LECTURE NOTES ON MECHATRONICS
Lecture NotesMechatronics (M.Tech, Design Dynamics)LECTURE NOTES ONMECHATRONICSPREPARED BYDr PRAMOD KUMAR PARIDAASSISTANT PROFESSORDEPARTMENT OF MECHANICAL ENGINEERINGCOLLEGE OF ENGINEERING & TECHNOLOGY (BPUT)BHUBANRSWAR1 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)SYLLABUSMECHATRONICS (3-0-0)Fundamental of Mechantronics: Definition and concepts of Mechatronics, Conventional systemvs. mechatronic system, Need and Role of Mechantronics in Design, Manufacturing andFactory Automation. Hardware components for Mechatronics Number system inMechatronics, Binary Logic, Karnaugh Map Minimization,Transducer signal conditioning and Devices for Data conversion programmable controllers. ;Sensors and Transducers: An introduction to sensors and Transducers, use of sensor andtransducer for specific purpose in mechatronic. ;Signals, systems and Actuating Devices: Introduction to signals, systems and control system,representation, linearization of nonlinear systems, time Delays, measures of systemperformance, types of actuating devices selection. ; Real time interfacing: Introduction,Element of a Data Acquisition and control system, overview of the I/O process. Installation ofthe I/O card and software. ;Application of software in Mechatronics: Advance application in Mechantronics. Sensors forconditioning Monitoring, Mechatronic Control in Automated Manufacturing, Micro sensors inMechatronics. Case studies and examples in Data Acquisition and control. Automatedmanufacturing etc.Essential Reading:1. C.W.De Silva, Mechatronics: An Integrated Approach, Publisher: CRC;2 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)Module-IWhat is “Mechatronics”?Mechatronics is a concept of Japanese origin (1980’s) and can bedefined as the application of electronics and computer technology to controlthe motions of mechanical systems.Definition of MechatronicsIt is a multidisciplinary approach to product and manufacturing systemdesign (Figure). It involves application of electrical, mechanical, control andcomputer engineering to develop products, processes and systems withgreater flexibility, ease in redesign and ability of reprogramming. Itconcurrently includes all these disciplines.Mechatronics: a multi-disciplinary approachMechatronics can also be termed as replacement of mechanics withelectronics or enhance mechanics with electronics. For example, in modernautomobiles, mechanical fuel injection systems are now replaced withelectronic fuel injection systems. This replacement made the automobilesmore efficient and less pollutant. With the help of microelectronics andsensor technology, mechatronics systems are providing high levels ofprecision and reliability. It is now possible to move (in x – y plane) the work3 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)table of a modern production machine tool in a step of 0.0001 mm. Byemployment of reprogrammable microcontrollers/microcomputers, it is noweasy to add new functions and capabilities to a product or a system. Today’sdomestic washing machines are “intelligent” and four-wheel passengerautomobiles are equipped with safety installations such as air-bags, parking(proximity) sensors, antitheft electronic keys etc.4 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)Concept of Mechatronics System5 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)Evolution Level of Mechatronics1. Primary Level Mechatronics: This level incorporates I/O devices such assensors and actuators that integrates electrical signals with mechanicalaction at the basic control levels.Examples: Electrically controlled fluid valves and relays2. Secondary Level Mechantronics: This level integrates microelectronicsinto electrically controlled devices.Examples: Cassette players3. Third Level Mechatronics: This level incorporates advanced feedbackfunctions into control strategy thereby enhancing the quality in terms ofsophistication called smart system. The control strategy includes microelectronics, microprocessor andother ‘ Application Specific Integrated Circuits’ (ASIC)Example: Control of Electrical motor used to activate industrial robots,hard disk, CD drives and automatic washing machines.4. Fourth Level Mechatronics: This level incorporates intelligent control inmechatronics system. It introduces intelligence and fault detection andisolation (FDI) capability systems.Advantages and Disadvantages of Mechatronics system:6 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)Components of Mechatronics system:The term mechatronics system (sometimes referred to as smart device)encompasses a myriad of devices and systems. Increasingly,microcontrollers are embedded in the elctromechanical devices, creatingmuch more flexibility and control possibilities in system design. Components of a typical Mechatronics systemActuators: produce motion or cause some action. Solenoids, voice calls, DCmotors, Stepper motor, servomotor, hydraulic, pneumatic.Sensors: detect the state of the system parameters, inputs and outputs. Switches,potentiometer, photoelctrics, digital encoder, strain gauge, thermocouple,accelerometer etc.7 Page
Lecture Notes Mechatronics (M.Tech, Design Dynamics)Input/output Signal conditioning and interfacing: provide connection betweenthe control system circuits and the input/output devices. Discrete circuits,amplifiers, filters, A/D, D/A, power transistor etc.Digital devices: controls the system. Logic circuits, micro controller, SBC, PLCetcGraphic Display: provide visual feed back to users. LEDs, Digital Displays, LCD,CRTImportance of Mechatronics in automation:Operations involved in design and manufacturing of a productToday’s customers are demanding more variety and higher levels of flexibilityin the products. Due to these demands and competition in the market,manufacturers are thriving to launch new/modified products to survive. It isreducing the product life as well as lead-time to manufacture a product. It istherefore essential to automate the manufacturing and assembly operationsof a product. There are various activities involved in the productmanufacturing process. These are shown in figure 1.1.3. These activities canbe classified into two groups viz. design and manufacturing activities.8 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)Mechatronics concurrently employs the disciplines of mechanical, electrical,control and computer engineering at the stage of design itself. Mechanicaldiscipline is employed in terms of various machines and mechanisms, whereas electrical engineering as various electric prime movers viz. AC/DC, servomotors and other systems is used. Control engineering helps in thedevelopment of various electronics-based control systems to enhance orreplace the mechanics of the mechanical systems. Computers are widelyused to write various softwares to control the control systems; product designand development activities; materials and manufacturing resource planning,record keeping, market survey, and other sales related activities.Using computer aided design (CAD) / computer aided analysis (CAE) tools,three-dimensional models of products can easily be developed. Thesemodels can then be analyzed and can be simulated to study theirperformances using numerical tools. These numerical tools are beingcontinuously updated or enriched with the real-life performances of thesimilar kind of products. These exercises provide an approximate idea aboutperformance of the product/system to the design team at the early stage ofthe product development. Based on the simulation studies, the designs canbe modified to achieve better performances. During the conventional designmanufacturing process, the design assessment is generally carried out afterthe production of first lot of the products. This consumes a lot of time, whichleads to longer (in months/years) product development lead-time. Use ofCAD–CAE tools saves significant time in comparison with that required inthe conventional sequential design process.CAD-CAE generated final designs are then sent to the production andprocess planning section. Mechatronics based systems such as computeraided manufacturing (CAM): automatic process planning, automatic partprogramming, manufacturing resource planning, etc. uses the design dataprovided by the design team. Based these inputs, various activities will thenbe planned to achieve the manufacturing targets in terms of quality andquantity with in a stipulated time frame.Mechatronics based automated systems such as automatic inspection andquality assurance, automatic packaging, record making, and automaticdispatch help to expedite the entire manufacturing operation. These systemscertainly ensure a supply better quality, well packed and reliable products inthe market. Automation in the machine tools has reduced the human9 Page
Lecture NotesMechatronics (M.Tech, Design Dynamics)intervention in the machining operation and improved the process efficiencyand product quality. Therefore, it is important to study the principles ofmechatronics and to learn how to apply them in the automation of amanufacturing system.Digital Codes:Logic Gates:10 P a g e
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Lecture NotesMechatronics (M.Tech, Design Dynamics)Module-IISensors and Transducers: An introduction to sensors and Transducers, use of sensor and transducer forspecific purpose in mechatronics. Transducer signal conditioning and Devices for Data conversionprogrammable controllers. ;Sensors and transducersMeasurement is an important subsystem of a mechatronics system. Its mainfunction is to collect the information on system status and to feed it to themicro-processor(s) for controlling the whole system.Measurement system comprises of sensors, transducers and signal processingdevices. Today a wide variety of these elements and devices are availablein the market.For a mechatronics system designer it is quite difficult to choose suitablesensors/transducers for the desired application(s). It is therefore essential tolearn the principle of working of commonly used sensors/transducers.Sensors in manufacturing are basically employed to automatically carry out theproduction operations as well as process monitoring activities. Sensortechnology has the following important advantages in transforming aconventional manufacturing unit into a modern one. Sensors alarm the system operators about the failure of any of the subunits of manufacturing system. It helps operators to reduce thedowntime of complete manufacturing system by carrying out thepreventative measures. Reduces requirement of skilled and experienced labors. Ultra-precision in product quality can be achieved.SensorIt is defined as an element which produces signal relating to the quantity beingmeasured. According to the Instrument Society of America, sensor can bedefined as “A device which provides a usable output in response to aspecified measurand.” Here, the output is usually an ‘electrical quantity’ andmeasurand is a ‘physical quantity, property or condition which is to bemeasured’. Thus in the case of, say, a variable inductance displacement14 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics)element, the quantity being measured is displacement and the sensortransforms an input of displacement into a change in inductance.Input SignalOutput SignalSensorSensors are also called detectors.Need for Sensors Sensors are omnipresent. They embedded in our bodies, automobiles,airplanes, cellular telephones, radios, chemical plants, industrial plantsand countless other applications. Without the use of sensors, there would be no automationTransducerIt is defined as an element when subjected to some physical changeexperiences a related change or an element which converts a specifiedmeasurand into a usable output by using a transduction principle. It can alsobe defined as a device that converts a signal from one form of energy toanother form.A wire of Constantan alloy (copper-nickel 55-45% alloy) can be called as asensor because variation in mechanical displacement (tension orcompression) can be sensed as change in electric resistance. This wirebecomes a transducer with appropriate electrodes and input-outputmechanism attached to it. Thus we can say that ‘sensors are transducers’.Basic elements of transducer There are basically two elements which constructs a transducer andthey are A sensing ELEMENT15 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics) Sensor/transducers specificationsTransducers or measurement systems are not perfect systems. Mechatronicsdesign engineer must know the capability and shortcoming of a transduceror measurement system to properly assess its performance. There are anumber of performance related parameters of a transducer or measurementsystem. These parameters are called as sensor specifications.Sensor specifications inform the user to the about deviations from the idealbehavior of the sensors. Following are the various specifications of asensor/transducer system.1. RangeThe range of a sensor indicates the limits between which the input can vary.For example, a thermocouple for the measurement of temperature mighthave a range of 25-225 C.2. SpanThe span is difference between the maximum and minimum values of the input.Thus, the above-mentioned thermocouple will have a span of 200 C.3. ErrorError is the difference between the result of the measurement and the true valueof the quantity being measured. A sensor might give a displacement readingof 29.8 mm, when the actual displacement had been 30 mm, then the erroris –0.2 mm.4. AccuracyThe accuracy defines the closeness of the agreement between the actualmeasurement result and a true value of the measurand. It is often expressedas a percentage of the full range output or full–scale deflection. A16 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics)piezoelectric transducer used to evaluate dynamic pressure phenomenaassociated with explosions, pulsations, or dynamic pressure conditions inmotors, rocket engines, compressors, and other pressurized devices iscapable to detect pressures between 0.1 and 10,000 psig (0.7 KPa to 70MPa). If it is specified with the accuracy of about 1% full scale, then thereading given can be expected to be within 0.7 MPa.5. SensitivitySensitivity of a sensor is defined as the ratio of change in output value of asensor to the per unit change in input value that causes the output change.For example, a general purpose thermocouple may have a sensitivity of 41μV/ C.6. NonlinearityNon-linearity errorThe nonlinearity indicates the maximum deviation of the actual measured curveof a sensor from the ideal curve. Figure above shows a somewhatexaggerated relationship between the ideal, or least squares fit, line and theactual measured or calibration line. Linearity is often specified in terms ofpercentage of nonlinearity, which is defined as:Nonlinearity (%) Maximum deviation in input Maximum full scale input (1)The static nonlinearity defined by Equation (1) is dependent uponenvironmental factors, including temperature, vibration, acoustic noise level,17 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics)and humidity. Therefore it is important to know under what conditions thespecification is valid.7. HysteresisHysteresis error curveThe hysteresis is an error of a sensor, which is defined as the maximumdifference in output at any measurement value within the sensor’s specifiedrange when approaching the point first with increasing and then withdecreasing the input parameter. Figure above shows the hysteresis errormight have occurred during measurement of temperature using athermocouple. The hysteresis error value is normally specified as a positiveor negative percentage of the specified input range.8. ResolutionResolution is the smallest detectable incremental change of input parameterthat can be detected in the output signal. Resolution can be expressed eitheras a proportion of the full-scale reading or in absolute terms. For example, ifa LVDT sensor measures a displacement up to 20 mm and it provides anoutput as a number between 1 and 100 then the resolution of the sensordevice is 0.2 mm.9. Stability18 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics)Stability is the ability of a sensor device to give same output when used tomeasure a constant input over a period of time. The term ‘drift’ is used toindicate the change in output that occurs over a period of time. It is expressedas the percentage of full range output.10.Dead band/timeThe dead band or dead space of a transducer is the range of input values forwhich there is no output. The dead time of a sensor device is the timeduration from the application of an input until the output begins to respond orchange.11.RepeatabilityIt specifies the ability of a sensor to give same output for repeated applicationsof same input value. It is usually expressed as a percentage of the full rangeoutput:Repeatability (maximum – minimum values given) X 100 full range (2)12.Response timeResponse time describes the speed of change in the output on a step-wisechange of the measurand. It is always specified with an indication of inputstep and the output range for which the response time is defined.Classification of sensorsSensors can be classified into various groups according to the factors such asmeasurand, application fields, conversion principle, energy domain of themeasurand and thermodynamic considerations. These generalclassifications of sensors are well described in the referencesDetail classification of sensors in view of their applications in manufacturing isas follows.A. Displacement, position and proximity sensors Potentiometer Strain-gauged element Capacitive element Differential transformers Eddy current proximity sensors Inductive proximity switch19 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics) Optical encoders Pneumatic sensors Proximity switches (magnetic) Hall effect sensorsB. Velocity and motion Incremental encoder Tachogenerator Pyroelectric sensorsC. Force Strain gauge load cellD. Fluid pressure Diaphragm pressure gauge Capsules, bellows, pressure tubes Piezoelectric sensors Tactile sensorE. Liquid flow Orifice plate Turbine meterF. Liquid level Floats Differential pressureG. Temperature Bimetallic strips Resistance temperature detectors Thermistors Thermo-diodes and transistors Thermocouples Light sensors Photo diodes Photo resistors Photo transistor20 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics)Displacement and position sensorsDisplacement sensors are basically used for the measurement of movementof an object. Position sensors are employed to determine the position of anobject in relation to some reference point.Proximity sensors are a type of position sensor and are used to trace whenan object has moved with in particular critical distance of a transducer.Displacement sensors1. Potentiometer SensorsSchematic of a potentiometer sensor for measurement of lineardisplacementFigure above shows the construction of a rotary type potentiometer sensoremployed to measure the linear displacement. The potentiometer can be oflinear or angular type. It works on the principle of conversion of mechanicaldisplacement into an electrical signal. The sensor has a resistive elementand a sliding contact (wiper). The slider moves along this conductive body,acting as a movable electric contact.The object of whose displacement is to be measured is connected to theslider by using a rotating shaft (for angular displacement) a moving rod (for linear displacement)21 P a g e
Lecture NotesMechatronics (M.Tech, Design Dynamics) a cable that is kept stretched durin
Fundamental of Mechantronics: Definition and concepts of Mechatronics, Conventional system . systems and Actuating Devices: Introduction to signals, systems and control system, . electronic fuel injection systems. This replacement made the automobiles
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