INTRODUCTION TO MECHANICAL ENGINEERING

(1BESC104D/204D)

MODULE - 05
 Syllabus: Module-5
Advances in mechanical engineering
Automation technology: Definition of automation, types of automation, basic elements of
automation.
Mechatronic systems: Definition of mechatronics, elements of mechatronics systems,
examples.
Elementary sensors: Working principle and applications of Potentiometer, capacitive
sensor and Optical encoders.
Integrated system: Need for integration of technologies, ADAS (Advanced Driver
Assistance System).

AUTOMATION
Automation is a technology concerned with the application of mechanical, electronic, and
computer-based systems to operate and control production activities with little or no hums
intervention

Types of automation
Automated manufacturing system can be classified into three basic types:
1) Fixed automation (Hard automation)
2) Programmable automation (Soft automation)
3) Flexible automation

Fixed automation
Fixed automation is a type of automation where the process of manufacturing stays fixed by
the way it is configured, following a fixed sequence of automated processes.
An example of this is flow production, where products are continuously being made. This is
often also known as “hard automation”.

Fixed automation can be expensive to set up initially due to the equipment required, but in
return, it provides high production rates.
However, it is relatively inflexible when it comes to making changes to the product.
This is relatively useful for many companies who use automation to create food products of
One type and variant.

Advantages
• High levels of production(mass production)
• Consistent quality in production
• Low cost per unit produced
Disadvantages
• High initial cost
• Difficult to accommodate changes

Programmable automation
In this, the production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations. The operation sequence is
controlled by a program, which is a set of instructions coded so that they can be read and
interpreted by the system. New program can be prepared and entered into the equipment to
produce new products.
It’s used more commonly in low to medium levels of production, often being most suitable
for batch production.
Programmable automation will often be used by factories who make different variants of foods.
This allows them to make batches, from a few dozen to potentially thousands at a time, of one
product. If the product needs changing, it simply needs to be reprogrammed.

Advantages
• Flexibility to change products if needed
• Suitable if batch production is required
Disadvantages
• Expensive for equipment
• Lower production levels
• Often time-consuming to change products

• This type of automation is well suited for: Low/Medium demand and

occasional changes in products.

Flexible automation
• It is an extension of programmable automation. A flexible automation is capable of
producing a variety of parts (or products) with virtually no time lost for changeover
from one part style to the next. There is no lost production time while reprogramming
the system and physical setup. Accordingly, the system can produce various mixes
and schedules of parts or products instead of requiring that they be made in batches.
This type of automation tends to have medium levels of production.
Advantages
• Flexibility of products
• No time lost with new changes to production
Disadvantages
• High custom machinery/automation cost
• Higher cost per unit

Advantages of automation

 Increase in accuracy and repeatability – when an automated machine is programmed

to perform a task over and over again, the accuracy and repeatability compared to an
employee is far greater.
 Less human error –A machine that performs repeated tasks is less likely to make
mistakes than an employee.
 Less employee costs – by adding automated machines to an operation, means less
employees are needed to get the job done. It also indicates less safety issues, which
leads to financial savings.
 Increased safety – having automated machines means having less employees who
perform tasks that can be dangerous and prone to injury, which can make the work
environment safer.
 Higher volume production – investing in automated equipment creates a valuable
resource for large production volumes, which in turn, will increase profitability.
Disadvantages of automation

 Less versatility – by having a machine that can perform a certain task limits to the
flexibility and variety of tasks that an employee could do.
 Large initial investment – automated machines can be one of the most costly
operating costs for a company. With automated machines running anywhere between
thousands and millions of dollars depending on the type and degree of automation.
 Increase in unemployment – by increasing the amount of automation, there are less
employees required causing high unemployment rates.
 Unpredictable costs – there can be several unpredictable costs that may exceed the
actual cost saved by the automation itself. Some of these costs could include research
and development costs of automating a process, preventative maintenance costs, and
the cost of training employees to operate automated machines.
 MECHATRONIC SYSTEMS

Definition of Mechatronics
 A multidisciplinary field that blends mechanical engineering with electronics and
computer control to design advanced products and processes.
 The term is a portmanteau of "mechanics" and "electronics," focusing on intelligent
integration.
 Mechatronics is an interdisciplinary field of engineering that focuses on the synergistic
integration of mechanical engineering, electronics, computer science, and control
engineering to design and create intelligent systems and products

Elements of Mechatronic Systems

These components form a crucial control loop:

1. Mechanical Systems: The physical structure, gears, linkages, and moving parts.
2. Sensors: Detect physical parameters (light, temperature, position) and convert them into
electrical signals (input).
3. Actuators: Convert electrical signals into physical actions (motion, force).
4. Controllers (Microprocessors/Computers): Process sensor data, execute algorithms,
and send commands to actuators.
5. Software / Control Algorithms: The intelligence that dictates system behaviour and
decision-making.
6. Signal Conditioning: Circuits for filtering, amplifying, and converting signals
(ADC/DAC).
Examples of Mechatronic Systems

 Robotics: Industrial robots, autonomous drones, robotic vacuums.

 Automotive: Anti-lock Braking Systems (ABS), cruise control, airbag systems, engine
management.
 Consumer Electronics: Digital cameras, automatic washing machines, CD/DVD
players, smart home devices.
 Aerospace: Aircraft flight control systems, navigation systems.
 Manufacturing: CNC machines, automated assembly lines.
Automotive & Transportation
 Anti-lock Braking Systems (ABS): Use sensors to detect wheel speed and a
microprocessor to control the brakes, preventing skidding.
 Engine Control Units (ECUs): Employ sensors and microprocessors to manage fuel
injection and ignition timing for optimal performance.
 Adaptive Cruise Control: Automatically adjusts a vehicle's speed based on surrounding
traffic using sensors and control algorithms.
 Self-driving/Autonomous Vehicles: Integrate a vast array of sensors (LiDAR, cameras),
advanced control systems, and mechanical components to navigate independently.
 High-speed trains (e.g., magnetic levitation): Utilize sophisticated control systems to
achieve high speeds with precision.
Industrial & Manufacturing
 Industrial Robotic Arms: Automated systems on assembly lines that perform precise
tasks like welding and painting, integrating mechanical arms with advanced software
control.
 Computer Numerically Controlled (CNC) Machines: Use computer programming to
control machine tools (like drills and cutters) with high accuracy for manufacturing parts.
 Automated Guided Vehicles (AGVs): Robots used in warehouses and factories for
material handling, guided by sensors and programmed paths.
 Sorting and Packaging Systems: Automated production lines that use sensors and
actuators to streamline processes, minimize errors, and maximize throughput.
Consumer Products & Home Automation
 Washing Machines: Use sensors (water level, temperature, door closure) and a
microcontroller to manage the mechanical functions of valves, pumps, and motors.
 Robotic Vacuum Cleaners (e.g., Roomba): Autonomous devices that use cliff sensors,
 wall-following sensors, and control algorithms to navigate and clean rooms.
 Autofocus Cameras: Integrate mechanical lens movement with electronic sensors and
microprocessors to automatically adjust focus.
 Inkjet Printers: Combine precise mechanical movement of the print head and paper with
electronic control circuits to transfer images.
 Smart Thermostats and Security Systems: Home automation devices that use sensors
and internet connectivity to learn preferences and provide remote control.
Medical & Healthcare
 Robotic Surgical Systems: Allow surgeons to perform minimally invasive procedures
with enhanced precision using robotic arms, cameras, and haptic feedback.
 Prosthetic Limbs (Bio mechatronics): Advanced bionic limbs with sensors that respond
to muscle signals to provide natural movement and restore mobility.
 Exoskeletons: Wearable robotic systems designed to aid rehabilitation or enhance human
strength and endurance for lifting heavy loads.

ELEMENTARY SENSORS:

1. Potentiometer
A potentiometer is a simple, contact-type position sensor that converts linear or
rotational mechanical displacement into a proportional electrical signal by using a variable
resistor.
Working Principle: It operates on the principle of a voltage divider. A fixed, uniform
resistance element (often a resistive track made of carbon or conductive plastic) has a
constant reference voltage applied across its two ends. A movable contact, called a "wiper,"
slides along this track. The position of the wiper determines the resistance between one end
terminal and the wiper terminal. This change in resistance results in a proportional change in
the output voltage, which can be measured to determine the position of the object attached to
the wiper.
Applications:
 Volume and tone control in audio equipment.
 Position feedback in robotics and industrial machinery.
 Joysticks and control knobs in user interfaces.
 Throttle control and suspension measurement in automotive systems.
2. Capacitive Sensor
A capacitive sensor is a non-contact proximity or displacement sensor that detects
objects or measures physical quantities by sensing changes in an electrical property called
capacitance.
Working Principle: The sensor creates an electrostatic field using two conductive
electrodes. This setup functions like a capacitor, where the capacitance is determined by the
area of the plates, the distance between them, and the dielectric constant of the material in
between. When an object (conductive or non-conductive, as long as its dielectric constant
differs from air) approaches the sensor's sensing surface, it enters this electric field and alters
the overall capacitance of the system. An internal oscillator circuit detects this change, which
is then converted into a usable output signal.
Applications:
 Touch screens in mobile phones, tablets, and other consumer devices.
 Liquid level sensing inside non-metallic tanks or containers.
 Proximity detection of various materials (plastic, paper, glass, liquids, metals) in
industrial automation.
 Button replacement in appliances and control panels, offering durability by having no
moving parts.
3. Optical Encoder
An optical encoder is an electromechanical device that uses a light source and a
photo sensor to convert mechanical motion (rotary or linear) into digital signals related to
position, speed, and direction.
Working Principle: An LED or infrared light source shines a beam through or onto a
patterned disk (for rotary encoders) or strip (for linear encoders) called a code wheel or scale.
The code wheel has alternating opaque and transparent (or reflective and non-reflective)
segments. As the wheel or strip moves, the light beam is interrupted in a specific pattern. A
photo detector captures these light pulses and converts them into an electrical signal (usually
a square wave pulse train). The control circuitry processes these pulses to determine the
precise position and movement of the system.
Applications:
 Robotics: Tracking joint angles and motor positions in robotic arms.
 CNC Machines: Providing high-precision position feedback for automated machining
and cutting tools.
 Printers and Scanners: Controlling the movement of print heads and paper feed.
 INTEGRATED SYSTEM

Need for Integration of Technologies

The integration of various technologies (mechanical, electronic, software,
communication) is essential in modern engineering systems to manage complexity,
enhance functionality, and meet the demands of a connected world. This convergence, a
core principle of mechatronics, moves systems beyond isolated functions to achieve
greater efficiency, reliability, and intelligence.

Key reasons for this need include:

 Enhanced Functionality: Modern systems often require diverse capabilities that
a single discipline cannot provide. Integrating sensors, software, and mechanical
parts allows for "smart" features and automation (e.g., a car that can brake
automatically).
 Improved Efficiency and Productivity: Automating data flow between different
systems eliminates manual data entry, reduces human error, and speeds up
processes.
 Better Decision Making: Integrated systems consolidate data from multiple
sources into a single, comprehensive view, enabling more informed and real-time
decision-making.
 Increased Safety and Reliability: By combining sensor inputs and intelligent
software, systems can monitor conditions and react faster and more consistently
than a human operator, proactively preventing failures or accidents.
 Scalability and Flexibility: Modular, integrated architectures allow systems to
adapt to changing requirements and technological advancements without
requiring a complete redesign.
 Cost Reduction: While initial integration can be complex, it reduces long-term
operational costs by optimizing maintenance, minimizing downtime, and
improving resource utilization.
ADAS (Advanced Driver Assistance System) as an Integrated System

Advanced Driver Assistance Systems (ADAS) are a prime example of a

sophisticated integrated system in the automotive industry. They demonstrate how the
seamless fusion of diverse technologies creates a complex, intelligent, and highly
effective application that significantly enhances vehicle safety and convenience.
How ADAS Works as an Integrated System:
ADAS is not a single technology but a suite of electronic systems that work in synergy.
1. Sensing the Environment (Hardware Integration): The system relies on a variety of
sensors as its "eyes and ears" to monitor the vehicle's surroundings. These include:
 Cameras: Capture visual data like lane markings, road signs, traffic lights, and
pedestrians.
 Radar: Uses radio waves to detect objects and measure their distance and relative
speed, especially useful in poor weather or low light.
 LiDAR: Uses laser pulses to create a detailed 3D map of the environment,
improving object detection.
 Ultrasonic Sensors: Used for short-range detection, primarily for parking
assistance.
 GPS/Navigation Systems: Provide real-time location data and route information.
2. Processing and Decision Making (Software & Computer Science Integration): The
 raw data from these different sensors is sent to powerful onboard computers
(Electronic Control Units, or ECUs) where it undergoes sensor fusion.
Sophisticated software algorithms and Artificial Intelligence (AI) process this vast
amount of data in real-time to build a comprehensive 360-degree model of the
environment. The system analyses potential hazards and determines the appropriate
response, often much faster than a human.
3. Acting on the Information (Mechanical & Control Engineering Integration): Based
on the software's decisions, the system can intervene through the vehicle's
mechanical and control systems. It communicates with:
 Braking system: To apply automatic emergency braking (AEB).
 Steering system: To provide lane-keeping assist (LKA) or emergency steering
assistance.
 Throttle control: To manage speed for adaptive cruise control (ACC).
 Driver interfaces: To issue visual, acoustic, or haptic (vibration) warnings to the
driver.
The integration of these diverse components ensures that ADAS functions reliably to
improve safety, reduce accidents caused by human error, and pave the way for future
fully autonomous vehicles.