[Introduction to Mechanical Engineering] MODULE 5

MODULE 5

MECHATRONICS

Mechatronics is a multidisciplinary field that combines mechanical engineering, electrical

engineering, and computer science to design and control advanced systems. Mechatronic systems
can be classified into two categories based on their feedback mechanism: open-loop and closed-
loop systems.

Mechatronics systems are found in a wide range of applications, such as robotics, automotive
systems, aerospace systems, manufacturing processes, and medical devices. They typically
include sensors to measure physical parameters, actuators to control physical processes, and
microcontrollers or programmable logic controllers (PLCs) to control the system.

Mechatronics systems are designed to operate in a closed-loop control system where the output of
the system is monitored and compared to a desired setpoint. If there is a difference between the

Page 1
[Introduction to Mechanical Engineering] MODULE 5
output and the setpoint, the control system takes action to adjust the input to the system to bring
the output closer to the setpoint.
Overall, mechatronics systems provide advanced functionality and precision control, which
is essential in many modern technologies.

Mechatronics in daily life

Mechatronics is becoming increasingly common in our daily lives, as it is used in many

consumer products and systems that we interact with every day. Here are a few examples:
Smartphones: Our smartphones are complex mechatronics systems that combine sensors,
processors, and actuators to provide us with a range of functions, such as touchscreens, cameras,
GPS, and wireless connectivity.
Home appliances: Many home appliances, such as washing machines, refrigerators, and air
conditioners, are mechatronics systems that incorporate sensors, microcontrollers, and actuators
to provide advanced functionality and control.
Automobiles: Modern automobiles are advanced mechatronics systems that incorporate
sensors, control systems, and actuators to provide features such as advanced safety systems,
engine control, and entertainment systems.

Page 2
[Introduction to Mechanical Engineering] MODULE 5
Robotics: Robotics is a field that relies heavily on mechatronics systems to control the
movements and actions of robots used in a wide range of applications, such as manufacturing,
medical devices, and space exploration.
Industrial automation: Industrial automation systems, such as manufacturing lines and
packaging systems, are complex mechatronics systems that use sensors, controllers, and
actuators to optimize production efficiency and product quality.
Overall, mechatronics has become an integral part of many modern systems and technologies,
making our daily lives more convenient, efficient, and safe.

Open-Loop Mechatronic System

An open-loop mechatronic system is a system that operates without feedback control. In an open-
loop system, the control input is determined based on the system's initial conditions and is not
adjusted based on the system's output or performance. The control action is predetermined and
does not change in response to changes in the system's environment or behavior.

open-loop control system, the motor is operated without any feedback control. The input to the
motor is directly controlled by the user, and the output of the motor is not measured or monitored.
For example, in a simple electric toy car, the motor is driven by a switch or a button, and the
speed of the car is not controlled based on any feedback from the environment or the user. In this
case, the motor is operating as an open-loop system.

Page 3
[Introduction to Mechanical Engineering] MODULE 5

An on-off bulb can be considered as an example of an open-loop control system. When the user
switches on the bulb, it operates at a fixed level of brightness, irrespective of any changes in the
ambient lighting conditions or any feedback from the user. The user has no control over the
brightness level of the bulb, and it does not respond to any feedback from the environment or the
user.

Closed-Loop Mechatronic System

On the other hand, a closed-loop mechatronic system is a system that uses feedback to adjust its
control action based on the system's output or performance. In a closed-loop system, a sensor is
used to measure the system's output or performance, and the feedback signal is used to adjust the
control action to improve the system's performance. Closed- loop systems are also known as
feedback control systems.
Examples of closed-loop systems include thermostats, cruise control in cars, and
aircraft autopilot systems.

Example:

The closed-loop control system ensures that the iron box operates at the correct temperature,
improving its efficiency and safety. It also reduces the risk of overheating, which can damage
clothes or cause a fire.
In the case of an automatic iron box, the temperature sensor measures the temperature of the
heating element and sends this information to the microcontroller. The microcontroller
compares the measured temperature with the desired temperature set by the user and adjusts the
Page 4
[Introduction to Mechanical Engineering] MODULE 5
heating element's power input accordingly. This feedback loop continues until the desired
temperature is achieved and maintained throughout the ironing process.
This closed-loop control system ensures that the iron box operates at the correct temperature,
improving its efficiency and safety. It also reduces the risk of overheating, which can damage
clothes or cause a fire. Overall, closed-loop control systems are widely used in many applications,
such as robotics, manufacturing, and process control, to ensure accurate and reliable operation.
In summary, open-loop systems operate without feedback control, while closed-loop systems
use feedback to adjust their control action based on the system's output or performance.

Automatic Speed Control Of Motors

Automatic speed control of motors using a closed loop control system involves measuring the
actual speed of the motor and comparing it to the desired speed. The difference between the two
is used to adjust the input to the motor controller, which in turn adjusts the speed of the motor.
This process continues until the actual speed of the motor matches the desired speed. Closed loop
control systems provide a robust and accurate way to control the speed of motors, which is
important in a wide range of applications.

Automatic Speed
Control of Motors

Domestic Washing machine as a Closed loop control system

Page 5
[Introduction to Mechanical Engineering] MODULE 5
A domestic washing machine can be considered as a closed-loop control system because it takes
input (dirty clothes, detergent, water), processes it through the washing cycle, and produces an
output (clean clothes). The machine uses sensors to measure the water level, temperature, and
other variables to ensure that the washing cycle runs smoothly and produces the desired output.
In a washing machine, the closed-loop control system uses sensors and feedback to ensure that
the washing cycle runs smoothly and produces the desired output. Here is a more detailed
explanation of how the closed-loop control system
works in a washing machine:
Sensors: The washing machine has various sensors that measure different parameters
such as water level, temperature, and load balance. These sensors provide feedback to the
control unit about the washing cycle's progress and performance.
Control Unit: The control unit receives feedback from the sensors and uses that
information to adjust the washing cycle. For example, if the water level is too high, the
control unit will signal the water valve to stop filling the machine with water.
Actuators: The control unit also uses actuators to make adjustments to the washing
cycle. For instance, if the water temperature is too low, the control unit will increase
the heating element's power to raise the temperature.
Closed-Loop Feedback: As the washing cycle progresses, the closed-loop control
system continuously receives feedback from the sensors and adjusts the washing cycle's
parameters accordingly. This closed-loop feedback system ensures that the washing cycle
runs efficiently and produces clean clothes as output.

For example, if the washing machine is overloaded with clothes, the load balance sensor will
detect the imbalance and signal the control unit to adjust the washing cycle. The control unit will
then adjust the motor's speed to balance the load and prevent the machine from vibrating
excessively.

Page 6
[Introduction to Mechanical Engineering] MODULE 5

ROBOTICS AND AUTOMATION

ROBOTICS can be defined as“A field of technology that deals with the conception,
design, construction,operation and application of robots”Robot
A Robot is a reprogrammable, multifunctional manipulator designed to move material, parts,
tools or specialized devices through variable programmed motions of performance of a variety of
tasks.
Industrial Robot
An industrial robot can perform wide range of industrial tasks like loading, unloading,
welding, painting, inspection, assembly, material transfer, etc.
A robot is a machine that is designed to perform tasks that are typically done by humans,
either autonomously or under the control of a human operator. Robots can be programmed to
perform a wide range of tasks, from simple actions such as picking up an object to complex tasks
such as assembling a car. Robots typically consist of mechanical components, such as arms,
grippers, and wheels, as well as electronic components such as sensors, actuators, and control
systems. These components work together to enable the robot to interact with its environment and
perform its designated tasks.
There are many types of robots, each designed for specific applications. Some
examples include:
Industrial robots: These are used in manufacturing and production lines to perform tasks
such as welding, painting, and assembly.
Service robots: These are used in a variety of applications, such as in healthcare,
hospitality, and transportation. Examples include cleaning robots, delivery robots, and
surgical robots.
Military robots: These are used for tasks such as reconnaissance, surveillance,
and bomb disposal.
Exploration robots: These are used in space and underwater exploration to gather data and
perform tasks that would be difficult or dangerous for humans.

Page 7
[Introduction to Mechanical Engineering] MODULE 5
Basic term related to Industrial Robot
Manipulator: A manipulator is a robotic arm that consists of a series of joints and links
that allow it to move and position objects.
Joint: A joint is a connection between two or more links that allows motion in one
or more degrees of freedom. Examples include rotational joints, linear joints, and
orthogonal joints.
Link: A link is a rigid component of a manipulator that connects two joints. Links can
have different shapes and sizes depending on the requirements of the application.
Degrees of freedom (D.O.F): The degrees of freedom of a robotic manipulator
refers to the number of independent motions that it can perform. Each joint in a
manipulator typically provides one degree of freedom. The total number of degrees of
freedom in a manipulator determines its range of motion and flexibility.

End effector: The end effector is the tool or device that is attached to the end of the
robotic arm and is used to interact with objects. Examples include grippers, welding
torches, and sensors.
Base: The base of a robotic manipulator is the fixed point from which the arm operates.
It provides a stable foundation for the arm and often includes motors and sensors that
control its motion.

Elements of a Robotic System

• The Robot - manipulator, end effector, actuators, transmission elements
• Control system – mechanical controls, hydraulic control, electrical controls, sensors
• Computer system – use to program the robots to perform required tasks
• Power source – to supply electrical energy

Page 8
[Introduction to Mechanical Engineering] MODULE 5
1. Robot Manipulator: This refers to the robotic arm that carries out various tasks. It
consists of multiple joints connected by links, and each joint can move in a specific
direction to provide a range of motion.
2. End Effector: This refers to the tool or device attached to the end of the robot
manipulator that is used to perform specific tasks, such as a gripper, welding torch, or
cutting tool.
3. Actuators: These are the components that generate motion in the robot. They can be
electric, hydraulic, or pneumatic, and they convert energy into motion to move the robot's
joints and end effector.
4. Transmission Elements: These are the mechanical components that transmit motion
from the actuators to the robot's joints and end effector. Examples include gears, belts, and
pulleys.
5. Control System: This refers to the system that controls the robot's motion and behavior.
It can be mechanical, hydraulic, or electrical, and it includes sensors, controllers, and
feedback mechanisms to ensure the robot moves accurately and safely.
6. Sensors: These are the components that detect and measure physical quantities such as
position, velocity, and force. They provide feedback to the control system to ensure the
robot moves accurately and safely.
7. Computer System: This is used to program the robot to perform specific tasks. It
includes software and hardware components, and it enables the robot to be programmed
for different applications.
8. Power Source: This is the energy source that powers the robot's motion and control
systems. It can be electrical, hydraulic, or pneumatic, depending on the robot's design and
application.

TYPES OF ROBOT JOINTS

• Rotational joint or the R-joint
• Linear joint or the L-joint
• Orthogonal joint or the O-joint
• Twisting joint or the T-joint
• Revolving joint or the V-joint

Page 9
[Introduction to Mechanical Engineering] MODULE 5

The five joints mentioned are types of robot joints that are commonly used in robotic systems.
Here is a brief description of each joint:
Rotational joint (R-joint): This joint allows rotation around an axis, such as a shoulder joint
in a human arm.
Linear joint (L-joint): This joint allows linear motion along a straight line, such as a
piston moving in a cylinder.
Orthogonal joint (O-joint): This joint allows rotation around two orthogonal axes,
such as a wrist joint in a human arm.
Twisting joint (T-joint): This joint allows twisting motion around an axis, such as a
screwdriver.
Revolving joint (V-joint): This joint allows rotation around a central axis, such as a
wheel rotating around its axle.
These joints are combined to create robotic arms and end effectors that can perform a wide
range of tasks. For example, a robotic arm might have several rotational joints and one linear
joint to enable it to reach and manipulate objects in three-dimensional space. The specific type
and number of joints used depend on the specific application and the required range of motion and
precision.

Page 10
[Introduction to Mechanical Engineering] MODULE 5

Classification Based On Robotics Configuration

• Polar Configuration (Spherical Configuration)
• Cylindrical Configuration
• Cartesian Co-ordinate Robot
• Jointed – arm Configuration

Polar Configuration (Spherical Configuration): A polar or spherical configuration has three

rotary joints that allow the end effector to move in a spherical coordinate system. This
configuration is useful for applications that require a high degree of accuracy and precision,
such as assembling electronic components.

A polar or spherical configuration is a type of robotic manipulator that has three rotary joints
that allow the end effector to move in a spherical coordinate system. This configuration is also
referred to as a spherical configuration. The three rotary joints are arranged in a radial pattern
around the base of the manipulator, with one joint providing rotation around the vertical axis,
another joint providing rotation around the horizontal axis, and a third joint providing rotation
around the end effector axis.

Page 11
[Introduction to Mechanical Engineering] MODULE 5

Cylindrical Configuration: A cylindrical configuration has one rotary joint and one linear joint
that allow the end effector to move in a cylindrical coordinate system. This configuration is
often used for applications such as arc welding or drilling.

A cylindrical configuration is a type of robotic manipulator that has one rotary joint and one
linear joint that allow the end effector to move in a cylindrical coordinate system. The rotary joint
provides rotation around the vertical axis, while the linear joint moves the end effector along a
straight line parallel to the vertical axis.

Cartesian Co-ordinate Robot: A Cartesian coordinate robot has three linear joints that move
the end effector along the X, Y, and Z axes. This configuration is useful for applications such
as pick-and-place operations in manufacturing.
A Cartesian coordinate robot, also known as a rectilinear or gantry robot, is a type of robotic
manipulator that has three linear joints that move the end effector along the X, Y, and Z axes of a
Cartesian coordinate system. The base of the manipulator typically has a fixed frame that supports
the linear joints and the end effector.

Page 12
[Introduction to Mechanical Engineering] MODULE 5

Jointed-arm Configuration: A jointed-arm configuration has several rotary joints that allow the
end effector to move in a wide range of directions. This configuration is often used for
applications such as welding or painting,pick and place robot.

A jointed-arm configuration, also known as an articulated robot, is a type of robotic

manipulator that consists of several rigid links connected by rotary or linear joints. This
configuration allows the robot to move its end effector in a wide range of motions and
orientations, making it well-suited for a variety of applications such as welding, painting, and
material handling.
ADVANTAGES OF ROBOTS
• Can work in hazardous work environment
• Can produce greater quantity in short span of time
• Provides consistency and repeatability with accuracy
• Can work at constant speeds without any break
• Can work in tight spaces
• Produces lesser or no defective parts and hence saves times of rework and money to the
organisation.
• Can perform risky jobs and avoids accidents at workplace.
DISADVANTAGES OF ROBOTS
• Organisations have to make huge investments
• Since parts of a robots are made very precisely, their replacements is very difficult and
to maintain, it costs huge amount of money
• it requires highly skilled technical engineers and programmers which again is a
significant cost for the organizations
• Need good program capability and computers for performing a given task
Page 13
[Introduction to Mechanical Engineering] MODULE 5
Cannot recharge themselves, and hence need energy/ command from outide

Industrial robots have a wide range of applications

1. Manufacturing: Industrial robots are widely used in manufacturing processes, including

welding, painting, material handling, and assembly. They can perform repetitive and
dangerous tasks with high accuracy and efficiency, leading to increased productivity and
reduced labor costs.
2. Packaging and Palletizing: Industrial robots can be used for packaging and palletizing
products in factories and warehouses. They can handle different types of products and
packaging materials, and can work at high speeds and with precision, leading to increased
throughput and efficiency.
3. Inspection and Testing: Industrial robots can be used for inspecting and testing products,
components, and materials during the manufacturing process. They can use sensors and
cameras to detect defects, measure dimensions, and perform quality checks, leading to
improved product quality and reduced waste.
4. Material Removal: Industrial robots can be used for cutting, grinding, and polishing
materials such as metals, plastics, and composites. They can work with high precision and
speed, leading to improved accuracy and reduced processing time.
5. Cleaning and Maintenance: Industrial robots can be used for cleaning and maintaining
equipment, machinery, and facilities in factories and warehouses. They can work in
hazardous or hard-to-reach areas, leading to improved safety and reduced downtime.
6. Food and Beverage Industry: Industrial robots are increasingly being used in the food
and beverage industry, for tasks such as sorting, packaging, and quality control. They can
work in sterile environments and handle delicate or perishable products, leading to
improved hygiene and reduced waste.

Page 14
[Introduction to Mechanical Engineering] MODULE 5

AUTOMATION
„Automation‟ – greek words
“Auto” means self
“Matos” means moving
Automation can be defined as
“the set of technologies of carrying out a process or procedure without human
assistance and achieves performance superior to manual operation”

TYPES OF AUTOMATION
1. Fixed Automation or Hard Automation
2. Programmable Automation or Soft Automation
3. Flexible Automation

The three main types of automation are fixed automation, programmable automation, and flexible
automation.
1. Fixed Automation or Hard Automation: Fixed automation, also known as hard automation,
is a type of automation that is designed to perform a specific task repeatedly. The equipment
used in fixed automation is usually specialized and dedicated to a particular function. It is not
easily adaptable to changes in product design or production volume. Examples of fixed
Page 15
[Introduction to Mechanical Engineering] MODULE 5
automation include assembly lines, conveyor belts, and specialized machinery used in
manufacturing processes.
2. Programmable Automation or Soft Automation: Programmable automation, also known as
soft automation, is a type of automation that uses computer-controlled equipment to perform
a variety of tasks. This type of automation is more flexible than fixed automation, as the
equipment can be reprogrammed to perform different tasks. Examples of programmable
automation include computer numerical control (CNC) machines, robots, and automated guided
vehicles (AGVs).
3. Flexible Automation: Flexible automation is a type of automation that combines the best
features of fixed and programmable automation. It is designed to be highly adaptable to changes
in product design and production volume, while still maintaining a high level of efficiency.
Flexible automation systems typically use computer-controlled equipment that can be
reconfigured quickly and easily. Examples of flexible automation include automated
manufacturing cells and flexible manufacturing systems (FMS).

Basic Elements of Automated system

The basic elements of an automated system typically include:

1. Sensors: Sensors are devices that detect physical or environmental changes, such as
temperature, pressure, motion, or light. They provide input data to the control system,
which uses this information to make decisions.
2. Actuators: Actuators are devices that convert the output signals from the control system
into physical actions, such as movement, heat, light, or sound. They are used to control the
physical processes in the system.

Page 16
[Introduction to Mechanical Engineering] MODULE 5
3. Control system: The control system is the "brain" of the automated system, which
receives input data from sensors, processes it, and sends output signals to actuators. The
control system can be programmed to perform
specific tasks, based on the input data and predefined logic.
4. Human-Machine Interface (HMI): The HMI is the user interface of the automated
system, which allows humans to interact with the control system. It can be a simple
display or a more complex system that includes touchscreens, buttons, and other
input/output devices.
5. Communication network: The communication network is used to connect the
different elements of the automated system, such as sensors, actuators, and the control
system. It can be a wired or wireless network, depending on the requirements of the
system.
6. Power supply: The power supply is responsible for providing the necessary electrical
power to the sensors, actuators, and control system. It can be a local or remote power
source, depending on the location of the automated system.

ADVANTAGES OF DISADVANTAGES OF
AUTOMATION AUTOMATION
• Increase in productivity • High initial cost
• Improvement in Product Quality • Additional cost
• Increase in accuracy and repeatability • Security threats
• Improved safety at workplace • Human dependency on machines
• Reduction in manufacturing lead time • Results in increased Unemployment
• Reduced direct human labour cost
and expenses
• Mitigation of Potential Labour
Shortages

Page 17
[Introduction to Mechanical Engineering] MODULE 5

Question Bank

1. With Suitable Example explain the concept of open and Closed loop System

2. What are robots? Explain Cartesian coordinates used for robots

3. Explain Fixed, programmable and flexible automation

4. Illustrate the working of an automated washing machine to demonstrate the

mechatronic system

5. What is open and Closed loop mechatronic systems System? Explain with example

6. Write a note on Characteristics, Physical design of IOT, List its application area

7. What are robots? Explain the application of robot in assembly and inspections

8. What is IOT? Explain how IOT improve Automation in industries?

9. Write a note on Characteristics, Physical design of IOT, List its application area

10. What are robots? Explain polar & cylindrical coordinates used for robots

11. Explain Future of Smart manufacturing

12. Explain Fixed, programmable and flexible automation

13. Explain scope and Future of IOT

Page 18
[Introduction to Mechanical Engineering] MODULE 5
14. What is IoT? Explain The physical design of an IoT

15. Explain Logical design of IoT with block diagram

16. What is IOT? Communication Models Used In Iot Systems

17. With Suitable Example explain the concept of Open and Closed loop System

18. Write a note on Fixed, programmable and flexible automation

19. What is Smart Manufacturing? Discuss the role of IoT in smart manufacturing

Page 19