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BASICS OF MECHATRONICS SYSTEMS
Mechatronics is a methodology used for the optimal design of electromechanical
products. The mechatronic design methodology is based on a concurrent (instead of
sequential) approach to discipline design, resulting in products with more synergy.
Mechatronic system is not just a marriage of electrical and mechanical systems and
is more than just a control system; it is a complete integration of all of them in which
there is a concurrent approach to the design.
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BASIC CONCEPTS IN MECHATRONICS
Integration of mechanical engineering with electronics and intelligent computer
control in the design and manufacture of products and processes.
Mechatronic products have many mechanical
functions replaced with electronic ones. This results in
much greater flexibility, easy redesign and
reprogramming, and the ability to carry out automated
data collection and reporting.
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GENERAL SCHEME OF HARDWARE AND SOFTWARE INTEGRATION
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MECHATRONICS SYSTEMS DESIGN APPROACH
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HARDWARE-IN-THE-LOOP SIMULATION -
DIFFERENT CONFIGURATIONS FOR HARDWARE-IN-THE-LOOP
SIMULATION
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HARDWARE-IN-THE-LOOP MODEL
Simulate the electronics where the actuators, mechanics and sensors are the real
hardware. On the other hand, if appropriate models of the mechanical systems,
actuators, and sensors are available, the electronics could be the only hardware.
There are different ways in which hardware-in-the-loop could be simulated, such as
electronics simulation, simulation of actuators and sensors, or simulation of mechanical
systems alone.
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KEY ELEMENTS OF MECHATRONICS SYSTEM
Information systems
Mechanical Systems
Sensors and Actuators
Real-Time Interfacing
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INFORMATION SYSTEMS
Information systems include all aspects of information transmission—from signal
processing to control systems to analysis techniques. An information system is a
combination of four disciplines: communication systems, signal processing,
control systems, and numerical methods. In mechatronics applications, we are
most concerned with modeling, simulation, automatic control, and numerical
methods for optimization.
Mechatronics, optimization is primarily used to establish the optimal system
configuration. However, it may be applied to other issues as well, such as
Identification of optimal trajectories, Control system design & Identification of
model parameters.
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Optimization procedure is the same for any application and requires the following
formulation to be started.
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MECHANICAL SYSTEMS
Mechanical systems are concerned with the behavior of matter under the action of
forces. Such systems are categorized as rigid, deformable, or fluid in nature.
A mechanical system is a set of physical components that convert an input motion
and force into a desired output motion and force. Mechanical systems have at least
three elements: input, process and output. The input part of the system is any type of
motion and force that drives the mechanical system.
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ELECTRICAL SYSTEMS
Electrical systems are concerned with the behavior of three fundamental quantities: charge,
current, and voltage (or potential). When a current exists, electrical energy usually is being
transmitted from one point to another.
Electrical systems consist of two categories: power systems and communication systems.
Communication systems are designed to transmit information as low-energy electrical signals
between points. Functions such as information storage, processing, and transmission are
common parts of a communication system. Electrical systems are an integral part of a
mechatronics application.
The following electrical components are frequently found in such applications.
Motors and generators, Sensors and actuators (transducers), Solid state devices including
computers, Circuits (signal conditioning and impedance matching, including amplifiers) &
Contact devices (relays, circuit breakers, switches, slip rings, mercury contacts, and fuses)
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SENSORS AND ACTUATORS
The term sensor is used for an element which produces a signal relating to the
quantity being measured. thus in the case of, say, an electrical resistance temperature
element, the quantity being measured is temperature and the sensor transforms an
input of temperature into a change in resistance.
The term transducer is often used in place of the term sensor. Transducers are
defined as elements that when subject to some physical change experience a related
change.
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Sensors are required to monitor the performance of machines and processes. Using a
collection of sensors, one can monitor one or more variables in a process. Sensing
systems also can be used to evaluate operations, machine health, inspect the work in
progress, and identify part and tools. The monitoring devices are generally located near
the manufacturing process measuring the surface quality, temperature, vibrations,
and flow rate of cutting fluid.
Sensors are needed to provide realtime information that can assist controllers in
identifying potential bottlenecks, breakdowns, and other problems with individual
machines and within a total manufacturing environment.
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Smart sensors
Sensors come combined with their signal conditioning all in the same package. such
an integrated sensor does still, however, require further data processing. however, it
is possible to have the sensor and signal conditioning combined with a
microprocessor all in the same package. Such an arrangement is termed a smart
sensor.
A smart sensor is able to have such functions as the ability to compensate for random
errors, to adapt to changes in the environment, give an automatic calculation of
measurement accuracy, adjust for non-linearities to give a linear output, self-
calibrate and give self-diagnosis of faults.
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Actuator
Actuators are another important component of a mechatronic system. Actuation
involves a physical action on the process, such as the ejection of a work piece from a
conveyor system initiated by a sensor. Actuators are usually electrical, mechanical,
fluid power or pneumatic based. They transform electrical inputs into mechanical
outputs such as force, angle, and position. Actuators can be classified into three general
groups.
1. Electromagnetic actuators, (e.g., AC and DC electrical motors, stepper motors,
electromagnets)
2. Fluid power actuators, (e.g., hydraulics, pneumatics)
3. Unconventional actuators (e.g., piezoelectric, magnetostrictive, memory metal)
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REAL-TIME INTERFACING
The process of simulation requires that all cause-and effect equations in the model be ordered
(or sorted) with inputs on the left and outputs on the right prior to simulation. During
simulation, the sorted equations are solved, time is advanced, the equations are again
solved, and the process continues. One passage through the equations is called a loop.
The real-time interface process really falls into the electrical and information system
categories but is treated independently as was computer system hardware because of its
specialized functions. In mechatronics, the main purpose of the real-time interface system is
to provide data acquisition and control functions for the computer. The purpose of the
acquisition function is to reconstruct a sensor waveform as a digital sequence and make it
available to the computer software for processing.
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ROLE OF SENSORS, ACTUATORS AND MEASUREMENTS
SENSORS IN MECHATRONICS
The vital part of a mechatronics system is the sensing of physical parameters—
either discrete or continuous. In Electrical Transducer Nomenclature and Terminology
standard, a sensor is defined as “a device which provides a usable output in response to
a specified measurand”.
Sensors are elements for monitoring the performance of machines and processes. The
common classification of sensors is: distance, movement, proximity, stress/
strain/force, and temperature. There are many commercially available sensors but we
have picked the ones that are frequently used in mechatronic applications. Often, the
conditioned signal output from a sensor is transformed into a digital form for display
on a computer or other display units.
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Actuators are used to produce action or motion; they together with sensors and
digital electronics are increasingly integrated into mechanical systems.
They play a major role in mechatronic systems and are essential for efficient design
process.
MECHANICAL ACTUATORS:
Mechanical actuators are transducers that convert mechanical energy into electrical
energy. Some of the important mechanical actuators used in mechatronic systems
include hydraulic cylinders and pneumatic cylinders.
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ELECTRICAL ACTUATORS
Sensor is a device that can convert mechanical energy to electrical energy, an
electrical actuator, on the other hand, is a device that can convert electrical energy to
mechanical energy.
Actuators are transducers (as they convert one form of energy into another form).
Some sensors are transducers (e.g. mechanical actuators), but not all.
Actuators are used to produce motion or action, such as linear motion or angular
motions. Some of the important electrical actuators used in mechatronic systems
include solenoids, relays, electric motors (stepper, permanent magnet, etc.). These
actuators are instrumental in moving physical objects in mechatronic systems.
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MEASUREMENT SYSTEM
Measurement is an important subsystem of a mechatronics system. Its main function
is to collect the information on system status and to feed it to the micro-processor(s)
for controlling the whole system. Measurement system comprises of sensors,
transducers and signal processing devices.
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FEEDBACK IN MECHATRONICS SYSTEMS
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MECHATRONIC SYSTEM WITH OPEN ARCHITECTURE PLATFORM
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FRAMEWORK FOR INTEGRATING HETEROGENEOUS SYSTEMS
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EMERGING APPLICATION AREAS OF MECHATRONICS
Automotive Industry
Vehicle diagnostics and health monitoring. Various sensors are used to detect the
environment or road conditions; Sensors to monitor engine coolant, temperature and quality;
Engine oil pressure, level, and quality; tire pressure; brake pressure. Pressure, temperature
sensing in various engine and power train locations Manifold control
Pressure sensors; exhaust gas analysis and control; Crankshaft positioning; Fuel pump
pressure and fuel injection control; Transmission force and pressure control.
• Airbag safety deployment system. Micro-accelerometers and inertia sensors mounted on
the chassis of the car measures car deceleration in x or y directions can assist in airbag
deployment.
• Antilock brake system, cruise control. Position sensors to facilitate antilock braking
system; Displacement and position sensors in suspension systems.
• Seat control for comfort and convenience. Displacement sensors and micro actuators for
seat control; Sensors for air quality, temperature and humidity, Sensors for defogging of
windshields.
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Health Care Industry
• Medical diagnostic systems, non-invasive probes such as ultrasonic probe. Disposable
blood pressure transducer; Intrauterine pressure monitor during child delivery.
• Pressure sensors in several diagnostic probes. Systems to control the intravenous fluids
and drug flow; Catheter tip pressure sensor.
• Endoscopic and orthopedic surgery. Angioplasty pressure sensor; Respirators; Lung
capacity meters.
• Other products such as Kidney dialysis equipment; MRI equipment.
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Aerospace Industry
• Landing gear systems; Cockpit instrumentation; Pressure sensors for oil, fuel,
transmission;
Air speed monitor; Altitude determination and control systems.
• Fuel efficiency and safety systems; Propulsion control with pressure sensors;
Chemical
leak detectors; Thermal monitoring and control systems.
• Inertial guidance systems; Accelerometers; Fiber-optic gyroscopes for guidance
and
monitoring.
• Communication and radar systems; High bandwidth, low-resistance radio
frequency
switches; Optical instrumentation using laser communications.
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Consumer Industry
• Consumer products such as auto focus camera, video, and CD players;
Consumer electronic products; User-friendly washing machines with water level
controls, dish washers, and other home appliances.
• Video game entertainment systems; Virtual instrumentation in home
entertainment.
• Home support systems; Garage door opener; Sensors with heating, ventilation,
and airconditioning system; Home security systems.
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Industrial Systems and Products
• Monitoring and control of the manufacturing process; CNC machine tools; Advanced
high
speed machining and quality monitoring; Intelligent machining and on-line quality check;
Digital torque wrenches, variable speed drilling and other hand tools.
• Rapid prototyping; Manufacturing cost saving by rapid creation of models done by
CAD/CAM integration and rapid prototyping equipment.
• Autonomous production cells with image-based object recognition; Flexible
manufacturing
and other factory automation systems.
• Specialized manufacturing process such as the use of welding robots; Procedure for
automatically
programming and controlling a robot from CAD data; Robotics in nuclear inspection
and space applications.
• Automatic guided vehicles, space application; Use of automated navigation system for
NASA projects; Use of automated systems in under water monitoring and control.
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Other Applications
• Telecommunications.
• Biorobotics, which utilize the biofunctions for applications in environmental
control.
• Magnetically levitated vehicles.
• Scanners and copying machines and other office products.
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