UNIT - 1

INTRODUCTION TO
MECHATRONICS

AUTOMATION
 AUTOMATION
AUTOMATION IS THE TECHNOLOGY BY WHICH A
PROCESS OR PROCEDURE IS ACCOMBLISHED
WITHOUT HUMEN 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.
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 &
UNDERSTANDARD.
 NEED OF AUTOMATION
5. SAFETY
BY AUTOMATION THE OPERATOR IS TRANSFFERED
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 INPROCESS 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 HUMENBEING 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

 DISADVANTAGES OF AUTOMATION
(ARGUMENTS AGAIST AUTOMATION)
2. AUTOMATION LEADS TO UNEMPLOYEMENT

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.
 DISADVANTAGES OF AUTOMATION
(ARGUMENTS AGAIST AUTOMATION)

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
FIXD AUTOMATION IS A SYSTEM IN WHICH
SEQUENCE OF PROCESSING (or assembling) IS FIXED
BY EQUIPEMENT CONFIGURATION.
ONLY ONE OR TWO PRODUCTS – SPECIAL PURPUSE
MACHINES ARE ARREANGED 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 EXTENTION 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.
FLEXIBITY IS LESS THAN THE PROGRAMMABLE
AUTOMATION. But TIME FOR CHANGEOVER IS ZERO.
SUITABLE FOR CONTINUOUS PRODUCTION OF VARIABLE
MIXTURES OF PRODUCTS.
Example:- FMS
 FIXED PROGRAMMABLE FLEXIBLE
  AUTOMATION AUTOMATION AUTOMATION
1 CUSTOM ENGINEERED
MACHINES ARE USED
GENERAL PURPUSE
MACHINES ARE USED
GENERAL PURPUSE MACHINES ARE
USED

VOLUME OF PRODUCTION IS
2 HIGH VOLUME OF
PRODUCTION
LESS VOLUME OF
PRODUCTION
INBETWEEN FIXED &
PROGRAMMABLE AUTOMATIONS

HIGH FLEXIBILITY BUT A LITTLE BIT

3 NO FLEXIBITY - ONLY 1
OR 2 PRODUCTS
HIGH FLEXIBILITY - LARGE
VARIETY OF PRODUCT
LESS COMPARED WITH
PROGRAMMABLE AUTO:

A CONSIDERABLE TIME IS
4 CHANGE OVER IS NOT
POSSIBLE 
CONSUMED FOR CHANGE
OVER OF PRODUCTS
NO TIME IS CONSUMED FOR
CHANGE OVER OF PRODUCTS

SUITABLE FOR CONTINUOUS

5 SUITABLE FOR MASS
PRODUCTION
SUITABLE FOR BATCH
PRODUCTION PRODUCTION OF VARIABLE
MIXTURE OF PRODUCTS
Questions:-
1. Describe the need of Automation.
2. List out the advantages of automation.
or
Arguments supporting the automation.
3. List out the disadvantages of automation.
or
Arguments against the automation.
4. Explain 3 different types of automation.
5. Compare 3 different types of automation.
THANKS
INTRODUCTION
TO
MECHATRONICS
DEFENITION :-
MECHATRONICS IS THE SYNERGETIC
INTEGRATION OF MECHANICAL
ENGINEERING WITH ELECTRONICS
ENGINEERING AND INTELLIGENT
COMPUTER CONTROLL IN THE DESIGN AND
MANUFACTURE OF PRODUCTS AND
PROCESS.
MODERN COST EFFECTIVE TECHNOLOGIES
ARE USED TO IMPROVE THE PERFORMANCE
& FLEXIBILITY OF PRODUCT & PROCESS
APPLICATION OF COMPUTER AND CONTROLL
TECHNOLOGIES GIVE A BETTER DESIGN SOLUTION
BETTER THAN PURE MECHANICAL APPROCH.
MANUFACTURING SYSTEMS OF
COMPLEX PRODUCTS SUCH AS CARS, ROBOTS ,
SPACE CRAFT, MEDICAL EQUIPMENT etc USE
PROPER BLENDING OF DIFFERENT TECHNOLOGIES.
THE CURRENT APPROCH IS TO SYNTHESIZE
DIFFERENT METHODOLOGIES & TECHNICS THAT
MAY BE ORIGININATED FROM ELECTRONICS OR
MECHANICAL ENGINEERING TO ACHIEVE AN
OPTIMUM PERFORMANCE AND IS CALLED
MECHATRONICS.
 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
DOMINES OF MECHATRONICS
 THE MECHATRONICS APPROCH
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.
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.
EXAMPLE OF MECHATRONICS APPROCH
(WASHING MACHINE)
MECHATRONICS TECHNOLOGY
 MECHATRONICS TECHNOLOGY
A MECHATRONIC SYSTEM HAS TWO COMPONENTS
1. CONTROLLING SYSTEM
2. COMTROLLED 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 IN MANUFACTURING
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
 BENEFITS OF MECHATRONICS
1. 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)
 BENEFITS OF MECHATRONICS
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.
 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
 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
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.
 MODULAR DESIGN
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.
DESIGN PROCESS IN MECHATRONICS
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) .
 DESIGN PROCESS IN MECHATRONICS
4. 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 PRESSURE SWITCH.
DESIGN PROCESS IN MECHATRONICS
5. APPLY ENHANCEMENT MECHANISM
ACCURACY AND RELIABILITY ARE
ENHANCED USING COMPUTER
PROGRAMS, REDUNDANT etc.
DESIGN PROCESS IN MECHATRONICS
DESIGN PROCESS IN MECHATRONICS
DESIGN PROCESS IN MECHATRONICS
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.
DESIGN PROCESS IN MECHATRONICS
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.
 MEASUREMENT SYSTEM & CONTROL
SYSTEM
CONTROL SYSTEM
OUTPUT QUANTITY IS CONTROLLED BY
ALTERING THE INPUT QUANTITY.
THERE ARE TWO TYPES OF CONTROL
SYSTEMS:-
1. OPEN LOOP CNTROL SYSTEM
2. CLOSED LOOP CONTROL SYSTEM
 MEASUREMENT SYSTEM & CONTROL
SYSTEM
1. OPEN LOOP CNTROL SYSTEM
 MEASUREMENT SYSTEM & CONTROL
SYSTEM
1. CLOSED LOOP CNTROL SYSTEM
 SYNTHESIS OF MECHANISMS

AN INPUT MOTION HAS TO BE CONVERTED

INTO A DESIRED OUTPUT MOTION.
FOR THAT PURPUSE A SUITABLE MECHANISM
HAS TO BE CREATED USING LINKS AND
JOINTS.
THE PROPORTIONS and DIMONSIONS OF THESE
LINKS ARE IMPORTANT.
DETERMINATION OF THESE PROPORIONS IS
CALLED SYNTHSIS OF MECHANISMS.
SYTHESIS IS THE OPPOSITE OF ANALYSIS
THANKS