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INTRODUCTION:
Mechatronics is the complete integration or adoption of electrical,
electronics, computer technology and control engineering with mechanical
engineering. (OR)
Mechatronics is the synergistic combination of mechanical engineering,
electronic engineering, computer technology, control engineering and systems in
the design and manufacturing of products and processes.
a) Primary level Mechatronics: In the early days Mechatronics products were at primary level containing l/O devices
such as sensors, actuators integrated electrical signals with mechanical action at the basic control level.
Example: Electrically controlled fluid valves and relays.
b) Secondary level Mechatronics: This level integrates microelectronics into electrically controlled devices. Sometimes
these products are stand alone ones. Example: cassette player.
c) Tertiary level Mechatronics (third): This incorporates advanced feedback functions into control strategy, thereby
enhancing the quality is terms of sophistication. A Mechatronics system at this level is called smart system. The
control strategy includes microelectronics, microprocessor and other Application Specific Integrated Circuits (ASIC),
Example: hard disk, CD drives, automatic washing machines etc.
d) Quaternary level Mechatronics (fourth): This level incorporates intelligent control in Mechatronics system. This
level attempts to improve smartness a step ahead by introducing intelligence and Fault Detection and Isolation (FDI)
capability systems. Example: Artificial neural network and Fuzzy logic technologies.
1.4 Advantages and disadvantages of Mechatronics:
Advantages:
1. The products produced are cost effective and very good quality.
2. High degree of flexibility
3. Greater extent of machine utilization
4. Greater productivity
5. High life expected by proper maintenance.
6. The integration of sensor and control system in a complex system reduces capital expenses.
Disadvantages:
1. Higher initial cost of the system.
2. Imperative to have Knowledge of different engineering fields for design and implementation.
3. It is expenses to incorporate Mechatronics approaches to existing/old systems.
4. Specific problem of various systems will have to be addressed separately and properly.
1. A Sensor/Transducer which responds to the quantity being measured by giving as its output a signal which is related
to the quantity to be measured. The output of this unit is input to the signal conditioner which is next element.
For example, a thermo- couple is a temperature sensor. The input to the sensor is a temperature and the output is
an e.m.f which is related to the temperature value.
2. A Signal conditioner takes the signal from the sensor and manipulates it into a condition which is suitable either for
display, or, in the case of a control system, for use to exercise control. Thus, for example, the output from a
thermocouple is a rather small e.m.f and might be fed through an amplifier to obtain a bigger signal. The amplifier is
the signal conditioner.
The following functions of signal conditioners are:
I. Amplification of signals: the level of signals from the transducer may be of low level for the next use and hence
need to be amplified (increased).
II. Attenuation: similarly the level of signals from the transducer may be of higher level for the next use and hence
need be attenuated (decreased).
III. Filtering: signals from the transducer may contain some other undesirable signals which need to be filtered or
eliminated before it is used. Otherwise a corrupt output will be generated.
IV. Analog to digital conversion (ADC): the signals from the transducer may be analog in nature and if these signals
were to be used as input to electronic system/computer system, they need to be converting to digital form.
Similarly sometimes we use DAC.
3. A Display system where the output from the signal conditioner unit is displayed and this display will be the
quantitative form of the measurand. The display unit may be analog (dial gauge) or digital (LED) type. For example, a
pointer moving across a scale or a digital readout.
Ex: Consider a digital thermometer; this has an input of temperature to a sensor, probably a semiconductor diode. The
potential difference across the sensor is a measure of the temperature. This potential difference is then amplified by an
operational amplifier to give a voltage which can directly drive a display. The sensor and operational amplifier may be
incorporated on the same silicon chip.
1.8.2 Control System:
A control system is an arrangement of physical components connected or related in such a manner as to command,
direct or regulate itself or another system. (Or)
A group of devices/elements which maintains the required output based on the predefined value by controlling the
parameter responsible for output constitutes a control system.
For instance, consider a domestic air-conditioning control system. The input to this system is the temperature
required in the house and its output, the house at that temperature.
Following are some examples of control system applications:
1. Steering control of automobile.
2. Print wheel control system.
3. Industrial sewing machine.
4. Sun-tracking control of solar collectors.
5. Speed control system.
6. Temperature control of an electric furnace.
The elements of an open-loop control system can usually be divided into the following two parts:
(i) Controller Unit (ii) Processing Unit/Controlled Process
An input signal or command is applied to the controller, whose output acts as the actuating signal; the actuating signal
then controls the controlled process so that the controlled variable will perform according to prescribed standards.
Ex:
i. ON/OFF of an electric lamp: Electric lamps are used for lighting the lamp. ON/OFF control is carried out with the help
of a switch and the switch is generally operated by an operator depending on the amount of light that exist in that area.
If the switch is ON, the lamp is glow. If the person operating the switch does not switch OFF, the lamp will remain ON
until he switches OFF. So it is called open loop control system.
ii. Control the temperature of the room with room heater: the amount of heat developed by a room heater depends on
the amount of input power controlled by a regulator. If the power is switch ON, the power supplied to the heater
continues and temperature of the room goes on increasing immaterial of whether heat is required in the room or not.
Here, the person has to go and switch OFF the power supply and there by cooling the temperature of the room.
1. Comparison element
This compares the reference value of the variable that to be controlled with the measured value of what is being
achieved and produces an error signal.
Error signal = reference value signal - measured value signal
2. Control element
This unit analyzes error signal and decides what action to be taken when it receives an error signal. It may be, for
example, a signal to operate a switch or open a valve. The manipulation of the control unit is such that the error will
approach zero.
3. Correction element
The modified signal from the control unit will be received by the correction element which produces a change in the
process to correct or change the controlled condition. The term actuator is used for the element of a correction unit
that provides the power to carry out the control action.
4. Process element
The process is what is being controlled. It could be the speed of motor, speed of vehicle, central heating unit, central
air conditioner, tank of water with its level being controlled etc,
5. Measurement element / Feedback unit
The measurement element is used to produce a signal related to the variable condition of the process that is being
controlled and sends the signal to the comparison element.
Ex: i) One of the best examples of a closed loop system is human being. Consider a person who wants to reach for a
book on the table, position of the book is given as reference; feedback signal from eyes compares the actual position of
hands with reference position. Error signal is given to brain. Brain manipulates this error and gives signal to the hands.
This process continues till the hand reaches the book.
ii) Automatic Speed Control system: In this system, speedometer measures the actual speed of the engine and
compares with desired speed to generate the error. Based on the error controlling elements such as eyes and brain
takes a decision and leg muscle and accelerator is actuated to increase or decrease the speed of the engine.
iii) Constant water level in a tank: The reference value is the initial setting of the lever arm arrangement so that it
just cuts off the water supply at the required level. When water is drawn from the tank the float (feedback element)
moves downwards with the water level. This causes the lever arrangement (control element) to rotate and opening
of flap (correction element) takes place which allows water to enter the tank. This flow continues until the ball has
risen to such a height that it has moved the lever arrangement to cut off the water supply
iv) Room Heating System: In this system, thermostat acts as a feedback element, its function is to sense the actual
temperature and compares with the desired temperature. Based on the deviation obtained, control element (relay)
and correction element (switch) are activated to produce necessary signal to the process element (furnace) so as to
obtain the desires output temperature of the room.
Advantages and limitations of Closed-loop control system:
Advantages:
1. More accurate comparatively.
2. Usually performs accurately even in the presence of non-linearity.
3. Change in system Component is automatically taken care of.
4. The use of feedback system response is relatively insensitive to external disturbances and internal variations in
system parameters. It is thus possible to obtain the accurate control of a given plant.
Limitations / Disadvantages:
1. Generally complicated in construction
2. Generally higher in cost and power
3. May become unstable at times.
4. High maintenance cost.
Microprocessors are now rapidly replacing the mechanical operated controllers and being used in general to
carry out control functions. They have the great advantage that a greater variety of programs become feasible. In many
simple systems there might just an embedded microcontroller, this being a microprocessor with memory all integrated
on one chip, which has been specifically programmed for the task concerned. A more adaptable form is the
PROGRAMMABLE LOGIC CONTROLLER. This is a microprocessor-based controller which uses programmable memory to
store instructions and to implement functions such as logic, sequence, timing counting and arithmetic to control events
and can be readily programmed for different tasks. Fig. shows the control action of a programmable logic controller, the
inputs being signals from switches being closed and the program used to determine how the controller should respond
to the inputs and the output it should then give.
1.9.1 Block diagram of a microprocessor based processor control system of an Automatic camera:
Working:
o Camera is used to photograph an object, the switch is pressed which activates the system.
o The range sensor sense the distance of the object to be photographed and this data is input to microprocessor.
o The microprocessor in turn sends on output to motor to drive to position the lens for focusing.
o The position of the lens is input to microprocessor.
o Next the light sensor sends the signal of light intensity on the object to microprocessor.
o Based on this, signals are sent to control the duration of time the shutter have to be kept open.
o All these action and reaction take place within a fraction of second.
o Once the film has exposed, the information is input to the microprocessor which gives output for driving the
motor for advancing the film to drive and the camera is ready for the next exposure.
1.9.2 Block diagram of microprocessor based processor control system of Engine management system:
Working:
o Engine management system is used for managing the ignition and air/fuel requirement of an IC engine.
o In the case of four stroke multi cylinder petrol engine, each cylinder has a piston performing all the four stroke
(suction, compression, working or expansion and exhaust strokes)
o The pistons of each cylinder are connected to a common crankshaft and their power strokes occur at different
times so that there is continuous power for rotating the crankshaft.
o The power and speed of an engine are functions of ignition timing and air/fuel mixture.
o Hence, by controlling the ignition timing and air/fuel mixture it is possible to control the speed and power of the
engine.
o In modern cars the ignition timing, opening and closing of valves at appropriate time, quality of air/fuel mixture
are controlled by microprocessor with the help of sensors.
o For ignition timing the crankshaft drives a distributor which makes electrical contacts for each spark plug and
turns a timing wheel.
o The timing wheel generates pulses which are input the microprocessor.
o The microprocessor as per the program adjusts the timing at which high voltage pulses are sent to the
distributor so that spark occurs at the right time resulting in complete combustion of fuel.
o The quantity of air/fuel mixture entering the cylinder during suction stroke is again controlled by microprocessor
by varying the time for which the solenoid is activated to open the intake and throttle position.
o The quantity of fuel injected into the air stream is sensed by sensor of the mass flow rate computed from one
method, and then input to the microprocessor which in turn gives an output to control the fuel injection.
1.9.3 Block diagram of a microprocessor based processor control system of Automatic washing machine:
Working:
o This is a sequential control system wherein control is exercised based on event, or parameter etc., i.e., control
action will be executed one after another event.
o The events to be carried out in a domestic washing machine are soaking, washing, rinsing and drying.
o Each of these operations involves a number of steps.
o Soaking involves selection of correct quantity of detergent and water based on the type and amount of cloth.
o This requires opening of the valve to fill the machine drum to required level and closing the valve once the
required level of water has reached and rotating the drum in either directions for a pre-set amount of time
during the soaking operation.
o This is followed by washing which is a time parameter event.
o Then the rinsing event which measures the pH value using a chemical sensor of water in the drum and compares
it with supply of water.
o This event continues till the pH value of the water in the cloth and the supply water are equal.
o Finally drying operation till the minimum percentage of moisture is retained in the cloth.
o All these events were earlier controlled with the help of mechanical system involving a set of cam operated
switches.
o In modern washing machine mechanical system is replaced by digital devices. i.e., a microcontroller and the
sequence of instruction; program embedded in the microcontrollers.
ASSIGNMENT QUESTIONS
3. Explain the differences between conventional approach and Mechatronic approach to product design.
5. What is a control system? Explain open loop and closed loop control system with examples.
8. What is sequential controller and explain with a block diagram working automatic washing machine.
9. Draw the structure of a programmable logic controller and mention the functions of each block.
10. Explain with block diagram the working of microprocessor based automatic camera.
11. With the help of block diagram explain microprocessor based engine management system.