Mechatronics

Mechatronics may be defined as” the complete integration of mechanical system with
electronics, electrical and computer system into a single system”.

Evoluation of Mechatronics:
The technology has evolved through several stages that are termed as levels. The evolution
levels of Mechatronics are:
a. Primary level Mechatronics (first)
b. Secondary level Mechatronics (second)
c. Tertiary level Mechatronics (third)
d. Quaternary level Mechatronics (fourth)

a. Primary level Mechatronics (first): In the early days Mechatronics products were at
primary level containing I/O devices such as sensors, and actuators that integrated electrical
signals with mechanical action at the basic control level. Examples: electrically controlled fluid
valves and relays
b. Secondary level Mechatronics (second): This level integrates microelectronics into
electrically controlled devices. Examples: cassette player.
c. Tertiary level Mechatronics (third): This incorporates advances feedback functions into
control strategy, thereby enhancing the quality in terms of sophistication.
Mechatronics system at this level is called ‘smart system’. The control strategy includes
microelectronics, microprocessor and other application, specific integrated circuits‟ (ASIC).
Examples: DVD player, CD drives, automatic washing machine etc.
d. Quaternary level Mechatronics (fourth):
This level includes intelligent control in Mechatronics system.
The level attempts to improve smartness a step ahead by introducing intelligence and fault
detection and isolation (FDI) capability system.
Examples: artificial neural network and fuzzy logic technologies.

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.

Application
Mechatronics can be incorporated into a range of industries and support a variety of
applications.
 Robotic automation
 Home and building automation
 Computer-driven machinery
 Medical imaging systems
 Robotic surgery
 Machine vision and inspection
 Various sensing and control systems
 Temperature/humidity control
 Automotive engineering
 Computer-aided design and production (such as CNC)
 Transportation
Industrial applications/Scope of Mechatronics:
1. Design and Modelling
Design and modelling are simplified to a large extent by the use of mechatronic systems.
Basically, design involves drawing, analysis, and documentation. In earlier days, the
processes of design were performed manually and it took weeks or months together. Now,
the computer is used to complete processes of design faster. There are many designing tools
such as AUTOCAD, IDEAS, and PROENGG, through which 2D or 3D drawings can be
made. There are a number of tools to edit drawings at a faster rate. Analysis of the design
involves working out the stress distribution, temperature distribution, weight analysis, and
animations. The virtual modelling of a manufacturing plant gives an idea of the time taken
for a particular component to be manufactured and also shows virtually how the operations
will be performed. The drum plotter, x-y plotter, printer, etc. give complete documentation
of design drawings. Important parameters such as surface roughness and tolerance value can
be incorporated in the drawing. Digitizers, plotters, CD drives, and many such devices are
mechatronic systems.
2. Software Integration
Different kinds of software are used in manufacturing, design, testing, monitoring, and
control of the manufacturing process. Examples of such software include computer aided
design (CAD), computer aided testing (CAT), computer aided engineering (CAE), and
computer aided processing planning (CAPP). The integration of the packets of software
leads to computer integrated manufacturing (CIM) or just-in-time (JIT) manufacturing.
Software integration is not only used for manufacturing but also for communication
networks, economic analysis, etc.
3. Actuators and Sensors
Mechanical, electrical, hydraulic, and pneumatic actuators are widely used in the industry.
Toggle linkage and quick return mechanics are typical examples of mechanical actuators.
Switching devices, solenoid-type devices, and drives such as alternative current (ac) and
direct current (dc) motors can be used as electrical actuators. Hydraulic and pneumatic
drives use linear cylinders and rotary motors as actuators. The term sensor is used for an
element which produces a signal relating to the quantity being measured. For example, an
 electrical resistance temperature device transforms the input of temperature into change in
resistance. The term transducer is often used in place of sensor. Transducers are defined as
devices which when subject to some physical change experience a related change. In the
displacement transducer, force is not an error. Addition of extra force into the system
reduces backlash and play. For example, in the dial gauge, an additional tension spring is
provided on the rack so that the play between the set of gear trains is minimized. Similarly,
in a force-transmitting transducer, the provision of more displacement is not an error.
Reduction in the play in force transmitting devices produces a loss in power due to friction.
4. Intelligent Control
Feedback control systems are widespread not only in nature and the home but also in
industry. There are many industrial processes and machines which control many variables
automatically. Temperature, liquid level, fluid flow, pressure, speed, etc. are maintained
constant by process controllers. Adaptive control and intelligent manufacturing are the areas
where mechatronic systems are used for decision making and controlling the manufacturing
environment.
5. Robotics
Robot technology uses mechanical, electronic, and computer systems. A robot is a
multifunctional reprogrammable machine used to handle materials, tools, or any special
items to perform a particular task. Manipulation robots are capable of performing
operations, assembly, and spot welding, spray painting, etc. Service robots such as mail
service robots, household servant robots, nursing robots in hospitals are being used
nowadays.
6. Manufacturing
In the domain of factory automation, mechatronics has had far-reaching effects in
manufacturing. Major constituents of factory automation include computer numerically
controlled (CNC) machines, robots, automation systems, and computer integration of all
functions of manufacturing. Low volume, more variety, higher levels of flexibility, reduced
lead time in manufacture, and automation in manufacturing and assembly are likely to be
the future needs of customers, and mechatronic systems will play an important role in this
context.
7. Motion control
 A rigid body can have a very complex motion which might seem difficult to describe.
However, the motion of any rigid body can be considered to be combinations of
translational and rotational motions. By considering a three dimensional space, a
translational movement can be considered to be one which can be resolved into components
along one or more of three axes. The rotation of a rigid body has rotating components about
one or more of the axes. A complex motion may be a combination of translational and
rotational motion. Motion control is important in many industrial applications such as
robots, automated guided vehicles, NC machines, etc. If the robot arm cannot reach a
particular location, then the movements of work piece have to be analyzed further. Anybody
has six degrees of freedom, three translations and three rotations. A point has only three
translations. In a machine tool, the work piece has six degrees of freedom and the tools also
havesix degrees of freedom. Thus, a machine tool with twelve degrees of freedom can be
manufactured. Such a tool can perform a complicated machining operation.

Introduction to autotronics, bionics, and avionics and their applications Autotronics:

Autotronics can be defined as the combination of automobile and electronics or use of
electronics science in automobile vehicles is called autotronics.
Autotronics = Automobile + Electronics

The use of electronics in the automobile field makes the system safe, improved and
efficient. In a vehicle almost all significant parts are featured with electronic items. New
developments are coming very frequently in this field because there no limitations in the
development of new autotronics. It helps to improve overall automobile system. At present,
in the new generation automobiles almost 75%-85% of automobile parts are embedded with
electronics system. The main areas of automobiles using autotronics are engine controlling
system, airbags, antilock braking system, lightening interiors, GPS, music systems etc. The
application area of autotronics is very vast, brakes, steering system, engine controlling unit,
transmission and suspension in the vehicles are the main phases where autotronics are used.
The various systems are given below
1. Autotronic braking system/Electronic braking system
 The braking system in such a system is denoted s EBS (electronic braking system). A
braking system is defined by its stopping distance. The system with shortest stopping
distance is considered the best braking system. So the development phase in the braking
system is to minimize the stopping distance of vehicle but without compromising the safety.
The ECB solve these purposes with an advance control system. The anti-lock braking
system and traction control system are the essential components of ECB.
ABS is responsible for maneuver control by deciding the braking pressure and wheel
rotation control.
Traction means providing movement or acceleration to a vehicle. So, to control the
acceleration the control on traction system should be applied. This system controls the
movement of wheel and its steadiness.
2. Control of steering system
In the vehicle the power steering system is used. Which maintains the communication
between pressure applied by steering system on the hydraulic pump and the speed of the
automobile. The EPS (electric power steering) uses sensors and motors, which controls the
maneuver. Motor controls the steering motions and sensors gives signal to the wheels by
analyzing the speed and torque.
3. Suspension system
Suspension system makes the ride on vehicle shock free, comfortable and safe. There are
three types of suspension system 1. Passive, 2. Semi active, and 3. Active suspension
system. The important task of the system is to dissipate the heat produced in the system due
to friction. The conventional method of suspension is called passive suspension and when
we add electronic sensors and hydraulic system then its performance increases and it is
called active suspension system.
4. Transmission control
The transmission of gearing system controls the shifting of gears. Using the electronic gear
transmission improves the shifting operation and increases the fuel efficiency by reducing
the losses.
5. Electronic control of fuel intake in engine
The electronic system used to analyze the amount of fuel to supply to the cylinder of engine
so that the maximum efficiency can be achieved with minimum loss of energy.
6. Air Bag Deployment System
A sensor and an actuator embedded in a microsystem are used to operate the air bag
deployment system in an automobile. The impact of the car in a serious collision is felt by a
micro-inertia sensor built on the principle of micro-accelerometer. The sensor generates an
appropriate signal to actuate the deployment of an air bag to protect the driver and
passengers from serious injuries due to the impact of collision. Figure shows a micro-inertia
sensor employed for rapid deployment of an air bag.

7. Antilock or Antiskid Device

A vehicle stops more quickly when the brakes are applied just hard enough to get maximum
static friction between the tyres and the road. If the brakes are applied harder than this, the
tyres will skid or slide on the road and lesser kinetic friction will result. In this situation,
applying brakes is less effective.
Several devices have been developed to prevent a vehicle from skidding and thus provide
maximum effective braking. Skid control is employed generally for the rear wheel only. As
long as the wheels are turning/rotating, the antiskid device permits normal application of the
brakes. But if the brakes are applied so hard that wheels stop turning, skid starts to develop.
At this point, the antiskid device starts operating and partially releases the brakes so that the
wheels continue to turn/rotate. However, intermittent braking continues, but it is held to just
below the point where a skid would start.
8. Car Park Barrier
Consider the cam-operated barrier for a car park. The barrier opens and allows a car in when
the correct money is inserted into the collection box. The barrier opens again to allow the
car out on its detection on the park side of the barrier. Figure shows the type of the wall
system that can be used to lift and lower the pivoted barrier. When a current flows through
 the solenoid of valve A, the piston in the cylinder moves upwards and causes the barrier to
rotate about its pivot and raise to let a car through. When the current through the solenoid of
valve A ceases, the return spring of the valve results in the valve position changing back to
its original position. When the current flows through the solenoid of valve B, pressure is
applied to the lower barrier. Limit switches are used to detect whether the barrier is in down
or up position.

9. Engine Temperature Measurement

Temperature sensors (i.e thermistors, thermostat etc) are employed for measurement and
control the engine temperature in automobiles.

BIONICS
Bionics refers to the flow of concepts from biology to engineering and vice versa. Bionics is a
common term for bio-inspired information technology, typically including three types of
systems, namely:
1. Bio-morphic (eg neuromorphic) and bio-inspired electronic/optical devices,
2. Autonomous artificial sensor-processor-activator prostheses and various devices built into
the human body, and
3. Living-artificial interactive symbioses, e.g. brain-controlled devices or robot
Bionics is poised to have significant stake in mechatronic sensors market in the near future.
Biomedical sensors are mainly used for diagnostic analyses. Because of its miniature size, a
biomedical sensor requires less amount of sample and can produce results significantly faster.
These sensors can be produced in batches, thus resulting low unit cost of the sensor. Another cost
cutting factor is that most of these sensors are disposable, thus manual labour involving cleaning
and proper treatment for reuse is saved. Biosensors are extensively used in analytical chemistry
and biomedical care as well as genetic engineering. These sensors usually involve biological
molecules such as antibodies or enzymes, which interact with analytes that are to be detected.

Major advantages of the use of mechatronic systems in biomedicine are as follows:

1. Functionality for biomedical operators
2. Adaptability to existing instruments and equipment
3. Compatibility with biological systems
4. Controllability, mobility, and easy navigation facilities for operators
5. Possibility of the fabrication of mechatronic structures with a high aspect ratio

Application
Glucose Detection
Detection of glucose levels in human body is a classic case of bio sensing. Diabetic patients
cannot control their insulin level if the level of blood glucose fluctuates tremendously. If the
level gets either too high or too low, their condition can be life threatening. Currently such
patients must actually draw blood on a daily basis or even more often to monitor the blood
glucose level. Sensing the blood glucose level can be done in many ways, using optical,
conduction, or molecular recognition methods. None of these have yet been shown to be
compatible with an implantable simple device that could automatically show or continuously
sense the glucose level in the blood.
Drug Delivery
The size of the human body is very large compared to the size of a molecule. It is important for
the thermofusion effectiveness that drug molecules find/reach the place in the body where they
are needed/effective. Bio-availability refers to the presence of drug molecules where they are
needed in the body and where they will do the most good. The issue of drug delivery aims at
maximizing bio-availability both over a period of time and at the specific place in the body.
Increasing the bioavailability is seldom as simple as increasing the amount of drug used. The
drugs used in chemotherapy are actually somewhat toxic and need to be target-specific to avoid
damage to the normal/healthy tissue. It is necessary to keep the drug doses to a minimum,
otherwise the amount
used can adversely affect or even kill a patient. Taking these issues into account, drug delivery
assumes a lot of significance. Nanotechnology and Nano science are very useful in developing
entirely new ways for increasing bio-availability and improving the drug delivery.
Photodynamic Therapy
In photodynamic therapy, a particle is placed within the patient’s body. This particle is
illuminated with a light source from outside of the body. The light may come from outside from
a laser or light bulb. The light is absorbed by the particle, after which several things might
happen. If the particle is simply a metal nanodot, the energy from the light will heat the dot,
which, in turn, will heat any tissue within its neighborhood. With the same particular molecular
dot, light can also be used to produce highly energetic oxygen molecules. Such oxygen
molecules are very reactive and will chemically react with (and, therefore, destroy) many organic
molecules that are next to them. The photodynamic therapy is attractive for many reasons. One
reason is that, unlike the traditional
chemotherapy, it is directed at the damaged/diseased cell. The chemically reactive excited
oxygen or quantum data is released only where such cells are present and where the light is
illuminated. This ensures that, unlike the traditional chemotherapy, the photodynamic therapy
does not leave a fixed trail of highly aggressive and reactive molecules throughout the body.
Biotechnology
Mechatronics plays an important role in biotechnology even though it is a small subdomain of
biotechnology. Biotechnology includes all techniques that use living organisms or substances
obtained from them to make or modify a product. It involves improvement of microbe, plant, and
animal species. Genes and gene products are the basic tools in biotechnology. Biotechnology
aims at harnessing the genetic diversity in the living organisms for the benefit of the humankind.

Avionics
It is a varientb of of mechatronics system that blends avitation and electronics. Considerable
effort and progress have been made in recent years in the development of mechatronic systems in
the aerospace industry. Numerous and complex mechatronic systems are used in advanced
commercial and military aircrafts. With the ever-increasing emphasis on robustness and safety,
there is a trend towards using more mechatronic systems in aerospace industry. This has given
rise to a new area of mechatronics in the form of avionics. The major applications of
mechatronic systems in aerospace industry can be classified as follows:
 Cockpit instrumentation
 Safety devices
 Wind tunnel instrumentation
 Sensors for fuel efficiency and safety
 Microgyroscope for navigation and stability
 Microsatellites

Cockpit Instrumentation
Air-data systems vary in complexity from a light airplane to advanced commercial or military
aircrafts. However, all air-data computations are based upon four sensed parameters, namely,
static pressure, total pressure, temperature, and the angle of attack. Pressure and temperature of
the atmosphere are functions of the altitude above the sea level, latitude, season, and time of day.
Alarms and Safety Devices
An alarm is a protective device for maintaining critical points in a system under constant
surveillance. In basic principles, alarm differs little from other forms of indication and control
instruments. Strong emphasis is placed on reliable performance of alarms. Such devices must
remain operable over long periods of inactivity and need periodic, scheduled check, because the
equipment does not function except in case of emergency. Most alarm installations are of
audiovisual type, with illuminated name plates or bull-eye lights. There is a means to silence the
alarm and switch the light to steady state. Another push button usually is provided for testing
other components of the system. Micro-accelerometers or micro-inertial sensors are used to eject
the pilot seat from the aircraft, especially in military airplanes. The use of the seat eject system
protects the pilot in the event of an emergency. The sensor opens the latch where the seat is
loaded with a spring, which throws the seat along with the pilot a distance away from the
aircraft. When it is detached from the aircraft, a parachute automatically opens to ensure safe
landing of the pilot.
Aircraft Guidance and Control
To guide and control an aerospace vehicle successfully is a matter of measuring position,
determining path errors, and controlling to correct the path. These three functions usually are
called navigation, guidance, steering, and control. Navigation determines the position, guidance
determines the error from the indicated path, steering is used to select a proper series of changes
in the path, and control changes the forces on the vehicle to adjust them with the direct path
changes.
Aircraft Engine Control
The extent and sophistication of engine instrumentation vary widely with the type of the aircraft
and intended use. In a small-engine plane, most instruments are simple and a mechanically
connected throttle suffices. It is highly desirable to keep fuel and oil under pressure out of the
cockpit. Thus most engine parameters are remotely indicated in the cockpit from a transmitter
mounted near or on the engine.
Sensors and Transducers
Sensors senses physical quantities and convert them into signals read by an instrument.

A transducer is a physical device that converts one form of energy into another. Mostly
transducers convert energy into an electrical signal because it is easy to record and magnify.

Classification of Sensors and Transducers

1. Sensors based on the power requirement
• Active Sensors
• Passive Sensors.
Active Sensors
Does not need any external energy source but directly generates an electric signal in response to
the external.
Example: Thermocouple, Photodiode, Piezoelectric sensor.
Passive Sensors
The sensors require external power called excitation signal. Sensors modify the excitation signal
to provide output.
Example: Strain gauges

2. Primary and Secondary Transducers

Some transducers consist of a mechanical device along with an electrical device.
The mechanical device acts as a primary transducer and converts physical quantity into the
mechanical signal.
The mechanical signal produced by the primary transducer converts into an electrical signal by
the electrical device and it is called a secondary transducer.
Therefore, an electrical device acts as a secondary transducer.

3. Sensors-based on Contact and Non-Contact type

Contact type
A sensor that requires physical contact with the parameter to be measured.
Example:
Strain gauges, temperature sensors.
Non-contact type
It requires no physical contact.
Example:
Optical pyrometer, Magnetic sensors, Infrared thermometer.
4. Based on output
Analog and Digital Transducers
Analog Transducers
This type of Transducers converts the input quantity into an analog signal output, which is a
continuous function of time.
A strain gauge, LVDT, Thermocouples are called analog transducers as they give an output that
is a continuous function of time.
Digital Transducers
Digital transducers generate an electrical output in the form of pulses which form a unique code.
Thereby a unique code is generated for each discrete value sensed.
Ex – Tachometer for RPM measurement
5. Based on the Physical Parameter being measured
The physical parameters such as Flow, Level, Temperature, Pressure, etc.,
Flow
 Venturimeter
 Orifice meter
 Differential pressure,
 positional displacement,
Temperature
 Thermometers
 thermocouples,
 Pyrometers
 RTDs,
 Thermistors,
Pressure
 Liquid-based manometers,
 Bourden gauge
 piezoelectric,
 fiber optic,
 vacuum.
Proximity and displacement
 Potentiometric,
 LVDT
 capacitive,
 magnetic,
 photoelectric,
  magnetostrictive.
Gas and chemical
 Electrochemical,
 thermal conductance,
 paramagnetic,
 ionization,
 infrared,
 semiconductor.
Level
 Mechanical,
 magnetic,
 differential pressure,
 thermal,
 displacement,
 vibrating rod,
 magnetostrictive,
 ultrasonic,
 radiofrequency,
 capacitance type,
 microwave/radar.

Characteristics of Transducers
The performance characteristics of a Transducer are key in selecting the best suitable transducer
for a particular design. So, it is very important to know the characteristics of transducers for
proper selection.
Performance characteristics of transducers can be further classified into two types:
1. Static Characteristics
The static characteristics of transducers relate to its performance when the measured
quantity is not a function of time or it varies very slowly with respect to time.

Example:
1. Sensitivity: It is the ratio of change in output to change in input. (Senstivity=Change in
output/ Change in input).
2. Linearity: Linearity is the maximum deviation between the measured values of a sensor
from ideal curve.

3. Span and Range

The range of a transducer defines the limits between which the input can vary on the
working.
The Span is the difference between the maximum value and the minimum value.
Example: A force tarnsducer for the measurement of forces might have a range of 0 to
50kN and its span is 50kN (50 kN – 0 kN = 50kN).
4. Drift: The term drift is used to describe the change in output for a given period of time
for the same input.
5. Threshold
6. Stability
7. Resolution
8. Precision (Accuracy)
9. Repeatability

2. Dynamic Characteristics
The dynamic characteristics of transducers relate to its performance when the measured
quantity is a function of time i.e. it varies rapidly with respect to time.

Example:
1. Fidelity: Fidelity of a measurement system is defined as the ability of the system to
reproduce the output in the same variation of the input.
2. Speed of Response: It is rapidity with which the transducer responds to changes in the
measured quantity. The speed of the response of the transducer should be as high as
practicable
3. MEASURING LAG: Measuring Lag is defined as the delay in the response of an
instrument to a change in a Measuring quantity.