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6ME3A: Mechatronics

Tarun Kr. AseriAsst. Prof.

Mechanical Engineering Govt. Engineering College Ajmer

Barliya Chouraha, NH-8,Ajmer-305001, India

Email: tarunaseri@gmail.com

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An Introduction to Mechatronics

Reference Books and Text Books

1. Bolton, W. Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, Pearson, 4Ed, 2013; ISBN: 978-81-317-3253-3.

2. Alciatore DG, Histand MB, Introduction to Mechatronics and Measurement Systems, McGraw-Hill, 4Ed, 2012; ISBN: 978-0-07-338023-0.

3. Kuttan, AKK. Introduction to Mechatronics, Oxford University Press, 2013; ISBN: 978-0-19-568781-1.

4. Ramachandran KP, Vijayaraghavan GK, Balasundaram MS. Mechatronics: Integrated Mechanical Electronic Systems, Wiley, 2010; ISBN: 978-81-265-1837-1.

5. Onwubolu, GC. Mechatronics Principles and Applications, Elsevier, 2005; ISBN: 0-7506-6379-0.Download from google drive: https://drive.google.com/open?id=0B9TJesZvD5x-S1kxaWxia3JYMkU

6. Bishop RH, The Mechatronics Handbook, CRC Press, 2002; ISBN: 0-8493-0066-5. Download from google drive: https://drive.google.com/open?id=0B9TJesZvD5x-ZmZvY3hSYlZjQ0k

7. Bishop RH, Mechatronics: An Introduction, CRC Press, 2006; ISBN: 0-8493-6358-6. Download from google drive: https://drive.google.com/open?id=0B9TJesZvD5x-bEc1YTdOWGM4TG8

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MECHanical + elecTRONICS

A philosophy in which there is a coordinated and concurrently

developed, integration of mechanical engineering with electronics

and intelligent computer control in the design and manufacture of

products and processes.

A multidisciplinary approach

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Mechatronics

Mechanical Engineering

Electrical Engineering

Control Engineering

Computer Engineering

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Results:

Much greater flexibility,

Ease in redesign ReprogrammableAutomated data collection and

reporting

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•Sequential approach

•Cocurrent approach

Design

Juice filling and packing machine Video

7 8Pick and Place, chip shooter video

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9Automotive Assembly line video

With the help of microelectronics and sensor technology, mechatronics systems are

providing high levels of precision and reliability.

It is now possible to move (in x – y plane) the work table of a modern production

machine tool in a step of 0.0001 mm.

By employment of reprogrammable microcontrollers/microcomputers, it is now easy

to add new functions and capabilities to a product or a system.

Today’s domestic washing machines are “intelligent” and four-wheel passenger

automobiles are equipped with safety installations such as air-bags, parking

(proximity) sensors, antitheft electronic keys etc.

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Process planning

Production planning

Design procurement of new tools

Order material

NC, CNC, DNC programming

ProductionQuality control

PackagingShippingMarketing

Design needDesign

specifications

Feasibility study with collecting

information

Design conceptu-alization

Analysis model

DesignDesign

analysis, optimization

Design evaluation

Design documentatio

n

Des

ign

Pro

cess

Man

ufa

ctu

rin

g P

roce

ss

Automated Manufacturing Systems

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► Operates in the factory on the physical product► Automated operations:

► Processing, Assembly, Inspection. Material Handling

► Automated: Reduced level of Human intervention

► 3 Basic Types:► Fixed Automation► Programmable Automation► Flexible Automation

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Three Type of Automation

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A

B

C

Production Quality

100 10k 10t

Product Variety

A=?B=?C=?

Three Type of Automation

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A

B

C

Production Quantity

100 10k 10t

Product Variety

A=?B=?C=?

Flexible AutomationProgrammable AutomationFixed Automation

Human & Machines

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Relative strength of Human and Machine

Human & Machines

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Relative strength of Human and Machine

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Human & Machines

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According to a research at Cambridge University, 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.

Relative strength of Human and Machine

Human & Machines

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Relative strength of Human and Machine

HUMANS MACHINES

Sense unexpected Stimuli Perform repetitive tasks

Develop new solutions to problems Store large amount of data

Adapt to changes Retrieve data from memory

Cope with abstract problems Perform multitasks simultaneously

Generalize from observations Apply high forces & power

Learn from experience Perform simple computations quickly

Make difficult decisions based on

incomplete data

Make routine decisions quickly

Mechatronics

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Engineering Mechanics of Machine Elements

► Kinematics

• Position

• Velocity

• Acceleration

► Kinematics Analysis

• Impact (due to change in momentum)

• Jerk (due to change in acceleration)

Mechatronics

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Engineering Mechanics of Machine Elements

► Dynamics

• Torque

• Force

► Dynamic Analysis

• Friction

• Inertia

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Mechatronics

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Electronics Engineering

► Measurement systems

• Sensors, Signal conditions and display units

► Actuators

► Power Electronics

► Microelectronics

Mechatronics: Informatics/Information System

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Informatics/

Information System

Tools/Devices

Automation

Software design

Artificial intelligence

Programmable logic control (PLC)

Microcontroller

Personal Computers

Output

Reduce human errors

Solve complex engineering problems

Communication system

Finance system

Virtual modelling

Data storage

Access/Retrieved data

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. Analyse its elements and state its importance in the functioning of that system.

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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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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

Classified into:

─Flexible Manufacturing Cell (FMC),

─Flexible manufacturing System (FMS) and

─Flexible manufacturing Line (FML)

FMCs have high flexibility but handle less volume while FML have less

flexibility but can handle very large volumes.

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Flexible Manufacturing System

There are three levels of manufacturing flexibility.

1-Basic Flexibilities

Machine flexibility - the ease with which a machine can process various operations

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

2-System flexibilities:

Volume flexibility

Expansion flexibility

Routing flexibility

Process flexibility

Product flexibility

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Flexible Manufacturing System

3-Aggregate flexibilities

Program Flexibility

Production Flexibility

Market Flexibility

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Video of FMC

Applications

1) Design and Modelling

2) Software Integration

3) Actuator and Sensors

4) Intelligent Control

5) Robotics

6) Manufacturing

7) Motion Control

8) Vibration and Noise Control

9) Optics

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Micro-

Electro-

Mechanical

System

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 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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Videos

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

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MEMS – Micro-electro-mechanical-systems

Micro Nano-World

Micro-ProbingMicro-Optics

Pressure, Force, Inertial,

Sound, etc.

RF-MEMSMicro-Scale

Actuation and Motion

Bio-MEMS

Micro-Fluidics

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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.

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There are following three types of PLDs are being employed in mechatronics systems.

1. MicroprocessorIt 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

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Microprocessor -based controllers and Microelectronics

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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Components

• 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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Microprocessor

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Applications of microprocessors are classified primarily in two categories:

1. Reprogrammable Systems : Micro computers

2. Embedded Systems : photocopying machine, Digital camera

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Microprocessor

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Microprocessor works or operates in binary digits i.e. 0 and 1, bits.

These bits are electrical voltages in the machine, generally 0 - low

voltage level, and 1 -high voltage level. A group of bits form a ‘word’.

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

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Microprocessor: Configuration

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Microprocessor: Working 53 54 55

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.

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Microprocessor: Functions of components

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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: Function of components

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).

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Microprocessor: Functions of components

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.

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Microprocessor: Functions

A simple microprocessor consists of following basic elements:

• Data Bus: Through data bus, the data flow between

a. various storage units

b. ALU and memory units

• Address Bus: It controls the flow of memory addresses between ALU and

memory unit.

• RD (read) and WR (write) lines set or obtain the addressed locations in the

memory.

• Clock line transfers the clock pulse sequence to the processor.

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Microprocessor: Elements Figure

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• Reset Line is used to restart execution and reset the processor to zero.

• 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 number of instructions executed. It can be set to zero when instructed.

• Test Register: It is a register which stores intermediate or in-process data of ALU operations. 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.

• 3-State Buffers: These are tri-state buffers. A tri-state buffer can go to a third state

in addition to the states of 1 and 0.

• The instruction register and instruction decoder are responsible for controlling the

operations of all other components of a microprocessor.

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Microprocessor: Elements Figure

There are following control lines present in a microprocessor, which are used to

communicate instructions and data with the instruction decoder.

• Instruct the A register to latch the value currently on the data bus.

• Instruct the B register to latch the value currently on the data bus.

• Instruct the C register to latch the value currently output by the ALU.

• Instruct the program counter register to latch the value currently on the data bus.

• Instruct the address register to latch the value currently on the data bus.

• Instruct the instruction register to latch the value currently on the data bus.

• Instruct the program counter to increment.

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Microprocessor: Elements Figure

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Microcomputer Central Processer

Memory

I/O Ports

MicroController

Microcomputer is a microprocessor

based system.

It is a data processing system that

employs a microprocessor as its

central unit.

Based on the input it takes decisions.

These decisions are further used to

control a system or to actuate an action

or operation.

It is a microprocessor-based system.

It implements the functions of a computer and a controller on a single chip.

Generally microcontroller is programmed for one specific application and it is dedicated to a specific control function.

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Microcontroller

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Microcontrollers find applications in Automobiles,

Aircraft,

Medical Electronics

Home Appliances.

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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Microcontroller-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

2. Tool monitoring systems

3. Advanced manufacturing systemsa. Flexible manufacturing system (FMS)

b. Computer integrated manufacturing (CIM)

4. Industrial robots

5. Automatic inspection systems: machine vision systems

6. Automatic packaging systems

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Mechatronics-Applications

Number System

Number system is a way of representing the value of any number

with respect to a base value.

Number System can be classified on the basis of its “base”.

Each number has a unique representation in a number system.

Different number systems have different representation of the same

number.

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Number System

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Number representation

Conversion of any number system to decimal number system

Example: what is the decimal equivalent of (11101011)2 ?

Here, we have taken An = 1, An-1= 1, ……. An-3=0, while n=8 and B = 2.

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Number representation

Conversion of any number system to decimal number system

Example: what is the decimal equivalent of (11101011)2 ?

Here, we have taken An = 1, An-1= 1, ……. An-3=0, while n=8 and B = 2.

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Number representation

Conversion of any number system to decimal number system

Example: what is the decimal equivalent of (11101011)2 ?

Here, we have taken An = 1, An-1= 1, ……. An-3=0, while n=8 and B = 2.

Ans = (235)10

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Number representation

Conversion of Decimal number

system to any number system

Any number in decimal system can

be changed to any other number

system by continuously dividing it

by base of the required number

system and then writing remainders

after each step in reverse order.

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Ans = (11101011)2

Binary representation of (235)10

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Hexadecimal system representation

• This system is quite extensively used in microprocessor programming.

• It facilitates much shorter representation of number in comparison

with that obtained by using the binary number system.

• Hexadecimal system has a base of 16 and it is easy to write and

remember the numbers and alphabets viz. 0 to 9 and A to F.

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Hexadecimal system representation

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Hexadecimal system representation: Example

• Let us convert the number (235)10 to hexadecimal equivalent.

Hence (235)10 = (EB)16

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Number Division RemainderHexadecimal equivalent of

remainder

235235 divided by 16

= 14 (full)11 B

1414 divided by 16= Cannot divide

14 E

Binary coded decimal (BCD)

• BCD code expresses each digit of a decimal system by its nibble

equivalent.

• It uses 4 bit binary strings to represent the digits 0 to 9.

523 010100100011

(235)10

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Thank You

For

Your Attention

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