED FORNO TIME IS CONSUMED FOR
4
POSSIBLE CHANGE OVER OFCHANGE OVER OF PRODUCTS
PRODUCTS

SUITABLE FOR CONTINUOUS

SUITABLE FOR MASS SUITABLE FOR BATCH
5 PRODUCTION OF VARIABLE
PRODUCTION PRODUCTION
MIXTURE OF PRODUCTS

ADVANTAGES AND DISADVANTAGES OF AUTOMATION CAN BE SIMPLY

LISTED AS FOLLOWS:

Advantages of Automation

• Increased labor productivity

• Reduce the labour and skilled workers
• Provides safety to workers and reduced accidents
• Reduced scrap and wastages and thus saving material cost.
• Reduced manufacturing lead time (Time between customer order and product
delivery)
• Reduced in-process inventory by reducing the time a work part spends in the
factory.
• Consistant product quality
• Lower product price and better products.
• Automation increase standard of living.
• Lesser floor space
• Machining of advanced materials can be easily done

Disadvantages of Automation

• It reduces the labour force especially skilled employees, so that the employment
opportunity reduces.
• Automation may treat the human as a machine
• It reduces the purchasing power since the market is saturated with products that
the people cannot afford to purchase.
• Initial expenses are more.
• Setting time of machine takes more.
• Breakdown or shut down of at any point may idles the entire system.
• Servicing requires more skill.

INTRODUCTION TO MECHATRONICS

What is Mechatronics?
• Mechatronics is the integration of mechanical, electrical, and computer technologies into
the design of complex products.
Mechatronics Defined — I

• “The word, mechatronics is composed of mecha from mechanics and tronics from
electronics. In other words, technologies and developed products will be incorporating
electronics more and more into mechanisms, intimately and organically, and making it
impossible to tell where one ends and the other begins.”

Mechatronics Defined — II

1.As per W. Bolton, Mechatronics is defined as :

“Integration of electronics, control engineering, and mechanical engineering.”
2. As per D. M. Auslander and C. J. Kempf , Mechatronics is defined as :
“Application of complex decision making to the operation of physical systems.”
3. As per F. Harshama, M. Tomizuka, and T. Fukuda Mechatronics is defined as:
“Synergistic integration of mechanical engineering with electronics and intelligent
computer control in the design and manufacturing of industrial products and processes.”

Mechatronics Defined — III

4. As per S. Ashley Mechatronics is defined as :

“Synergistic use of precision engineering, control theory, computer science, and sensor and
actuator technology to design improved products and processes.”
5. As per D. Shetty and R. A Kolk, Mechatronics is defined as :
“Methodology used for the optimal design of electromechanical products.”
6. As per D. G. Alciatore and M. B. Histand Mechatronics is defined as :
“Field of study involving the analysis, design, synthesis, and selection of systems that combine
electronics and mechanical components with modern controls and microprocessors.”

Mechatronics: Working Definition for us

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.

BENEFITS OF MECHATRONICS

COMPLEX PRODUCTS CAN EASILY BE MANUFACTURED.

eg: car, Robots , plane , space craft etc contain different technologies. These products can easily
be manufactured by mechatronics.
2. ACCURATE AND QUICK CONTROLLING IS POSSIBLE.
(because controlling is done micro controller or PLC)
3. WASTAGE CAN BE MINIMISED.
(because real time control and error compensation avoid the possibility of wastage and rejection)
4. IN MECHATRONICS, PRODUCT IS COMPACT
(some bulky mechanical parts are replaced by electronic components)
5. GREATER FLEXIBITY IN PRODUCT DESIGN BY MODULAR DESIGN
6. PERFORMANCE OF PRODUCT WILL BE EXCELLENT.
7. THE OPERATIONS CAN BE PRE PROGRAMMED AND EXECUTED EASILY.
8. ASTHETICS AND ERGONOMICS ARE CONSIDERED IN DESIGN . LIFE &
RELIABILY IS OFFERED.

LIST THE BENEFITS OF MECHATRONICS

MECHATRONICS IN MANUFACTURING

MOVING PARTS OF MACHINE IS OPERATED BY ACTUATORS (CYLINDERS ,

MOTORS etc)
THESE ACTUATORS ARE MONITORED BY SENSORS AND SIGNAL IS FED INTO
THE CONTROL SYSTEM.
IN THE CONTROL SYSTEM A REFERENCE VALUE IS PRESET.
THE FEED BACK SIGNALS ARE PROCESSED AND REAL TIME VALUE IS
COMPARED WITH THE REFERENCE VALUE BY A PROGRAM. THEN AN OUT
PUT SIGNAL IS FED INTO THE ACTUATOR TO CONTINUE or STOP THE
OPERATION.
Mechatronics in products

1. Electronics and Consumer Durables: cameras and audio equipment, washing machines,
refrigerators, dishwashers, and dryers; printed circuit boards (PCBs) in a mechanical package;
can be freestanding, handheld, or mounted in racks or vehicles;
2. Vehicle Systems
• automobiles, small aircraft, trucks, small watercraft, and personal transportation;
• Control systems of automobiles such as Brake systems of automobiles
3.Communication Systems : Radio base stations, telephone switches, satellites, and radar
equipment; intricate electronics and control units to serve as communication infrastructure;
devices are usually freestanding or mounted on rooftops or towers.
4. Biomedical Instrumentation : MRI, CT scan, dialysis units, and airport security systems;
• Diagnostic and investigative equipment used in medicine; expensive and not mass produced.
5. Office Equipment: Copiers, fax machines, printers, computers.
6. Industrial Machinery and Equipment : large industrial equipment, silicon fabrication
machines, printing presses, gas turbines, weapon systems; simulators.
7.Large Scale Transportation and Equipment :large aircraft, locomotives, shipbuilding, and mass
transit systems; construction equipment (cranes, bulldozers, trucks) .

Some examples of mechatronic systems

• Domestic appliances, such as fridges and freezers, microwave ovens, washing machines,
vacuum cleaners, dishwashers, cookers, timers, mixers, blenders, stereos, televisions,
 telephones, lawn mowers, digital cameras, videos and CD players, camcorders, and many
other similar modern devices;
• Domestic systems, such as air conditioning units, security systems, automatic gate
control systems;
• Office equipment, such as laser printers, hard drive positioning systems, liquid crystal
displays, tape drives, scanners, photocopiers, fax machines, as well as other computer
peripherals;
• Retail equipment, such as automatic labeling systems, bar-coding machines, and tills
found in supermarkets;
• Banking systems, such as cash registers, and automatic teller machines;
• Manufacturing equipment, such as numerically controlled (NC) tools, pick-and-place
robots, welding robots, automated guided vehicles (AGVs), and other industrial robots;
• Aviation systems, such as cockpit controls and instrumentation, flight control actuators,
landing gear systems, and other aircraft subsystems.
ADVANTAGES OF MECHATRONICS OVER CONEVENTIONAL SYSTEM

FEATURE COVENTIONAL MECHATRONICS

SIZE BULKY COMPACT

MECHANISM COMPLEX SIMPLE

MOVEMENT NON ADJUSTABLE PROGRAMMABLE

SYNCHRONISATION MECHANICAL ELECTRONICS

STRUCTURE RIGID & HEAVY LIGHTER

ACCURACY DETERMINED BY BY FEED BACK

TOLERANCE

CONTROL MANUAL AUTOMATIC

Mechatronis and Engineering design

The engineering design process stages are:*

*The need
*Analysis of problem
*Preparation of a specification
*Generation of possible solutions
*Selection of a suitable solution
*Production of a detailed design
*Production of working drawing
Establishment of need and goal recognition

• Before any product development takes place, it is imperative that the need for the product
is established.
 • This requirement is usually driven by a customer or by an enterprise trying to anticipate a
market.
• If the need is not clear then, although the product may be technically sound, it may fail
commercially.
Specification

• Specifications should include a design specification, testing specifications, acceptance

specifications and development specifications, although others may well be required to
fully document what is required and how the end product will be verified to meet those
requirements.
• The specifications must also include details of how the end product will be maintained to
ensure that it continues to fully meet the customers requirement throughout its lifetime
The design specification should include:
• Introduction;
• Performance;
• life;
• Useful life (period);
• life between overhauls;
• Environment;
• Power;
• Reliability;
• Cost;
• Maintenance;
• Manufacturing process;
• Physical size and weight.
•
System conception

• This is the stage in which the specification is realized in conceptual designs.

• Normally, several design solutions are obtained during this stage, and using different
decision-making processes, the best design is chosen. Some detailed design may be
necessary to prove ‘ground-breaking’ concepts, but the overall cost/benefit will need to
be analyzed before embarking on this route.
• All stakeholders might be involved in choosing the final design. Decision-making
techniques include:
• Comparison charts;
• Category weighting;
• Decision networks;
• Morphological analysis of decision making (MADM).

Detailed design
• Once the conceptual design has been agreed, the detailed design to meet the specification
within the conceptual framework can begin.
• Engineering drawings showing all the necessary views and dimensions are prepared.
• The material for each component is specified and assembly drawings are made.
• Everything that will be required by the production teams and maintenance teams must
appear in the detailed design.
• An important part of the design process is the inclusion of a mechanism that allows the
design to be reviewed either continually or at key stages to ensure that it does not deviate
from the original intention.
• This process also caters for problems that might arise potentially affecting the end
product’s ability of meeting the specified requirements. These processes will be part of
the designer’s quality assurance system.
Prototyping

• The designer will work with the production department to produce models (prototypes) of
a design. Prototypes are built to verify that key or novel aspects of the design work as
expected or physically fit into existing plant or equipment.
• A close relationship with the production department also ensures that the design can
actually be manufactured using the techniques available to the department.
• If new production equipment and training are needed, it should be identified early in the
project.

Testing

• Complete advance prototypes, key components, and pre-production models of a design

are thoroughly tested to verify that the product meets the specification requirements.
• The tests form part of the quality assurance procedures of the project and usually have to
be signed off as being complete and satisfactory before the product goes into production.

Review and documentation

• The design is not complete until it has been thoroughly documented and reviewed. The
level of documentation required will depend on the nature of the project but may include
the following:
• Rationale behind the project (need, market, cost/benefit, etc.)
• specification;
• Detailed design to meet specification (explaining how the design meets the specifications
and how it works);
• User guides (how to use the product);
• Maintenance guides (how to keep the product working, e.g. spares, servicing schedules);
Mechatronic Design Process

THE MECHATRONICS APPROCH

MAINTAINING or IMPROVING THE PERFORMANCE OF EXISTING SYSTEM.

BULKY MECHANICAL PARTS ARE REPLACED BY COMPUTER BASED OR MICRO
PROCESSOR BASED SMART SYSTEMS. Eg., An earlier mechanical switches of a
domestic washing machines are now replaced by microprocessor.
But … AN EXISTING MECHANICAL SYSTEM CANNOT BE DIRECTLY REPLACED
BY AN ELECTRONIC SYSTEM. SO A COMPLETE RETHINKING ABOUT THE
REQUIREMENTS AND NECESSARY DESIGN CHANGES ARE DONE USING
COMPUTER OR MICROPROCESSOR.

REDUCE THE SIZE OF PRODUCT --- MAINTAINING or IMPROVING THE

PERFORMANCE OF EXISTING SYSTEM.
BULKY MECHANICAL PARTS ARE REPLACED BY COMPUTER BASED OR MICRO
PROCESSOR BASED SMART SYSTEMS. Eg., An earlier mechanical switches of a
domestic washing machines are now replaced by microprocessor.
But … AN EXISTING MECHANICAL SYSTEM CANNOT BE DIRECTLY REPLACED
BY AN ELECTRONIC SYSTEM. SO A COMPLETE RETHINKING ABOUT THE
REQUIREMENTS AND NECESSARY DESIGN CHANGES ARE DONE USING
COMPUTER OR MICROPROCESSOR.

MECHATRONICS TECHNOLOGY
A MECHATRONIC SYSTEM HAS TWO COMPONENTS
1. CONTROLLING SYSTEM
2. CONTROLLED SYSTEM
THE CONTROLLED SYSTEM INCLUDES ALL REQUIRED
ACTUATORS AND SENSORS.
CONTROLLING SYSTEM IS INTELLIGENT CONTROL
SYSTEM (ICS) CONSITS OF COGNITION , PERCEPTION
AND DECISION MAKING.
ICS PLANS A COURSE OF ACTION AND IT IS
EXECUTED BY ACTUATORS.

MECHATRONICS TECHNOLOGY

MODULAR DESIGN
IN MODULAR DESIGN, THE MACHINE IS ASSEMBLED AROUND THE
COMPONENT TO BE MACHINED.

MODULAR DESIGN MEANS TRYING TO SUBDIVIDE AN ASSEMBLY INTO

SMALL PARTS WHICH ARE EASILY AND INTERCHANGABLY USED.

MODULAR DESIGN
“KOENINGSBERGER” AND HIS MANCHESTER GROUP ADVOCATE
FOR THIS DESIGN OF WIDE VARIETY OF MACHINES OF LIMITED
CAPACITY INLINE WITH THE SPECIFIC NEEDS OF A CITUATION BY
COMBINING RELATIVELY SIMPLE INTERCHANGIBLE OPERATIONAL
UNITS TO SUIT THESE NEEDS.

MODULAR DESIGN GETS THE ADVANTAGE OF STANDARDISATION

AND CUSTAMISATION.
MACHINE TOOL IS CONSIDERD AS AN ASSEMBLAGE OF STANDARD
UNITS OR MODULES.
CONVENTIONAL DESIGN OF INDIVIDUAL WHOLE IS DICARDED.

IN MECHATRONICS, MODULAR DESIGN IMPLIMENTED. SO-------

IF THE PRODUCT DESIGN IS CHANGED, THE DESIGN OF MACHINE

CAN EASILY BE CHANGED TO ATTAIN THE NEW PRODUCTION.
DESIGN PROCESS IN MECHATRONICS

TO DESIGN AND ANALYSE A MECHATRONIC SYSTEM, A DEEP

KNOLEDGE OF VARIOUS CONVENTIONAL TECHNOLOGIES IN
MECHANICAL ENGG., ELECTRONICS ENGG., COMPUTER ENGG.&
CONTROL ENGG. ARE INEVITABLE.

DESIGN PROCESS IN MECHATRONICS

 STEPS
1. IDENTIFY THE REQUIREMENTS THE OUT PUT REQUIRED ARE
IDENTIFIED &LISTED.

2. ANALYSE THE PRESENT MECH: SYSTEM. BEFORE APPLYING

MECHATRONICS, EACH & EVERY PART OF THE PRESENT SYSTEM HAS
TO BE ANALYSED.

3. APPLY REPLACEMENT MECHANISM. Identify the correct electronic

components that can replace the mechanical component in the present
system. There should be significant benefits in replacing (simplicity, compactness,
accuracy etc) .
APPLY SIMPLIFICATION MECHANISM
simplification of certain mechanisms in present system can be achieved by combining,
rearranging etc. Eg: movement of work table in a surface grinding machine is
Adjusted by stoppers in mechanical system. These stoppers can be replaced by pressure
switches and movement is reversed by using sensors.
BUT ------THESE TWO OPERATIONS CAN BE COMBINED BY USING A TWO
WAY TWO WAY PRESSURE SWITCH.
5. APPLY ENHANCEMENT MECHANISM
ACCURACY AND RELIABILITY ARE ENHANCED USING COMPUTER
PROGRAMS, REDUNDANT etc.

6. APPLY SYNTHESIS MECHANISM:IN MECHANICAL SYSTEM MOST OF THE

OPERATIONS ARE SEQUENTIAL.BUT SOME OPERATIONS CAN BE DONE
SIMULTANEOUSELY. IN MECHATRONIC DESIGN, THE MOST
EFFICIENT SRQUENCE IS SYNTHESISED USING COMPUTER PROGRAMS.
7. APPLY MODULAR DESIGN:IN MODULAR DESIGN, INTERCHANGIBLE PARTS
(COMPONENTS) ARE KEPT AND THE REQUIRED
ASSEMBLY IS SET UP AS AND WHERE REQUIRED. IN MECHATRONIC DESIGN,
MODULAR DESIGN IS APPLIED WHEREVER IT IS POSSIBLE.

CONVENTIONAL & MECHATRONICS APPROACH

 ELEMENTS OF PRODUCT DESIGN

1 The control unit

2 The drive units
3 The position feedback package
4 Magnetic box
5 Manual control

*Control unit
A tape recorder reads the instructions for manufacturing the component-