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MECHATRONICS UNIT II
UNIT II ACTUATION SYSTEMS
(Pneumatic and Hydraulic Systems
Directional Control Valves Rotary
Actuators. Mechanical Actuation
Systems Cams Gear Trains Ratchet
and a!l "elt and Chain Drives
"earin#s. $lectrical Actuation Systems
Mechanical S!itches Solid State
S!itches Solenoids D.C Motors A.C
Motors Steer Motors.%
PNEUMATIC SYSTEM:
Pneumatics is a branch of
technology, which deals with the study
and application of use of pressurized gas
to afect mechanical motion.
Pneumatic systems are
extensively used in industry, where
factories are commonly plumbed with
compressed air or other compressed
inert gases. This is because a centrally-
located and electrically-powered
compressor that powers cylinders and
other pneumatic devices through
solenoid valves is often able to provide
motive power in a cheaper, safer, more
exible, and reliable way than a large
number of electric motors and actuators.
!orce " Pressure # $rea " p#$
Basic elements of pneumatic
system:
1. %ompressor and motor
&. Pressure relief valve and chec'
valve
(. %ooler, )lter and water trap
*. $ir receiver
+. ,irectional control valves
-. $ctuator or pneumatic cylinder
$ctuator or
Pneumati
c cyl
.asic /lements of Pneumatic 0ystem
Advantages of pneumatics
0implicity of ,esign and %ontrol
1eliability
0torage
0afety
Application of pneumatic system
1. 2anufacturing
&. Process industries
(. Transportation systems
*. 3tilities
%ompres
sor
2oto
r
Pressure
1elief valve
%ooler
!ilter 4
5ater Trap
,irectional
%ontrol
6alve
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MECHATRONICS UNIT II
HYDRAULIC SYSTEMS:
Hydrauic mac!inery is
machines and tools which use uid
power to do simple wor'. 7eavy
e8uipment is a common example.
9n this type of machine, high-
pressure li8uid : called hydraulic uid
: is transmitted throughout the
machine to various hydraulic motors and
hydraulic cylinders. The uid is
controlled directly or automatically by
control valves and distributed through
hoses and tubes.
The popularity of hydraulic
machinery is due to the very large
amount of power that can be transferred
through small tubes and exible hoses,
and the high power density and wide
array of actuators that can ma'e use of
this power. 7ydraulic machinery is
operated by the use of hydraulics, where
a li8uid is the powering medium
Basic elements of hydraulic system:
1. 7ydraulic pump unit
&. %ontrol valves
i pressure relief valves control the
uid pressure
ii non return valve control the bac'
ow uid
iii directional control valves control
the direction of uid
(. 1eciprocating or rotary unit
1eturn !luid

$ctuator or
7ydraulic
cyl
.asic /lements of 7ydraulic 0ystem
Advantages of hydraulics
1. 9ts uniform and smooth
&. /asy to maintain
(. 9t is safe and compact
*. !rictional resistance is less
5. .alancing hydraulic forces is
easier.
Pump
;on- 1eturn
valve
Pressure
1elief valve
$ccumulato
r
,irectional
%ontrol
6alve
2oto
r
Tan'
!ilter
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MECHATRONICS UNIT II
DIRECTIONAL CONTROL "AL"ES
#DC"$:
Dc%s are one of the most
fundamental parts in hydraulic
machinery. They allow uid ow into
diferent paths from one or more
sources. They usually consist of a piston
inside a cylinder which is electrically
controlled.
The movement of the cylinder
restricts or permits the ow, thus it
controls the uid ow.
Functions of Dcvs
%ontrolling the ow by guiding and
directing it to a load time
0elect the path
.loc'ing the path
2a'ing alert the signal
1eleasing the air or uid
Performing logic control functions
0topping and starting ow
0ensing cylinder positions
Dcvs are mainly two types:
7ydraulic
Pneumatic
%ommon types
a. 0liding spool valve
b. 1otary spool valve
c. Poppet valve
0liding spool valve
1otary spool valve
Poppet valve
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MECHATRONICS UNIT II
Pressure Control Valves
!unction of the pressure control
valves is to control the pressure of the
uid and maintain the pressure.
Types of Pressure Control Valves
Pressure regulating valves
Pressure limiting valves
Pressure se8uence valves
PROCESS CONTROL "AL"ES:
Process control valves are used to
control the rate of uid ow of a process
control system.
/xample< controlling the rate of uid
ow into a tan' the operation is based
on a variable resistance to the ow of
uid by altering the cross-section of the
pipe through which the uid ows.
$ process control valve consists of
an actuator and valve.
ACTUATORS:
$ctuators are a device is used as
an output device to do useful wor'.
5or' produced by both hydraulic
and pneumatic systems is in the form of
moving, gripping and applying force to
and particular ob=ect
Classifcation
inear actuators
Sin#le actin# cylinder
Dou&le actin# cylinder
!otary actuators
Vane
Rac' and inion
inear Actuators
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MECHATRONICS UNIT II
>inear actuators provide a
rectilinear movement realized by the
stro'e of a rod connected to a piston
sliding inside the cylinder.
"# $ingle acting cylinders
9n single acting cylinders, the uid
enters and leaves in one side of the
piston and the other side vented to
atmosphere
Therefore single acting cylinder
can produce wor' in one direction. The
spring force is used the piston to its
initial position
%# Dou&le acting cylinders
9n double acting cylinders, the
uid enters and leaves in both sides of
the piston an there is no return spring is
needed
There is two ports used
alternately, one for supply and other for
exhaust of air
!otary Actuators
1otary actuators are a device that
develops rotary motion, from an
available hydraulic or pneumatic energy
source. 9n construction terms, rotary
actuators are identical to rotary pumps.
/x< gear, vane, rac' and pinion
"# Vane actuators
$ vane motor consists of number of
spring loaded vanes slotted into a driven
rotor. 0pring loaded vane lips are held
against the housing and rotor is ofset
within the housing. The vanes are
contained by cam rings as the cross inlet
and outlet ports.
%# !ac' and pinion
$ rac' is a toothed bar or rod that
can be thought of as a sector gear with
an in)nitely large radius of curvature.
Tor8ue can be converted to linear force
by meshing a rac' with a pinion< the
pinion turns? the rac' moves in a
straight line. 0uch a mechanism is used
in automobiles to convert the rotation of
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MECHATRONICS UNIT II
the steering wheel into the left-to-right
motion of the tie rod@sA.
MECHANICAL ACTUATION SYSTEMS
2echanical actuation system
consist of various mechanical elements,
such as lin'ages, cams, gear trains, rac'
and pinion, ratchet and pawl, chains,
belt drives, bearings /tc.
Function of (echanical $ystem:
1. Transformation rotary motion for
long distance
&. Transformation rotary motion for
medium distance without slipping
(. Transformation rotary motion for
linear motion
*. >oc'ing of rotating elements
+. %hanging the direction
Cams:
$ cam is a rotating or sliding
piece in a mechanical lin'age used
especially in transforming rotary motion
into linear motion or vice-versa. 9t is
often a part of a rotating wheel @e.g. an
eccentric wheelA or shaft @e.g. a cylinder
with an irregular shapeA that stri'es a
lever at one or more points on its
circular path.
The cam can be a simple tooth, as
is used to deliver pulses of power to a
steam hammer, for example, or an
eccentric disc or other shape that
produces a smooth reciprocating @bac'
and forthA motion in the (ollo!er, which
is a lever ma'ing contact with the cam.
Types of Cams:
!lat
cams<
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MECHATRONICS UNIT II
,isc %ams
%ylindrical cams
Brooved %ams or .ox
/nd %am
%onical %ams
Types of Cam followers:
Cnife /dge follower
!lat foot follower
1oller follower
Dfset follower
Dscillating follower
&EAR:
$ gear is a rotating machine part
having cut teeth, or cogs, which mesh
with another toothed part in order to
transmit tor8ue. Two or more gears
wor'ing in tandem are called a
transmission and can produce a
mechanical advantage through a gear
ratio and thus may be considered a
simple machine. Beared devices can
change the speed, tor8ue, and direction
of a power source.
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MECHATRONICS UNIT II
The most common situation is for
a gear to mesh with another gear,
however a gear can also mesh a non-
rotating toothed part, called a rac',
thereby producing translation instead of
rotation.
Types of gear:
1. 0pur gears &. 1ac' and
pinion
(. 7elical gears *. .evel gears
+. 5orm gears -. /xternal
gearing
E. 9nternal gearing
$pur gear<
0pur gears or straight-cut gears
are the simplest type of gear. They
consist of a cylinder or dis' with the
teeth pro=ecting radially, and although
they are not straight-sided in form, the
edge of each tooth is straight and
aligned parallel to the axis of rotation.
These gears can be meshed together
correctly only if they are )tted to parallel
shafts.
)elical gears
7elical or Fdry )xedF gears ofer a
re)nement over spur gears.
The leading edges of the teeth are
not parallel to the axis of rotation, but
are set at an angle. 0ince the gear is
curved, this angling causes the tooth
shape to be a segment of a helix. 7elical
gears can be meshed in a parallel or
crossed orientations. The former refers
to when the shafts are parallel to each
other? this is the most common
orientation. 9n the latter, the shafts are
non-parallel, and in this con)guration
are sometimes 'nown as Fs'ew gearsF.
D'u(e !eica )ears
,ouble helical gears, or
herringbone gears, overcome the
problem of axial thrust presented by
FsingleF helical gears,
by having two sets of
teeth that are set in a
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MECHATRONICS UNIT II
6 shape. $ double helical gear can be
thought of as two mirrored helical gears
=oined together.
This arrangement cancels out the
net axial thrust, since each half of the
gear thrusts in the opposite direction.
,ouble helical gears are more diGcult to
manufacture due to their more
complicated shape.
Rac* and +ini'n:
$ rac' is a toothed bar or rod that
can be thought of as a sector gear with
an in)nitely large radius of curvature.
Tor8ue can be converted to linear force
by
meshing a rac' with a pinion< the pinion
turns? the rac' moves in a straight line.
0uch a mechanism is used in
automobiles to convert the rotation of
the steering wheel into the left-to-right
motion of the tie rod@sA. 1ac's
also feature in the theory of gear
geometry, where, for instance,
the tooth shape of an interchangeable
set of gears may be speci)ed for the
rac' @in)nite radiusA, and the tooth
shapes for gears of particular actual
radii then derived from that. The rac'
and pinion gear type is employed in a
rac' railway.
,e%e )ears
$ bevel gear is shaped li'e a right
circular cone with most of its tip cut of.
5hen two bevel gears mesh, their
imaginary vertices must occupy the
same point. Their shaft axes also
intersect at this point, forming an
arbitrary non-straight angle between the
shafts. The angle between the shafts
can be anything except zero or 1HI
degrees. .evel gears with e8ual
numbers of teeth and shaft axes at JI
degrees are called miter gears.
-'rm )ears
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MECHATRONICS UNIT II
5orm gears resemble screws. $
worm gear is usually meshed with a spur
gear or a helical gear, which is called the
gear, wheel, or worm wheel.
5orm-and-gear sets are a simple
and compact way to achieve a high
tor8ue, low speed gear ratio. !or
example, helical gears are normally
limited to gear ratios of less than 1I<1
while worm-and-gear sets vary from 1I<1
to +II<1.$ disadvantage is the potential
for considerable sliding action, leading
to low eGciency.
5orm gears can be considered a species
of helical gear, but its helix angle is
usually somewhat large @close to JI
degreesA and its body is usually fairly
long in the axial direction? and it is these
attributes which give it screw li'e
8ualities.
E.terna )earin) and interna
)earin)
$n external gear is one with the
teeth formed on the outer surface of a
cylinder or cone. %onversely, an internal
gear is one with the teeth formed on the
inner surface of a cylinder or cone. !or
bevel gears, an internal gear is one with
the pitch angle exceeding JI degrees.
9nternal gears do not cause direction
reversal
&EAR TRAIN
$ )ear train is a set or system of
gears arranged to transfer rotational
tor8ue from one part of a mechanical
system to another.
Bear trains may consist of<
,riving gears - attached to the input
shaft
,riven gearsK2otor gears - attached to
the output shaft
9dler gears - interposed between the
driving and driven gear in order to
maintain the direction of the output
shaft the same as the input shaft or to
increase the distance between the drive
and driven gears. $ compound gear
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MECHATRONICS UNIT II
train refers to two or more gears used to
transmit motion.
Types of *ear train:
0imple gear train
%ompound gear train
/picyclic gear train
1everted gear train
0imple Bear Train
%ompound Bear Train
/picyclic Bear Train
1everted Bear Train<
RATCHET / PA-L:
$ ratc!et is a device that allows
continuous linear or rotary motion in
only one direction while preventing
motion in the opposite direction.
.ecause most soc'et wrenches today
use ratcheting handles, the term
FratchetF alone is often used to refer to a
ratcheting wrench, and the terms
FratchetF and Fsoc'etF are closely
associated in many usersL minds.
$ ratchet consists of a round gear
or linear rac' with teeth, and a pivoting,
spring loaded )nger called a pawl that
engages the teeth. The teeth are
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MECHATRONICS UNIT II
uniform but asymmetrical, with each
tooth having a moderate slope on one
edge and a much steeper slope on the
other edge. 5hen the teeth are moving
in the unrestricted @i.e., forwardA
direction, the pawl easily slides up and
over the gently sloped edges of the
teeth, with a spring forcing it into the
depression between the teeth as it
passes the tip of each tooth. 5hen the
teeth move in the opposite @bac'wardA
direction, however, the pawl will catch
against the steeply sloped edge of the
)rst tooth it encounters, thereby loc'ing
it against the tooth and preventing any
further motion in that direction.
,ELT DRI"E:
$ (et is a loop of exible material
used to lin' two or more rotating shafts
mechanically. .elts may be used as a
source of motion, to transmit power
eGciently, or to trac' relative
movement. .elts are looped over
pulleys. 9n a two pulley system, the belt
can either drive the pulleys in the same
direction, or the belt may be crossed, so
that the direction of the shafts is
opposite. $s a source of motion, a
conveyor belt is one application where
the belt is adapted to continually carry a
load between two points.
Types of Belt Drives:
Dpen belt drive
%ross belt drive
.elt drive with idler pulleys
Types of &elt
1. !lat .elt
&. 6- .elt
(. 1ound .elt
*. Timing .elt
C!ain dri%e
C!ain dri%e is a way of
transmitting mechanical power from one
place to another. 9t is often used to
convey power to the wheels of a vehicle,
particularly bicycles and motorcycles.
9t is also used in a wide variety of
machines besides vehicles.
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MECHATRONICS UNIT II
The power is conveyed by a roller
chain, 'nown as the dri%e c!ain or
transmissi'n c!ain, passing over a
sproc'et gear, with the teeth of the gear
meshing with the holes in the lin's of
the chain. The gear is turned, and this
pulls the chain putting mechanical force
into the system.
,EARIN&S:
$ (earin) is a device to allow
constrained relative motion between two
or more parts, typically rotation or linear
movement. .earings may be classi)ed
broadly according to the motions they
allow and according to their principle of
operation as well as by the directions of
applied loads they can handle.
Princi+es '0 '+erati'n
There are at least six common principles
of operation<
1. plain bearing, also 'nown by the
speci)c styles< bushings, =ournal
bearings, sleeve bearings, rie
bearings
&. 1olling-element bearings such as
ball bearings and roller bearings
(. Mewel bearings, in which the load is
carried by rolling the axle slightly
of-center
*. !luid bearings, in which the load is
carried by a gas or li8uid
+. 2agnetic bearings, in which the
load is carried by a magnetic )eld
-. !lexure bearings, in which the
motion is supported by a load
element which bends.
E. $ngular contact bearing
Types of Bearings
The most common tyes
1. Plain =ournal bearing
&. 1olling element
bearing
(. !luid bearing
*. 2agnetic bearing
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MECHATRONICS UNIT II
ELECTRICAL ACTUATION SYSTEM:
$ome types of electrical actuators
0olenoid
/lectrical motors N $%, ,% motor
0tepper motor
2echanical 0witches
0olid 0tate 0witches
$+,-+.D:
$ solenoid is a device which is
used to convert an electrical signal into
mechanical motion usually in a straight
line
The coil may be $% or ,% which
when energized, pulls the core inside it
and this result in the mechanical motion
of the core
D1C M't'r:
Principle
5hen a current carrying a
conductor is placed in magnetic )eld, it
experiences a force.
5hen a conductor moves in a
magnetic )eld, an /2! is induced
/2! is /8ual to rate of change of
ux
Construction
The coil of wire acts as the rotor. 9n
conventional ,.% motor, several coils of
wire are mounted in slots on a cylinder
of magnetic material called armature
The armature is mounted on a
bearing and is free to rotate. 9t is
connected to source od ,.% %urrent
through a switch mounted on the shaft
and it is called as commutator
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MECHATRONICS UNIT II
/or'ing:
5hen the current ow
through the armature c'nduct'rs
placed in the 2agnetic )eld, it will
experience a force and it causes it to
rotate.
$rmature rotates commutator
reverses the current in each coil as it
moves to )eld poles
$s the commutators are split the
current direction through coil reverses
each time and the rotational tor8ue
present all the time and the coil
continues to rotate.
Ty+es '0 DC m't'rs
C'ntr' '0 DC m't'rs:
+pen loop control:
The
speed
control can be obtained by controlling
the voltage applied to the armature.
!ixed voltage supplies are often used.
%losed >oop control
The feedbac' signal generated by
tachometer @measurementA is given to
anlog to digital converter to convert
analog to digital and is given as input to
microprocessor, microprocessor to
control speed of the motor by
automatically
A1C MOTORS:
$n AC m't'r is an electric motor
that is driven by an alternating current.
9t consists of two basic parts, an outside
stationary stator having coils supplied
with alternating current to produce a
rotating magnetic )eld, and an inside
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MECHATRONICS UNIT II
rotor attached to the output shaft that is
given a tor8ue by the rotating )eld.
There are two types of $% motors,
depending on the type of rotor used
The )rst is the synchronous motor,
which rotates exactly at the supply
fre8uency or a submultiple of the supply
fre8uency. The magnetic )eld on the
rotor is either generated by current
delivered through slip rings or by a
permanent magnet. The second type is
the induction motor, which runs slightly
slower than the supply fre8uency. The
magnetic )eld on the rotor of this motor
is created by an induced current.
Construction:
9t consists of a s8uirrel cage rotor
and it is made of copper or aluminum
bars and it )ts into slots in end rings to
form complete electrical circuits
There are no external electrical
connections to the rotor. The stator has
set of windings.
/or'ing
$lternating current passes through
the stator windings an alternating
magnetic )eld is produced.
,ue to electromagnetic induction,
/2! are inducted in the conductor
present in the rotor and hence current
ows in the rotor
Control AC (otor:
%hange the number of poles
%hange the fre8uency of $% signal
%hange the slip
Types :
0ix step inverter N $% recti)ed to ,%
Pulse width modulation N ,% voltage
1ecti)ed $%
6ector ux N controlling the current
STEPPER MOTOR:
9t is a device that produces
rotation through e8ual angles when
digital pulses are supplied as input.
9n other word stepper motor
transforms the electrical pulses in to
e8ual increments of rotary shaft motion.
Ty+es '0 Ste++er M't'r:
6ariable reluctance
Permanent magnet
7ybrid stepper motor
Varia&le reluctance $tepper (otor:
5or'ing<
5hen current switched to a pair of
windings in stator, a magnetic )eld is
produced. The lines of force pass from
stator poles to nearest set of poles on
the rotor.
1otor will
move until
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MECHATRONICS UNIT II
the rotor and stator line up. This is
termed as position of minimum
reluctance. This motor generally gives
step angles of E.+O or 1+ O
Permanent magnet $tepper (otor:
5or'ing<
9f the current switched so that the
polarities are reversed, the rotor will
move a further *+O in order to line up
again
Thus by switching currents
through the coils the rotor rotates by
*+O steps
9n this type step angle is 1.HO,E.+
O,1+ O, (I O,(* O,JI Ocan be achieved
)y&rid $tepper (otor:
5or'ing?
The rotor sets itself in minimum
reluctance position if a pair of stator
coils is energized, in this stepper motor,
step angle of I.J O and 1.HO are
achieved.
S-ITCHIN& CIRCUITRIES 2OR
STEPPER MOTOR:
Two phase motors have four
connecting wires for signals to generate
the switching se8uences. The 7 circuit
contains P1 to PH totally H transistors.
The following table explains the
switching se8uence needed to carry out
four steps.
0witching 0e8uence for full step rotation
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MECHATRONICS UNIT II
0witching 0e8uence for half step
rotation
A1C and D1C Ser%'m't'rs:
$.% 0ervomotor<
5or'ing
The two windings are excited by
voltage of magnitude and JIO phase
shift.
9t develops a magnetic )eld of constant
magnitude rotating at synchronous
speed.
The direction of rotation depends upon
the phase relationship reference winding
and control winding.
The rotation magnetic )eld
interacts with the currents and
produces tor8ue in the direction of
rotation
,.%
0ervomotor<
9n which the speed of the ,% servo
motor is controlled by armature current
with )eld current constant
Mec!anica S3itc!es:
2echanical switches are elements
which are often used as sensors to give
inputs to systems. The electrical relay is
an example of a mechanical switch used
in control systems as actuators
!elays:
5hen there is a current through
the solenoid of the relay a magnetic )eld
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MECHATRONICS UNIT II
is produced which attracts the iron
armature, moves the push- rod, and so
closed the normally open switch
contacts and opens the normally closed
switch contacts
SOLID STATE S-ITCHES:
,iodes
Thyristors
.ipolar
Transistors
Power 2D0!/T0
D.+D,$:
The semiconductor diode conducts
in only one direction
6f " !orward voltage
6r N 1everse voltage
T)0!.$T+!$:
The Thyristor or silicon controlled
recti)er @0%1A is a three terminal * layer
Thyristor. 9n addition to an anode, and a
cathode the 0%1 has a gate terminal.
B.P+A!:
.ipolar transistor comes in to &
forms the ;P; and the P;P
;P; transistor the main current
ows at the collector and out at the
emitter, a controlling signal being
applied to the base.
P;P transistor has the main
current following at the emitter and out
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MECHATRONICS UNIT II
at the collector, a controlling signal
being applied to the base
(+$F,T$:
2etal oxide )eld efect transistor
is a unipolar device? because the current
conduction ta'es place only by the
ma=ority carriers here the gate voltage is
the controlling signal. 9f the gate voltage
is more negative, then the 2D0!/T is
switched D;.