UNIT 1

Introduction to Mechatronics systems, Mechatronics system

components - Measurement Systems, Control Systems - Open
and Closed Loops Systems Sequential Controllers with examples
– Water level controller, Shaft speed control, Washing machine
control, Automatic camera and Engine management
systems
 What is mechatronics
• Mechatronics is a concept of Japanese origin
(1970’s) and can be defined as the application
of electronics and computer technology to
control the motions of mechanical systems
Mechatronics application
 Examples of mechatronics system
• CNC machine
• Robots
• Automatic washing machine
• Automatic teller machine(ATM)
• Cockpit control
• Vending machine
Systems:
• A system can be defined as a box which has an input and an output where we
concentrate about the relationship between the input and output.
Example: a motor.
• A motor has input as electric power as input and rotation as output. The following
figure shows the representation
Measurement System Definition:
• A measurement system can be defined as a black box
which is used for making measurements.
• It has an input-the quantity being measured and
• Output-the value of that quantity.
• Example: A temperature measurement system. i.e.
Thermometer
 Elements of measurement system

• A sensor which responds to the quantity being measured by giving as its output a
signal which is related to the quantity. Ex. a thermocouple is a temperature sensor
• A signal conditioner takes the signal from the sensor and manipulates it into a
condition which is suitable for either display or in the case of a control system, for
use to exercise control. Thus for example the output from a thermocouple is a
rather small e.m.f and might be fed through an amplifier to obtain a bigger signal.
The amplifier is the signal conditioner.
• A display system where the output from the signal conditioner is displayed. This
might, for example be a pointer moving across a scale or a digital readout.
Control System:
• A control system can be defined as a block box which can be used
to control its output to some particular value.
• Example: a domestic central heating control system, air
conditioning system

• We can set the required temperature on the controller and the

pump can be adjusted to supply water through radiators. So the
required temperature can be maintained in the house.
Types of control system
• Open loop system
• Closed-loop system
 OPEN LOOP
eg:Air conditioning system
• There is no feed back to the
element to adjust it and maintain
a constant temperature
CLOSED LOOP
• There is feedback,
• the input to the system being
adjusted according to its output
(i.e required temperature).
• This means that the input to the
switch depends on the deviation
of the actual temperature from
the required temperature.
• The difference between them
determined by a comparison
element. The person in this case.
• Open-loop systems
Advantages
• relatively simple and
• consequently low cost with
generally good reliability.
Disadvantage
• inaccurate since there is no
correction for error.
• Closed-loop systems
• Advantages
• relatively accurate in
matching the actual to the
required values.
Disadvantages
• more complex
• so more costly
• greater chance of
breakdown as a
consequence of the greater
number of components.
 Basic elements of a closed-loop
system:
• Comparison element
• Control element
• Correction element
• Process element
• Measurement element
• Control unit- decides what action to take,
when it receives an error
• Correction element- produces change in
the process to correct
• Process element- what process is being
controlled
• Measuring element – produces a signal
related to variable condition
 Basic elements of a closed-loop system:

Comparison element
• This compares the required (reference value) of the variable
condition being controlled with the measured value of what is
being achieved and produces an error signal.
• It can be regarded as adding the reference signal, which is
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
• reference signal positive
• so that the sum gives the difference between the signals.
• A feedback loop is a means - a signal related to the actual
condition being achieved is fed back to modify the Input signal to
a process.
• The feedback is said to be negative feedback , when the signal
which is fed back subtracts from the input value. It is negative
feedback that is required to control a system. Positive feedback
occurs when the signal fed back adds to the input signal.
Control element
• This decides what action to take when it receives
an error signal
• Example, a signal to operate a switch or 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.
Measurement element
• The measurement element produces a signal related to
the variable condition of the process that is being
controlled.
• For example: thermocouple which gives an e.m.f
related to the temperature.
 Examples of closed loop system
• Automatic control of water level
• Shaft speed control
• Heating a room
Shaft speed control
The automatic control of water level
 The automatic control of water level

• Controlled variable - the water level in the tank

• Reference value – initial setting of the float and lever position
• Comparison element – the lever
• Error signal – the difference between the actual and initial
setting 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
 3) Heating a room

• With the closed-loop system illustrated in above figure 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 required value of
temperature
• Error signal – the difference between the measured and required temperature
• Control unit – the person
• Correction unit – the switch on fire
• Process – the heating on fire
• Measuring device- a thermometer
• 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.
Elements of mechatronics system
Actuating system
Example for signal conditioning
Sequential controllers
• A sequential control system involves the sequential execution of well defined
operations that are performed in a prescribed order.
• Each operation or a activity is called a event or step
• Sequential controller may be classified into 1) Event based & 2) Time based
• In event based controllers, the next event or step cannot be performed until
the previous event or step is completed. They are more reliable than time
based controllers
• In time based controllers, the series of operations are sequenced with respect
to time
• Such control could be obtained by – electric circuit with set of relays or cam-
operated switches which are wired up in such a way to give required
sequence.
• These hard wired circuits are now more likely to have been replaced by a
microprocessor controlled system with the sequencing being controlled by
means of a software program.
 Illustration of sequential control

1. Domestic washing machine

2. Engine management system
3. Automatic camera
The following events are performed in a particular sequence
• Pre wash cycle- clothes in the drum are given wash in cold water
• Main wash cycle- clothes are washed in hot water
• Rinse cycle- clothes are rinsed with cold water a number of preset time
• Spin cycle- spinning of drum takes place to drain the water from clothes and the
drum

• In earlier days, cam operated switch mechanism was used in washing machine
• In modern automatic washing machine, the cam operated switches are replaced
with microprocessor based controllers where the software programs are fed to
perform various sequential operations.
• The timer installed in the system determines the time for which the cycles to be
activated.
• The various sensors such as level sensor, position sensor, temperature sensor and
speed sensor provide input to the microprocessor.
Cam Operated Switch
 1)Washing machine system

• Control unit- decides what action to take, when it receives an error The various sensors such as level sensor,
• Correction element- produces change in the process to correct position sensor, temperature sensor and
• Process element- what process is being controlled speed sensor provide input to the
• Measuring element – produces a signal related to variable condition microprocessor.
Step 3:Rinse cycle:
• When the main wash is completed, the microprocessor gives an output for the rinse cycle, it
opens the valve to allow cold water to the drum and it closes when it reaches a preset level.
• A drum motor is operated to rotate the drum and the drain pump is operated to drain the
water after preset time
• This sequence is repeated for a number of times.
Step 4:Spin cycle:
• The microprocessor switches on the drum motor and it is signalled to rotate at a higher
speed than rinsing cycle.
• Due to the centrifugal action the water drains out from the clothes
 2)The Engine Management System

Four stroke sequence

• Intake stroke
• Compression stroke
• Power stroke
• Exhaust stroke
• 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 each 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.
• The power and speed of the engine are controlled by varying the ignition timing and
the air—fuel mixture.
• With modern car engines this is done by a microprocessor. Above Figure shows 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 the mass rate of air flow, or computed from other
measurements, and the microprocessor then gives an output to control a fuel
injection valve.
3) Elements of Automatic Camera
The modern camera is likely to have automatic focusing and exposure. Above Figure illustrates
the basic aspects of a microprocessor-based system that can’t 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:
Thank you