Mechatronics &

Microprocessor
Royson Dsouza
Lecturer, SJEC

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Unit 1:

Introduction to Mechatronic
Systems:
Measurement and control System
Their Elements and Functions
Microprocessor based Controllers

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Evolution of Mechatronics:
Since its emergence in the late 1960s, Mechatronics has become well established as an
academic subject, and is now researched and taught at a large number of universities
worldwide. The most widely-used definition of the subject today is centered on the
synergistic integration of mechanical engineering, electronics, and intelligent computer
control.
We are now witnessing a new scientific and social revolution known as information
revolution, where engineering specialization ironically seems to be simultaneously
focusing and diversifying. The manual operated world is turning to be more automated.
We can take an example of Aircraft. Few decades back the pilots used to control the
complete flight direction using the flight controls manually. But the technology of
Sensors, measuring systems and actuation systems has lead to the development of
Automatic flight control system wherein the complete aircraft is auto guided and auto
landed. It also has led to the invention of UAV (Unmanned aerial Vehicles).
To practice engineering today we must understand new ways to process information and
be able to utilize semiconductor electronics within our products. Today all mechanical
devices include electronic components and some type of computer controls. Hence
Mechatronics can be described as a marriage between electronic control systems and
Mechanical Engineering. The Term Mechatronics is used for the integration of
microprocessor control systems, Electrical systems and mechanical systems. It is a
complete integration of all of them..!

Fig 1.1
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 The word Mechatronics was coined in Japan in the late sixties, Spread through
Europe and now commonly used in United States.
The Mechatronic System Engineer must be able to Design and select Analog and
digital Circuits, Microprocessor based components, mechanical devices, Sensors,
actuators and controls to achieve the final products.

Mechatronics: Mechatronics is defined as the synergistic integration of mechanical

engineering, with electronics and intelligent computer control in the design and
manufacturing of industrial products and processes.
Mechatronics: Mechatronics is a methodology used for the optimal design of
electromechanical products.

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Systems:
To understand the term System let us consider the following example.

Input

MOTOR

Electric Power

Output

Rotation

Fig 1.2

It is very clear from the example that when the electric power is given as input to the
MOTOR the output will be the rotation of the Shaft. Here Motor is considered as
SYSTEM. Hence the System can be thought as a box which has an input and an output
and where we are not concerned with what goes inside the box but only the relationship
between the output and the input.
Examples: Heating System, Stereo System etc.
Systems in Engineering can be broadly classified into 2 types.
a) Basic Systems ( Pure System)
b) Combined Systems

Basic Systems:
These can be of 4 types:
1. Mechanical System
2. Electronic System
3. Electric System

Combined Systems: Combination of one or more basic systems is called as Combined

Systems.
These can be of 6 types:
1. Measurement System
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2.
3.
4.
5.
6.

Control System
Mechatronics
Hydraulic System
Thermal System
Electromechanical System

Let us explain all the systems in brief:

Mechanical System:
In this kind of System, input and output of the system are mechanical quantities such as
force and force related quantities such as pressure, couple. The mechanical system
consists of one or more moving elements. The following are the few examples of
mechanical systems,
1.
2.
3.
4.
5.

Belt Drive
Chain Drive
Gear Train
Bicycle
Manual drawing of water from well.

Electronic System:
Electronic systems are associated with electronic components. These electronic
components operate with a small quantity of electrical power as input. The assembly of
the components is called Hardware. The hardwares may be programmable or nonprogrammable ones. In Programmable hardware microcontrollers are used. The assembly
of the electronic components in a desired manner is called electronic circuit.
Electrical System:
An electrical system deals with the electrical power source. Generally electrical system
deals with high voltage power sources. The best examples are the rectifiers, transformers
and inverters, wherein both the input and the output parameters are electrical quantities.
Measurement System:
A measurement system can be thought as a black box which is used for making
measurements. It has the input, the quantity being measured and the output. A group of
elements or devices arranged in a rational manner to achieve the act of measurement is
called as measurement system.
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Ex: Thermometer, Barometer, Pressure Gauge etc

Control System:
A control system can be thought of as a black box which is used to control its output to
some particular value or particular sequence of values.
Ex: Central heating system.
Let us study in deep the measurement and the control system:

Measurement System:
A group of elements or devices arranged in a rational manner to achieve the act of
measurement is called as measurement system. A fundamental part of many Mechatronic
systems is a measurement system composed of three basic parts.
1. Sensor (Transducer)
2. Signal Conditioner
3. Display
The figure below shows the block diagram of generalized measuring system.

QUANTITY
BEING

VALUE
SENSOR

MEASURED

SIGNAL
CONDITIONING

DISPLAY

OF THE
QUANTITY

Fig 1.3

Sensor (Transducer): Sensor is the main component of any measuring system. Sensor
senses and transforms the physical phenomena to be measured from one form to another.
The output of sensors will basically be an electrical/ electronic signal which will be made
suitable as an input to the next unit (signal conditioner). Fig 1.4 gives the basic concept
of a transducer.

I/P

O/P
SENSOR

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THERMOCOUPLE
HEAT (I/P)

EMF (O/P)

THERMOCOUPLE

HEAT (I/P)

EMF (O/P)
Fig 1.4

In the measurement of temperature using a thermocouple, the input to thermocouple is

heat. The thermocouple senses the heat and transforms into proportional emf(electromotive force). Hence thermocouple acts as sensor.

Signal Conditioner:
A signal conditioner takes the signal from the sensor and manipulates into a condition
which is suitable for display or the output. The output signals from the sensor/
Transducer may not be of desired level. The signal has to be modified to the desired level
so that it can be used in the next level. Signal conditioner does it all. Thus, for example,
the output from the thermocouple is rather small e.m.f and might be fed through an
amplifier to obtain a bigger signal. The amplifier is the signal conditioner. The main
purposes of signal conditioner are,
1. Amplification of signals: Because real-world signals are often very small in
magnitude, signal conditioning can improve the accuracy of your data. Amplifiers
boost the level of the input signal to better match the range of the analog-to-digital
converter (ADC), thus increasing the resolution and sensitivity of the
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measurement. Amplification Is the process of making the signal stronger. If the

signal strength is low it is amplified to a signal of higher strength.

Fig 1.5

2. Attenuation: Attenuation Is the process of Reduction of signal strength during

transmission. Attenuation is the opposite of amplification, and is normal when a
signal is sent from one point to another. If the signal attenuates too much, it
becomes unintelligible, which is why most networks require repeaters at regular
intervals. Attenuation is measured in decibels.
3. Filtering: The output from the sensor/ Transducer may contain undesirable signals
which may affect the output of the system. This undesirable signal is generally
called as NOISE. This noise has to be filtered to get a desirable and a sustainable
output.
4. Isolation: Improper grounding of the system is one of the most common causes
for measurement problems, including noise and damaged measurement devices.
Signal conditioners with isolation can prevent most of these problems. Such
devices pass the signal from its source to the measurement device without a
physical connection by using transformer, optical, or capacitive coupling
techniques. Besides breaking ground loops, isolation blocks high-voltage surges
and rejects high common-mode voltage and thus protects both the operators and
expensive measurement equipment.

Display unit:
This unit displays the output of the signal conditioner. The display may be analog type or
digital type. An example for analogue system is a pointer moving across a scale. An
example for digital system is the LED display. With the development of the computer
technology, analog signals are converted to digital signal. This is basically done using
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analog to digital converter (ADC). Fig 1.6 shows the principle of measurement system of
a digital thermometer.

Fig 1.6

Fig 1.7

As an example consider a digital thermometer. Here thermocouple acts as sensor. The

input to the sensor is temperature. The transducer gives the output as electrical signal
which is amplified by an operational amplifier. Since the analog signal is difficult to
process it is converted to digital form using analog to digital converter (ADC) which
gives a voltage which directly drives the display.

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Control System:
Consider the following example to understand the
control system.
Consider the body temperature. Unless you are ill
the body temperature remains almost constant
regardless of whether you are in a cold or hot
environment. To maintain this constancy the body
has a temperature control system. If the
temperature begins to increase above the normal
you sweat, if it decreases you shiver. Both these
mechanisms are used to restore the body
temperature back to its normal value.
Fig 1.8

The control system is maintaining the constancy of the temperature. The system has an
input from the sensors which tell it what the temperature is and compares this data with
what the temperature should be and provides the appropriate response. This is an example
of feedback control. Feedback control is exercised by the control system comparing the
actual fed back output of the system with what is required and adjusting its output
accordingly.

REQUIRED
TEMPERATURE

BODY
TEMPERATURE
CONTROL SYSTEM

BODY TEMPERATURE

FEEDBACK OF DATA ABOUT ACTUAL TEMPERATURE

Fig 1.9

If you go to pick up a pencil from a bench there is a need for you to use a control system
to ensure that your hand actually ends up at the pencil.
The driver applies the brake of the vehicle, when he observes red traffic light.
The traffic personnel regulate the traffic in order to maintain smooth flow of traffic.
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These examples clearly explain the importance of control systems. There are 2 basic
forms of control systems, one being called open loop and the other closed loop.
1. Open-loop control system
2. Closed-loop control system
Open-loop control system:
A control system in which the output is dependent on input, but input is independent of
the output is called an open loop control system.
Ex:
1. Controlling the temperature of the room with a room heater.
2. Speed and load of a shaft
1.Controlling the temperature of a room with a room heater:
The amount of heat generated in a room depends on the amount of input power to the
heater controlled by a regulator. If the power supply is switched on , the power supplied
to the heater continues and the temperature of the room will drastically increase
immaterial of whether the heat is required for the room or not. The system has its no
control over the regulator and has to be controlled by the human being based on his/her
judgement.
2. Speed and load of the Shaft:
This is a very good example for open loop control system. The speed of the motor shaft
depends on the power supplied. If the load applied is more the speed reduces and if the
load applied is less, the speed of the shaft increases.

Advantages and disadvantages of Open-Loop Control System:

Advantages:
1.
2.
3.
4.
5.

Relatively simple
Low Cost
Good Reliability
Easy Maintenance
Inherently stable

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Disadvantages:
1.
2.
3.
4.

Response is slow
Often leads to wastage
Accuracy is very less
Low output Quality

Closed loop Control system:

A control system in which the input is dependent on the output is called closed loop
control system.
A closed loop control system is characterized by the presence of feedback unit. The
feedback unit allows the output of the system to be compared with the reference input
so that the error can be corrected. The ultimate feature of the closed loop control
system is the comparison of the actual value of the variable with the desired value of
that variable and any difference between these 2 values causes action to be taken to
make the error zero.
Elements of closed loop control system:
Forward Path
Comparison element
Control
Element

Reqd

Controlled variable
Correction
Element

Value
Feedback Element

Feedback Path

The basic elements of closed loop system are:

1.
2.
3.
4.

Comparison element
Control Element
Correction Element
Process Element

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Process Element

5. Feedback Element
Comparison element:
This compares the required or reference value of the variable condition being controlled
with the measured value of what is being achieved and produces an error signal. It c a n
b e r e ga r de d as a d di n g t h e re f er e nc e s i gn a l, wh i ch i s positive, to the
measured value signal, which is negative in this case:
Error signal = reference value signal - measured value signal.
The symbol used, in, general, for an element at which signals are summed is a segmented
circle, inputs going into segments.
The inputs are all added; hence the feedback input is marked as negative and the
reference signal positive so that the sum gives the difference between the signals.
Control element:
This decides what action to take when it receives an error signal. It ma y b e f o r
e x a mp l e, a si gn a l t o o p er a te a s w it ch o r open a valve. The control plan being
used by the element may be just to supply a signal which switches on or off when
here is an error, as in a room thermostat or perhaps a signal which proportionally
opens or closes a valve according to the size of the error.
Correction element:
The correction element produces a change in the process to correct or change the
controlled condition.
Thus it might be a switch which switches on a heater and so increases the temperature of
the process or a valve which opens and allows more liquid to enter the process.
The term actuator is used for the element of a correction unit that provides the power to
carry out the control action.
Process element:
The process is what is being controlled. It could be a room in a house with its temperature
being controlled or a tank of water with its level being controlled.

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Feedback element:
The feedback element produces a signal related to the variable condition of the process
that is being controlled.
For example, a switch which is switched on when a particular position is reached or a
thermocouple which gives an e.m.f related to the temperature.
With the closed-loop system illustrated in Fig. below, for a person controlling the
temperature of a room, the various elements are:

Controlled variable - the room temperature

Reference value - the required room temperature
Comparison element - the person comparing the measured value with the requiredvalue
of temperature
Error signal - the difference between the measured and requiredtemperatures.
Control unit - the person
Correction unit - the switch on the fire
Process - the heating by the fire
Measuring device - a thermometer

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AUTOMATIC WATER LEVEL CONTROLLER:

Fig. The automatic control of water level

An automatic control system for the control of the room temperature could involve a
temperature sensor, after Suitable signal conditioning, feeding an electrical signal to the
input of a computer where it is compared with the set value and an error signal generated.
This is then acted on by the computer to give at its output a signal, which, after suitable
signal conditioning, might be used to control a heater and hence the room temperature.
Such a system can readily be programmed to give different temperatures all different
times of the day. The above figure shows an example of a simple control system used to
maintain a constant water level in a tank. The reference value is the initial setting of the
lever arm arrangement so that it just cuts off the water supply at the required level. When
water is drawn from the tank the float moves downwards with the water level. This
causes the lever arrangement to rotate and so allows water to enter the tank. This flow
continues until the ball has risen to such a height that it has moved the lever arrangement
to cut off the water supply. It is closed loop control system with the elements being:
Controlled variable - the water level in the tank Reference value - initial setting of the
float and lever position Comparison clement - the lever Error signal - the difference
between the actual and initial settings 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 .

Advantages and disadvantages of Closed-Loop Control System:

Advantages:
1. More accurate.
2. Perform accurately even in the presence of non-linearities.
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3. Use of feedback system response is relatively insensitive to external disturbances

and internal variations in system parameters. It is thus possible to use relatively
inaccurate and inexpensive components to obtain the accurate control of a given
system.
Disadvantages:
1. Complicated and expensive
Differences between open and closed loop control system:

Open Loop

Closed Loop

1 Less accurate

More accurate

2 Easy to build and economic

Complex to build and expensive

3 Ensured Stability presence

May become unstable at times

4 Malfunctioning due to non linearity

Usually performs accurately even in non

linearities
Input Factor and the output factor both contribute
towards the control action

5 Input Parameter is the sole factor

responsible for providing the control
action
6 The control adjustment depends on
Human Judgement and estimate

The control judgement depends on the output and

feedback element

Advantages and Disadvantages of Mechatronic System:

Advantages:
1. A Mechatronic product exhibit performance characteristics that were previously
difficult to achieve without the synergistic combination.
2. Higher productivity, higher quality and production reliability by the use of sensors
and feedback system.
3. The integration of sensors and control systems in a complex system reduces
capital expenses.
4. Maintains higher degree of flexibility.
5. Higher percentage of machine utilization.
6. Products produced are extremely attractive to the customer in quality and cost
effectiveness.

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Disadvantages:
1. Expensive to incorporate to an existing system.
2. Initial cost of the system will be high.
3. Knowledge of different engineering fields is necessary for design and
implementation.
SEQUENTIAL CONTROLLERS:
When a controller operates in a sequence way i.e. Step by step, then that type of
controllers is called as sequence controllers. In sequential controllers, step 2 is started
only after completing step1 and after completing step 2 step 3 will be started. In
sequential controllers, the control .actions are ordered in time, which is obtained by an
electrical circuit with sets, of relays or cam operated switches which are wired up in such
a way as to give the required sequence.
Now-a-days hardwired circuits and relays are replaced by a microprocessor controlled
system, the sequencing are controlled by software program
Example: Washing machine.
Consider a washing machine; the numbers of sequential operations carried out are,
1.
2.
3.
4.

Pre wash cycle -the clothes in the drum are washed with coldwater.
Main wash cycle - the clothes are washed with hot water.
Rinse cycle - the washed clothes are rinsed with cold water number of times.
Spinning - the rinsed clothes are spinned to remove water.

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

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The system that is used for the washing machine controller was a mechanical system
which involved a set of cam-operated switches, i.e., mechanical switches. Figure below
show the basic principle of one such switch. When the machine is switched on, a signal
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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. The contours of the cams and the means by which the
program is specified and stored in the machine. The sequence of instructions and the
instructions used in a particular washing program are determined by the set of cams
chosen. 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 lie
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 tine 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.

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MICROPROCESSOR BASED CONTROLLERS:

Microprocessors are rapidly replacing the mechanical cam operated controllers. These
microprocessors are used to control the function. In many simple systems, an embedded
micro controller is used to control or perform the particular task. A more adaptable form
of controller is the programmable logic controller. The programmable logic controller is
defined as a sequential logic device that generates output signals according to logic
operations performed on the input signals. The PLC is a microprocessor based controller
which uses programmable memory to store instructions and to implement functions such
as logic sequence, timing counting and arithmetic to control events. This PLC can be
easily reprogrammed for different tasks. The PLC is shown below

The example for input devices are switches relays and limit switches. The examples for
output devices are motor to be controlled, Lamp, relay and solenoid. The
controller monitors the inputs and outputs according to the program stored in the PLC
by the operator. PLC is similar to computers but have certain features which
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are specific to their use of controllers. These are,1. They are rugged and
designed to withstand vibrations, temperature, humidity and noise.2. The
interfacing for inputs and outputs is inside the controllers.3 . T h e y a r e e a s i l y
p r o g r a m m e d a n d h a v e a n e a s i l y u n d e r s t o o d programming
language. The Programming is primari1y concerned with logic and switching
operations.
Note: Micro controller: - Microprocessor with integrated peripherals is called as micro
controller. Some of the microprocessor based control system is discussed below.

AUTOMATIC CAMERA:

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The modern camera is likely to have automatic focusing and exposure. The above Figure
illustrates the basic aspects of a microprocessor-based system that cant 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:

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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 incorrect position
send in-focus signal to view finder display
etc.

THE ENGINE MANAGEMENT SYSTEM:

The engine management system of a car is responsible for managing the ignition and
fuelling requirements of the engine. With a four-stroke internal combustion engine there
are several cylinders, each of which has a piston connected to a common crankshaft and
each of which carries out a four-stroke sequence of operations. When the piston moves
down a valve opens and the air-fuel mixture is drawn into the cylinder. When the piston
moves up again the valve closes and the air-fuel mixture is compressed. When the piston
is near the top of the cylinder the spark plug ignites the mixture with a resulting
expansion of the hot gases. This expansion causes the piston to move back down again
and so the cycle is repeated. The pistons of cacti cylinder are connected to a common
crankshaft and their power strokes occur at different times so that here is continuous
power for rotating the crankshaft

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The power and speed of the engine are controlled by varying the ignition timing and the
air - fuel mixture. With modem car engines this is done by a microprocessor. Figure hows
the basic elements of a microprocessor control system.
For ignition timing, the crankshaft drives a distributor which makes electrical contact for
each spark plug in turn and a timing wheel. This timing wheel generates pulses to
indicate he crankshaft position. The microprocessor then adjusts the timing at which high
voltage pulses are sent to the distributor so they occur at the right moments of time. To
control the amount of air fuel mixture entering a cylinder during the intake strokes, the
microprocessor varies the time for which a solenoid is activated to open the intake on the
basis of inputs received of the engine temperature and the throttle position. The amount
of fuel to be injected into the air stream can be determined by an input from a sensor of
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the mass rate of air flow, or computed from other measurements, and the microprocessor
then gives an output to control a fuel injection valve.
MECHATRONICS APPROACH:
The domestic washing machine that used cam operated switches in order to control the
washing cycle is out of date. Such mechanical switches are being replaced by
microprocessor. A microprocessor may be considered as being essentially a collection of
logic gates and memory elements that are not wired up is individual components but
whose logical functions are implemented by means of software. The microprocessorcontrolled washing machine can be considered an example of a mechatronics approach in
that a mechanical system has become integrated with electronic controls. As a
consequence, a bulky mechanical system is replaced by a much more compact
microprocessor system which is readily adjustable to give a greater variety of programs.
Mechatronics brings together a number of technologies like, mechanical engineering,
Electronic Engineering, electrical engineering, information technology, computer
technology and control engineering. This can be considered as the application of
Computer based digital control techniques, through electronic and electric interfaces to
mechanical engineering problems. There are many applications of mechatronics in the
mass produced products used in home. Microprocessor based controllers are to be found
in domestic washing machines, dish washers, microwave ovens, cameras, camcorders,
watches, hi-fi and video recorder systems, central heating controls, sewing machines,
etc.. They are to be found in cars in the active suspension, antiskid brakes, engine control,
speedometer display, transmission etc. A large scale application of mechatronics is a
flexible manufacturing engineering system (FMS) involving computer controlled
machines, robots, automatic material conveying and overall supervisory control.

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