Module 5: Advances in mechanical engineering
Automation:
Automation is the use of technology, control systems, and machines to perform tasks
automatically with minimal or no human intervention. It helps in increasing efficiency, accuracy,
productivity, and safety while reducing human effort and errors.
Types of Automation:
Automated production systems are classified into three basic types:
1) Fixed Automation
2) Programmable Automation
3) Flexible Automation
1. Fixed Automation (Hard Automation)
Fixed automation is a type of automation in which the sequence of operations is permanently
set and cannot be easily changed.
Characteristics
Designed for a specific task
High production rate
Low flexibility
Uses dedicated equipment
Advantages
Very high production speed
Low production cost per unit
High accuracy and consistency
Disadvantages
High initial investment
Difficult to modify for new products
Not suitable for product variety
Applications
Automobile assembly lines
Bottle filling plants
Automatic transfer lines
Conveyor-based manufacturing systems
Example
An automobile manufacturing line where the same car model is produced continuously.
2. Programmable Automation
Programmable automation is a type of automation where the operation sequence can be
changed by modifying the program.
Characteristics
Suitable for batch production
Moderate production volume
Reprogrammable machines
More flexible than fixed automation
Advantages
Product changes are possible
Suitable for multiple product types
Better flexibility
Disadvantages
Production rate is lower than fixed automation
Reprogramming requires time and skill
Higher cost compared to manual systems
Applications
CNC machines
Industrial robots
Numerical control systems
Batch manufacturing industries
Example
A CNC machine programmed to manufacture different mechanical components.
3. Flexible Automation (Soft Automation)
Flexible automation is an advanced form of programmable automation where product changes
can be made quickly with little or no production loss.
Characteristics
High flexibility
Handles product variety efficiently
Computer-controlled systems
Quick changeover between products
Advantages
Produces different products efficiently
Reduced setup time
High product quality
Better adaptability
Disadvantages
Very high installation cost
Complex system design
Requires skilled operators
Applications
Flexible Manufacturing Systems (FMS)
Robotic manufacturing cells
Modern automobile industries
Electronics manufacturing
Example
A robotic production system that manufactures different car models without major setup
changes.
Basic Elements of Automated System:
1. Sensors: Sensors detect physical parameters such as temperature, pressure, position,
speed, and force. They convert these parameters into electrical signals, providing data
for the system to respond appropriately.
Examples: temperature sensors, proximity sensors, pressure sensors.
2. Actuators: Actuators are devices that perform the physical work of the system by
converting electrical signals into mechanical motion. They execute the actions based on
control signals from the system.
Examples: motors, hydraulic cylinders, pneumatic actuators, solenoids.
3. Controllers: The controller is the brain of the automated system. It processes the input
from sensors, makes decisions based on pre-set logic, and sends commands to the
actuators. It ensures that the system operates according to the desired set of
instructions.
Examples: programmable logic controllers (PLC), microcontrollers, industrial computers.
4. Human-Machine Interface (HMI): The HMI provides a communication platform between
the operator and the automated system. It allows human operators to monitor and
control the system's performance, set parameters, and troubleshoot if necessary.
Examples: touch screens, control panels, computer interfaces.
5. Power Supply: The power supply provides the necessary energy to operate the sensors,
actuators, controllers, and other components of the automated system. This could be
electrical, pneumatic, or hydraulic power, depending on the system's design.
Examples: electrical power units, compressors for pneumatic systems, pumps for
hydraulic systems.
6. Communication Systems: These systems allow data exchange between different
elements of the automated system, such as sensors, controllers, and actuators.
Communication networks ensure real-time monitoring and coordination of system
components.
Examples: wired communication (Ethernet), wireless communication (Wi-Fi), fieldbus
networks (Modbus, Profibus).
7. Software: The software element includes the programs and algorithms that control the
automation system's operations. It provides the logic for decision-making, monitoring,
and troubleshooting.
8. Feedback Mechanism: The feedback mechanism ensures that the system can self-
regulate and adjust its operations based on real-time data.
Mechatronic Systems:
Definition of Mechatronics
Mechatronics is an interdisciplinary field that combines Mechanical Engineering, Electronics,
Computer Science, Control Engineering, and Information Technology to design and develop
intelligent systems and automated products.
Simple Definition:
Mechatronics is the integration of mechanical systems with electronics and computer-based
control systems.
The word Mechatronics is derived from:
“Mecha” → Mechanical
“Tronics” → Electronics
The main objective of mechatronics is to improve system performance, accuracy, reliability,
efficiency, and automation.
Elements of Mechatronic Systems
A mechatronic system consists of several integrated elements that work together to perform a
specific task.
1. Mechanical System
The mechanical system forms the physical structure of the mechatronic system.
It includes: Gears, Springs, Levers, Shafts, Bearings, Mechanical structures
The mechanical element performs the actual physical work or motion.
Example
Robot arm structure, conveyor mechanism, machine components.
2. Sensors
Sensors are devices used to detect physical quantities and convert them into electrical signals.
They provide information about system conditions such as: Temperature, Pressure, Position,
Speed, Light, Force.
Sensors help in monitoring and feedback control.
Examples
Temperature sensor, Proximity sensor, Pressure sensor, Encoder etc.
3. Actuators
Actuators convert electrical signals into mechanical motion or action.
They perform the actual movement in the system according to control signals.
Types
Electric actuators
Hydraulic actuators
Pneumatic actuators
Examples
DC motors, Servo motors, Hydraulic cylinders, Pneumatic cylinders
4. Controller
The controller acts as the brain of the mechatronic system.
It receives signals from sensors, processes the information, and sends commands to actuators.
Controllers make decisions based on programmed instructions.
Examples
Microcontroller, PLC, Embedded systems, Computer controller
5. Signal Conditioning and Interface Circuits
These circuits convert sensor outputs into suitable forms for the controller.
They help in: Amplification, Filtering, Signal conversion, Data acquisition.
6. Software and Computer System
Software provides intelligence to the mechatronic system.
It controls: Decision making, Data processing, Automation, Communication.
Programming languages and embedded software are used for system operation.
Examples of Mechatronic Systems
1. Automatic Washing Machine
Uses sensors, controller, and motor systems for automatic washing operations.
2. Industrial Robots
Robots use sensors, actuators, and computer control for industrial automation.
3. CNC Machines
Computer-controlled machines used for precise manufacturing operations.
4. Automatic Door System
Uses motion sensors and motors to open and close doors automatically.
5. Automobile ABS (Anti-lock Braking System)
Uses electronic sensors and controllers to improve vehicle braking safety.
6. Drones
Integrate sensors, controllers, motors, and embedded systems for flight control.