UNIT I INTRODUCTION

Introduction to Mechatronics Systems – Measurement Systems – Control Systems –

Microprocessor based Controllers – Sequential Control – Automatic Camera –
Washing Machine.

Mechatronics:
Mechatronics is a concept of Japanese origin and can be defined as the application
of electronics and computer technology to control the motions of mechanical
systems.

It is a multidisciplinary approach to product and manufacturing system design. It

involves application of electrical, mechanical, control and computer engineering to
develop products, processes and systems with greater flexibility, ease in redesign
and ability of reprogramming. It concurrently includes all these disciplines.

System:
A system may be defined as a black box which has an input and an output. System
concerned only with the relationship between the input and output and not on the
process going inside the box.

Mechatronic system:

Actuators: Solenoids, voice coils, D.C. motors, Stepper motors, Servomotor,

hydraulics, pneumatics.
Sensors: Switches, Potentiometer, Photo - electrics, Digital encoder, Strain
gauge, Thermocouple, accelerometer etc.

Input signal conditioning and interfacing: Discrete circuits, Amplifiers, Filters,

A/D, D/D.

Digital control architecture: Logic circuits, Microcontroller, SBC, PLC,

Sequencing and timing, Logic and arithmetic, Control algorithm, Communication.

Output signal conditioning and interfacing: D/A D/D, Amplifiers, PWM, Power
transistor, Power Op - amps.

Graphical displays: LEDs, Digital displays, LCD, CRT

Measurement system:
A measurement system can be defined as a black box which is used for making
measurements. It has the input as the quantity being measured and the
output as a measured value of that quantity.

Elements of Measurement Systems:

Measurement system consists of the following three elements.
a) Sensor b) Signal conditioner c) Display System

 Sensor:
A sensor consists of transducer whose function is to convert the one form of
energy into electrical form of energy. A sensor is a sensing element of
measurement system that converts the input quantity being measured into an
output signal which is related to the quantity.

 Signal Conditioner:
A signal conditioner receives signal from the sensor and manipulates it
into a suitable condition for display. The signal conditioner performs filtering,
amplification or other signal conditioning on the sensor output.

 Display System:
A display system displays the data (output) from the signal conditioner by
analog or digital. A digital system is a temporary store such as recorder.
Control system:

A black box which is used to control its output in a pre-set value

 Open loop control system:

If there is no feedback device to compare the actual value with desired

one. No control over its input

 Closed loop control system:

If there is feedback device to compare the actual value with desired one.

Elements of Closed Loop System:

The elements of closed loop control system are

 Comparison Unit
 Control Unit
 Correction Unit
 Process Unit
 Measurement Device
Open-loop systems have the advantage of being

 Relatively simple and

 Consequently low cost with generally good reliability.

However, they are inaccurate since there is no correction for error.

Closed-loop systems have the

Advantage of being relatively accurate in matching the actual to the required values.

They are, however, having disadvantages like,

 More complex and more costly and
 Greater chance of breakdown as a consequence of the greater number
of components

System of Controlling Water Level

Controlled variable : Water level in the tank

Reference variable : Initial setting of the float and lever position
Comparison Element : The lever
Error signal : Difference between the actual & initial setting of the lever
positions
Control Unit : The pivoted lever
Correction Unit : The flap opening or closing the water supply
Process : The water level in the tank
Measuring device : The floating ball and lever

Automatic Camera

The modern camera is likely to have automatic focusing and exposure. The basic
aspects of a microprocessor-based system that cannot be used to control the focusing
and exposure. When the switch is operated to activate the system and the camera
pointed at the object being photographed, the microprocessor takes the input from the
range sensor and sends an output to the lens position drive to move the lens to achieve
focusing. The lens position is fed back to the microprocessor so that the feedback
signal can’t be used to modify the lens position according to the inputs from the range
sensor. The light sensor gives an input to the microprocessor which then gives an
output to determine, if the photographer has selected the shutter controlled rather than
aperture controlled mode, the time for which the shutter will be opened. When the
photograph has been taken, the microprocessor gives an output to the motor drive to
advance the film ready for the next photograph.

The program for the microprocessor is a number of steps where the microprocessor
is making simple decisions of the form: is there an input signal of a particular input line
or not and if there is output a signal on a particular output line. The decisions are logic
decisions with the input and output signals either being low or high to give on-off states.
A few steps of the program for the automatic camera might be of the form:

begin
if battery check input OK
then continue
otherwise stop
loop
read input from range sensor calculate lens
movement output signal to lens position drive
input data from lens position
encoder
compare calculated output with actual output stop output when lens in
correct
position
send in-focus signal to viewfinder
display
etc.
Washing Machine

The above figure shows the basic washing machine system and gives a rough idea of
its constituent elements.

The system that was used for the washing machine controller was a mechanical
system which involved a set of cam-operated switches, i.e mechanical switches. The
figure below shows the basic principle of one such switch.
When, the machine is switched on, a signal electric motor slowly rotates its shaft, giving
an amount of rotation proportional no tune. The rotation turns the controller cams so that each
in turn operates electrical switches and so switches on circuits in the correct sequence. The
contour of a cam determines the time at which it operates a switch.

With modern washing machines the controller is a microprocessor and the program is not
supplied by the mechanical arrangement of cams but by a software program.

For the pre-wash cycle an electrically operated valve is opened when a current is supplied and
switched off when it ceases. This valve allows cold water into the drum for a period of time
determined by the profile of the cam or the output from the microprocessor used to operate
its switch.

However, since the requirement is a specific level of water in the washing machine drum, there
needs to be another mechanism which will stop the water going into the tank, during the permitted
time, when it reaches the required level.

A sensor is used to give a signal when the water level has reached the preset level
and give art output front the microprocessor which is used to switch off the current to
the valve. In the case of a cam-controlled valve, the sensor actuates a switch which
closes the valve admitting water to the washing machine drum

When this event is completed die microprocessor, or the rotation of the cams, initiates a pump to
empty the drum.

For the main wash cycle, the microprocessor gives an output which starts when the pre-wash part
of the program is completed: in the case of the cam-operated system the cam has a
profile such that it starts in operation when the pre-wash cycle is completed. It switches a
current into a circuit to open a valve to allow cold water into the drum. This level is sensed
and the water shut off when time required level is reached.
The microprocessor or cam then supplies a current to activate a switch which applies
a larger current to an electric heater to heat the water. A temperature sensor is used
to switch off the current when the water temperature reaches the preset value.

The microprocessor or cams then switch on the drum motor to rotate the drum. This
will continue for the time determined by the microprocessor or cam profile before switching off.
Then the microprocessor or a cam switches on the current to a discharge pump to empty
the water from the drum. The rinse part of the operation is now switched as a sequence
of signals to open valves which allow cold water into the machine. Switch it off, operate the motor
to rotate the drum, operate a pump to empty the water from the drum, and repeat this
sequence a number of times.

Engine Management System

 Engine management system is now-a-days, used in many of the modem cars,
this car includes many electronic control systems such as microcontrollers for
the control of various engine factors.
 The main objective of the system is to ensure that the engine is operated at its
optimum settings.
 The engine management system of a car is responsible for managing the ignition
and fuelling requirements of the engine.
 The power and speed of the engine are controlled by varying the ignition timing
and the Air fuel mixture. In modern cars, this is done by microprocessor.
 To control the ignition delay, the crank shaft drives a distribution which makes
electrical contacts for each spark plug in turn and a timing wheel. This timing
wheel generates pulses - to indicate the crankshaft position.
 The microprocessor then adjusts the timing at which high voltage pulses are sent
to the distributor so that they occur at right moments of time.
 To control the amount of air-fuel mixture entering into a cylinder during the
suction stroke, the microprocessor varies the time for which a solenoid is
activated to the inlet valve on the basis of inputs received by the engine
temperature and the throttle position.
 The amount of fuel to be injected into the air stream can be determined on input
from a sensor of the mass rate of air, or computed from other measurements.
 The microprocessor then gives as output to control of fuel inject valve.
 The system hence consists of number of sensor for observing vehicle speed,
Engine temperature, oil and fuel pressure, air flow etc.,
 These sensors supplies input signals to the microprocessor after suitable signal
conditioning and provides output signals via drivers to actuate corresponding
actuators.