Mectatronics & Iot Notes 2024
Mectatronics & Iot Notes 2024
COURSE OBJECTIVES
1 To make students get acquainted with the sensors and the actuators, which are commonly used in
mechatronics systems.
2 To provide insight into the signal conditioning circuits, and also to develop competency in PLC
programming and control
3 To make students familiarize with the fundamentals of IoT and Embedded systems.
4 To impart knowledge about the Arduino and the Raspberry Pi.
5 To inculcate skills in the design and development of mechatronics and IoT based systems.
UNIT – IV CONTROLLERS
Foundation topics: Programming Languages: C++ and Python - The Linux Operating System. Arduino: The
Arduino Boards - Arduino Peripherals- Arduino IDE – ESP8266 Wi-Fi module. Raspberry Pi: The
Raspberry
Pi Boards - The Raspberry Pi Peripherals - The Raspberry Pi Operating System. (typical peripherals)
Interfacing and Controlling I/O devices by Arduino and Raspberry Pi: LEDs - Push buttons - Light intensity
sensor - Ultrasonic distance sensor – Temperature sensor- Humidity sensor - Sensor and Actuator
interactions
Key Objectives:
1. Integration: Combine multiple disciplines to create innovative
solutions.
2. Automation: Develop smart systems that can interact with
their environment.
3. Optimization: Improve performance, efficiency, and reliability.
Mechatronics Components:
1. Sensors (input): Detect changes in the environment (temperature, pressure, motion).
2. Actuators (output): Convert energy into motion or action (motors, pumps, valves).
3. Controllers (processing): Interpret sensor data, make decisions, and control actuators (microcontrollers, PLCs).
4. Software (algorithmic): Program controllers to perform specific tasks.
Mechatronics Applications:
1. Robotics
2. Automotive Systems (ABS, traction control)
3. Industrial Automation (CNC machines, process control)
4. Medical Devices (insulin pumps, prosthetics)
5. Aerospace Engineering (flight control systems)
6. Consumer Electronics (smart home devices, wearable tech)
7. Internet of Things (IoT)
Mechatronics Design Process:
1. System definition
2. Requirements analysis
3. Component selection
4. System design
5. Simulation and modeling
6. Prototyping
7. Testing and validation
Benefits: Future Trends:
1. Improved performance 1. Artificial Intelligence (AI) integration
2. Increased efficiency 2. Internet of Things (IoT) expansion
3. Enhanced reliability 3. Autonomous Systems
4. Reduced cost 4. Human-Machine Interfaces (HMIs)
5. Increased functionality 5. Cyber-Physical Systems
Challenges: Required:
1. Interdisciplinary collaboration 1. Programming languages (C, C++, Python)
2. System complexity 2. Microcontrollers and embedded systems
3. Integration and compatibility 3. Electronics and circuit design
4. Real-time control and response 4. Mechanical design and analysis
5. Safety and security concerns 5. Software development and integration
6. Data analysis and interpretation
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
These characteristics describe the sensor's behavior under steady-state conditions, i.e., when the input is
constant.
1. Accuracy: The difference between the measured value and the true value.
2. Precision: The repeatability of the measurement.
3. Sensitivity: The ratio of the change in output to the change in input.
4. Range: The maximum and minimum values that can be measured.
5. Resolution: The smallest change in input that can be detected.
6. Linearity: The degree to which the output is directly proportional to the input.
7. Offset: The difference between the measured value and the true value at zero input.
8. Calibration: The process of adjusting the sensor to match a known standard.
Dynamic Characteristics:
These characteristics describe the sensor's behavior under changing conditions, i.e., when the input is
varying.
1. Response Time: The time taken for the sensor to respond to a change in input.
2. Rise Time: The time taken for the sensor to rise from 10% to 90% of its final value.
3. Settling Time: The time taken for the sensor to settle within a certain percentage of its final value.
4. Bandwidth: The range of frequencies over which the sensor can accurately measure.
5. Frequency Response: The sensor's ability to measure changes at different frequencies.
6. Overshoot: The magnitude of the sensor's response beyond its final value.
7. Damping: The rate at which the sensor's oscillations decay.
8. Noise: Random fluctuations in the sensor's output.
Understanding these characteristics is crucial when selecting and designing sensors for various
applications, such as industrial automation, robotics, medical devices, and more
Resistive Sensors
1. Measure changes in resistance
2. Types:
- Strain gauges (force, pressure, displacement)
- Thermistors (temperature)
- Potentiometers (position, rotation)
- Photoresistors (light)
3. Working principle: Changes in resistance due to physical or environmental parameters
4. Applications:
- Industrial automation
- Medical devices
- Automotive systems
- Consumer electronics
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Capacitive Sensors
Inductive Sensors
1. Measure changes in capacitance 1. Measure changes in inductance
2. Types: 2. Types:
- Proximity sensors (distance, presence) - Proximity sensors (distance, presence)
- Capacitive touch sensors (human interface) - Position sensors (linear, rotary)
- Humidity sensors - Current sensors
- Level sensors (liquid, solid) - Metal detectors
3. Working principle: Changes in capacitance due 3. Working principle: Changes in inductance due
to changes in distance or dielectric material to changes in magnetic field
4. Applications: 4. Applications:
- Touchscreens - Industrial automation
- Industrial automation - Automotive systems
- Medical devices - Medical devices
- Consumer electronics - Security systems
Resonant Sensors
Optical Sensors
1. Measure changes in resonant frequency
2. Types: 1. Measure changes in light properties
- Quartz crystal oscillators (temperature, 2. Types:
pressure) - Photodiodes (light intensity)
- Surface acoustic wave (SAW) sensors - Phototransistors (light detection)
(temperature, humidity) - Optical fibers (temperature, pressure)
- Film bulk acoustic resonator (FBAR) sensors - Camera systems (image recognition)
3. Working principle: Changes in resonant 3. Working principle: Changes in light
frequency due to physical or environmental absorption, reflection, or transmission
parameters 4. Applications:
4. Applications: - Industrial automation
- Industrial automation - Medical devices
- Medical devices - Security systems
- Aerospace engineering - Consumer electronics
- Research and development
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JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Stepper motors ?
Stepper motors convert electricity into rotation. Not only does a stepper motor convert electrical power
into rotation, but it can be very accurately controlled in terms of how far it will rotate and how fast.
Stepper motors are so named because each pulse of electricity turns the motor one step
The implementation of the design of stepper motors can be divided into three versions: variable
reluctance (VR) stepper motors, permanent magnet (PM) stepper motors and hybrid stepper
motors. These types are different in some performance characteristics. For example, VR stepper
motor can’t provide any holding torque because doesn’t have magnets in the design. VR stepper
motors provide more noise during operation. But these motors has better torque at higher
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
speeds compared to PM stepper motors. Hybrid stepper motors combine the characteristics of VR
and PM motors and are currently the most used.
When one of the windings excited, the nearest teeth of the rotor moves to align according
to the magnetic pole of the stator. In the picture below the rotor rotates counterclockwise
30° when the winding B is energized. The rotation stops at the moment the rotor takes
steady state position – aligned the magnetic pole.
Thus, when the current is turned on in one of the windings, the rotor tends to take a
position where the magnetic flux is closed, i.e. the rotor teeth will be opposite those poles
on which the powered winding is located. If then turn off this winding and turn on the next
one (as in the picture below – phase C is energized), the rotor will change position, again
closing the magnetic flux with its teeth.
In order to carry out continuous rotation, it is enough to turn on the windings alternately.
The motor is not sensitive to the direction of current in the windings. A real motor may
have more stator poles and more rotor teeth, corresponding to more steps per revolution.
Sometimes the surface of each stator pole is geared, which, together with the
corresponding rotor teeth, provides a very small pitch angle (about several degrees).
Variable reluctance motors are rarely used in industrial applications.
The motor shown in the figure below has 3 pairs of rotor poles and 2 pairs of stator poles. The
motor has 2 independent windings, each of which is wound on two opposite poles of the stator.
Such a motor, like the previously discussed VR stepper motor, has a step size of 30 degrees.
When the current is turned on in one of the windings, the rotor tends to take a position where
the opposite poles of the rotor and stator are opposite each other. To carry out continuous
rotation, it is needed to turn on the phases alternately.
In practice, PM stepper motors typically have 48 – 24 steps per revolution (step angle 7.5 – 15
degrees).
The rotor of a hybrid stepper motor has teeth located in the axial direction.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
The rotor is divided into two parts, between The stator of a hybrid motor also has teeth,
which there is a cylindrical permanent providing a large number of equivalent poles
magnet. Thus, the teeth of the upper half of as opposed to the main poles on which the
the rotor are the north poles, and the teeth windings are located. Typically 4 main poles
of the lower half are the south poles. In are used for 3.6 deg. motors and 8 main
addition, the upper and lower halves of the poles for 1.8 and 0.9 deg motors. Rotor teeth
rotor are rotated relative to each other by provide less resistance to the magnetic
half the pitch angle of the teeth. The number circuit at certain rotor positions, which
of pairs of rotor poles is equal to the number improves static and dynamic torque. This is
of teeth on one of its halves. The toothed ensured by the appropriate arrangement of
rotor pole pieces, like the stator, are the teeth, when part of the rotor teeth is
assembled from separate plates to reduce strictly opposite the stator teeth, and part is
eddy current losses. between them. The relationship between the
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
number of rotor poles, the number of the same plane. In a hybrid motor, this flux
equivalent stator poles and the number of is partially closed by the rotor pole pieces,
phases determines the pitch angle S of the and the permanent magnet «sees» it weakly.
motor: Therefore, unlike DC motors, the magnet of a
hybrid motor cannot be demagnetized at any
S = 360 / (Nph ∙ Ph) = 360 / N,
winding current level.
Nph – number of equivalent poles per phase
= number of rotor poles, The gap between the rotor and stator teeth
Ph – number of phases, is very small - typically 0.1 mm. This
N – total number of poles for all phases requires high precision during assembly, so it
together. is not recommended to disassemble a
stepper motor, otherwise its service life may
end.
The rotor of the motor shown in the figure
above has 100 poles (50 pairs), the motor To prevent the magnetic flux from closing
has 2 phases, so the total number of poles is through the shaft that passes inside the
200, and the pitch, accordingly, is 1.8 magnet, it is made of non-magnetic steel
degrees. grades.
The longitudinal section of the hybrid stepper To obtain large torques, it is necessary to
motor is shown in the figure below. The increase both the field created by the stator
arrows indicate the direction of the magnetic and the field of the permanent magnet. This
flux of the permanent magnet of the rotor. requires a larger rotor diameter, which
Part of the flux (shown in the figure as a worsens the torque to inertia ratio.
black line) passes through the rotor pole Therefore, powerful stepper motors are
pieces, air gaps and the stator pole piece. sometimes constructed from several sections
This part is not involved in generating in the form of a stack. This allows torque and
torque. moment of inertia to increase proportionally
to the number of sections, and their ratio
The air gaps at the upper and lower pole
does not worsen.
pieces of the rotor are different. This is
achieved by turning the pole pieces by half Most modern stepper motors are hybrid.
the tooth pitch. Therefore, there is another Essentially, a hybrid motor is a permanent
magnetic circuit that contains minimal air magnet motor, but with a larger number of
gaps and, as a result, has minimal magnetic poles. In terms of the control method, such
resistance. This circuit closes another part of motors are identical. Most often in practice,
the flux (shown in the figure with a dashed motors have 100, 200 or 400 steps per
white line), which generates torque. Part of revolution, respectively, the step is 3.6°,
the circuit lies in a plane perpendicular to the 1.8° or 0.9°. Most controllers allow half-
figure and is therefore not shown. The stepping or microstepping, where this angle
magnetic flux of the stator coil is created in is less.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
AC vs DC Motor Comparisons?
Electric motors drive industrial machinery and an array of devices throughout the world. The two main
sources of power, alternating current (AC) and direct current (DC), are complemented by two types of
electric motors that differ in operation and application. Engineers, technicians, and operators must
understand the key differences between AC and DC motors to achieve optimum performance of an
electrical machine or device.
The DC Motor
DC or Direct Current motors operate on power where the current flows in one direction such as the
power generated from batteries or AC power sources that are rectified to direct current. The two major
categories of DC motors are brushed and brushless; for more information on the specifics of brushed and
brushless motors, visit here: What is the difference between a brushed and brushless motor?
Both types of DC motors can be matched with integral gearboxes and other accessories (such as fans) for
air cooling and with additional feedback devices to improve precision. DC motors are used in a wide range
of applications that include electric wheelchairs, handheld sprayers and pumps, coffee machines, off-road
equipment amongst others.
Brushed DC Micro Motor
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Brushed DC Motor
The AC Motor
AC motors are powered by single or three phase alternating currents. The electromagnetic field in the
stator reacts with the rotor and causes the motor to rotate at a synchronous speed to match the frequency
of the AC current. AC motors are efficient, durable, quiet, and flexible, which makes them a viable solution
for many power generation needs.
AC motors are used in a number of applications that include food service, pumps, water heaters, lawn and
garden equipment, and others.
AC Synchronous Motor
AC vs DC Motor Comparisons
Speed Control:
Speed can be controlled in both types of motor. AC motor velocity is controlled by the frequency of the
power source. AC motors run directly off the power source and in most countries would be designed to
produce a rated speed based on an input frequency of 60 Hz. However, to vary the frequency to the
motor, many applications utilize specialized electronics (Variable Frequency Drives) to provide adjustable
speed control. DC motor speeds can be simply controlled by varying the available DC voltage to the
motor. Many control solutions exist to provide precision speed control for applications such as robotics.
Efficiency:
Three phase induction motors tend to offer improved efficiencies at higher power levels and rated
speeds. Brushless DC motors offer better efficiencies across a broader range of performance and provide
better performance at lower speeds and lighter loads. Brushed DC motors, however, have added
components (brushes and commutator) that introduce some inefficiencies.
Maintenance:
AC motors and Brushless DC motors are preferred in most manufacturing settings since these motors
require less maintenance and have longer life spans in comparison to brush DC motors, which need to be
serviced more often to replace brushes or to refurbish commutator surfaces.
Cost:
AC motors are often the most cost-effective solution for large power applications and applications with
constant speed and load requirements. Higher precision and increased load variations introduce more
sophisticated control requirements. While brushless DC motors with higher efficiencies and additional
control complexities may have higher initial costs, their lifetime costs are comparable to AC motors.
Starting Torque:
Induction motors have minimal starting torque compared with DC Motors that can be overcome with
starting devices. DC motors offer higher starting torques that translate to quick accelerations. Many
applications that require fast indexing and quick move and settle times require high acceleration
capabilities.
Applications:
AC motors make up a large volume of electric motors sold worldwide and are used in many applications
such as household appliances, pumps, fans, HVAC systems, and other industrial machinery. DC motors are
popular for mobile applications in electric vehicles, automated guided vehicles, and submersible ROV’s.
They are also found in robotics, conveyor systems, packaging machinery, and many types of precision
equipment.
In recent years, advancements in motor technology have led to more efficient and versatile options for
both AC and DC motors that sometimes blur the lines between their traditional differences. Continued
development in smaller and more economical electronics improves the ability to control most motors
more precisely. While the original DC and AC motors were developed in the 19th century, advances in
both magnet technologies and other material and fabrication processes have pushed both motor types to
new performance capabilities.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
UNIT – II
SIGNAL CONDITIONING CIRCUITS AND PLC
Operational Amplifiers – Inverting and Non-Inverting Amplifier – Wheatstone bridge Amplifier –
Instrumentation Amplifier – PID Controller, Protection Circuits, Filtering Circuits, Multiplexer, Data
Logger and
Data Acquisition System –, Switching Loads by Power Semiconductor Devices Circuits – Thyristors –
TRIAC
– Darlington Pair –MOSFET and Relays.
PLC – Architecture – Input / Output Processing – Logic Ladder Programming – Functional Block
Programming
using Timers and Counters – Applications.
An operational amplifier is an integrated circuit that can amplify weak electric signals.
An operational amplifier has two input pins and one output pin. Its basic role is to amplify and output the
voltage difference between the two input pins.
When an operational amplifier is combined with an amplification circuit, it can amplify weak signals to strong
[Link] behaves like a megaphone where the input signal is a person's voice and the megaphone is the
operational amplifier [Link] example, such a circuit can be used to amplify minute sensor signals.
Processing of sensor signals can be further improved by inputting the amplified signal to a
microcontroller* unit (MCU).
* Microcontroller... A compact computer for controlling electronic devices. As the brain of electronic
devices, MCUs operate according to input signals.
By operating as a filter of input signals, the operational amplifier circuit is able to extract the signal with
the target [Link] example, when an operational amplifier circuit is used for voice recognition or in
a voice recorder, it can extract frequencies close to the targeted sound while shutting out all other
frequencies as noise.
An operational amplifier circuit can be tweaked to perform a broad range of functions such as arithmetical
operations or signal synthesis.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
When an operational amplifier is combined with an amplification circuit, it can amplify weak signals to
strong [Link] behaves like a megaphone where the input signal is a person's voice and the megaphone
is the operational amplifier [Link] example, such a circuit can be used to amplify minute sensor
signals.
Processing of sensor signals can be further improved by inputting the amplified signal to a
microcontroller* unit (MCU).
* Microcontroller... A compact computer for controlling electronic devices. As the brain of electronic
devices, MCUs operate according to input signals.
By operating as a filter of input signals, the operational amplifier circuit is able to extract the signal with
the target [Link] example, when an operational amplifier circuit is used for voice recognition or in
a voice recorder, it can extract frequencies close to the targeted sound while shutting out all other
frequencies as noise.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
An operational
amplifier circuit can be tweaked to perform a broad range of functions such as arithmetical operations or
signal synthesis.
Inverting and non-inverting amplifiers are two fundamental configurations of operational amplifiers (op-
amps). Understanding the differences between them is crucial for designing and implementing various
electronic circuits.
Inverting Amplifier:
In an inverting amplifier, the input signal is applied to the inverting input (pin 2) of the op-amp through a
resistor (R1), and the non-inverting input (pin 3) is connected to ground.
Key Characteristics:
- The output is inverted (180° phase shift) relative to the input.
- The input impedance is low, making it suitable for high-impedance sources.
- Gain is determined by the ratio of feedback resistor (Rf) to input resistor (R1): -Rf/R1.
Non-Inverting Amplifier:
In a non-inverting amplifier, the input signal is applied to the non-inverting input (pin 3) of the op-amp,
and the inverting input (pin 2) is connected to ground through a resistor (R1).
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Key Characteristics:
- The output is in phase with the input.
- The input impedance is high, making it suitable for low-impedance sources.
- Gain is determined by the ratio of (Rf + R1) to R1.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Amplifier Configuration:
To amplify the output of the Wheatstone bridge, an operational amplifier (op-amp) is connected as a
differential amplifier.
Vout = (R3/R2) * (V2 - V1)
Instrumentation Amplifier?
An instrumentation amplifier (IA) is a type of differential amplifier that has been specifically designed for
use in measurement and instrumentation applications. It's commonly used to amplify low-level signals
from sensors, transducers, and other devices.
An instrumentation amplifier (INA) is a very special type of differential input amplifier; its primary focus
is to provide differential gain and high common-mode rejection. INAs offer high input impedance and low
output impedance; newer devices will also offer low offset and low noise.
Key Characteristics:
1. High Input Impedance: This prevents loading of the signal source.
2. Low Noise: To maintain signal fidelity.
3. High Gain Accuracy: To ensure precise amplification.
4. High Common Mode Rejection Ratio (CMRR): To reject unwanted signals.
Basic Structure:
The instrumentation amplifier typically consists of three operational amplifiers (op-amps) and several
resistors.
How It Works:
1. The input stage consists of two op-amps that buffer the input signals.
2. The buffered signals are then fed into a differential amplifier stage.
3. The gain of the instrumentation amplifier is set by a single resistor (Rg).
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Advantages:
1. High accuracy
2. Low noise
3. High input impedance
4. High CMRR
Applications:
1. Medical devices (ECG, EEG)
2. Industrial automation
3. Data acquisition systems
4. Audio equipment
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PID Components:
1. Proportional (P): Scales the output value PID Controller Equation:
proportional to the error (difference between
setpoint and PV). u(t) = Kp * e(t) + Ki * ∫e(t)dt + Kd * de(t)/dt
2. Integral (I): Adjusts the output value based on
the accumulation of past errors (summation of Where:
error over time). u(t) = output value
3. Derivative (D): Adjusts the output value based Kp = proportional gain
on the rate of change of the error. Ki = integral gain
Kd = derivative gain
e(t) = error (setpoint - PV)
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Applications:
1. Temperature control
PID Tuning: 2. Speed control (motors)
Adjusting the PID gains (Kp, Ki, Kd) to achieve 3. Position control (servos)
optimal performance: 4. Process control (chemical, manufacturing)
1. Stability 5. Robotics
2. Response time 6. Automotive systems
3. Overshoot minimization
Advantages:
Types of PID Controllers: 1. Improved stability
1. Ideal PID 2. Enhanced accuracy
2. Series PID 3. Faster response times
3. Parallel PID 4. Reduced oscillations
4. Digital PID
Challenges:
1. PID tuning complexity
2. System modeling requirements
3. Noise sensitivity
1. Protection Circuits:
These circuits safeguard electronic devices from damage caused by:
* Overvoltage
* Overcurrent
* Short circuits
* Electrical surges
* Power spikes
Examples: Surge protectors, fuse circuits, crowbar circuits.
2. Filtering Circuits:
These circuits remove unwanted signals or noise from a desired signal:
* Low-pass filters (LPF)
* High-pass filters (HPF)
* Band-pass filters (BPF)
* Band-stop filters (BSF)
* Notch filters
Applications: Audio processing, image processing, power supplies.
3. Multiplexer (MUX):
A multiplexer is a digital circuit that:
* Selects one of multiple input signals
* Routes the selected signal to a single output
* Allows multiple devices to share a common bus
Types:
* Analog multiplexers
* Digital multiplexers
* Time-division multiplexers
Applications: Communication systems, data acquisition, instrumentation.
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
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JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
A Data Logger:
A data logger is an electronic device that records and stores data over time, often used for monitoring and
analyzing physical parameters.
Applications:
1. Industrial monitoring (e.g., temperature,
Types of Data Loggers: pressure)
1. Temperature Data Loggers 2. Environmental monitoring (e.g., weather
2. Humidity Data Loggers stations)
3. Pressure Data Loggers 3. Medical research (e.g., patient monitoring)
4. Voltage/Current Data Loggers 4. Transportation (e.g., vehicle tracking)
5. GPS Data Loggers 5. Scientific research (e.g., data collection in field
6. Acceleration Data Loggers studies)
7. Environmental Data Loggers (e.g., air quality, 6. Quality control (e.g., manufacturing process
noise) monitoring)
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JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
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JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
A Thyristor TRIAC
A TRIAC (Triode for Alternating Current) is a type of thyristor, a semiconductor device that controls
electrical current flow.
Limitations:
1. Limited switching frequency.
2. Voltage and current limitations.
3. Heat dissipation
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JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
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JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
- OR
PLC – Architecture – Input / Output - NOT
Processing – Logic Ladder Programming – - TIMERS
- COUNTERS
Functional Block Programming
4. Instruction set:
- Coil (output)
What is a Programmable Logic - Contact (input)
Controller (PLC) - Branch
A programmable Logic Controller(PLC) is a - Jump
specialized digital computer employed in
industrial settings for automation and control. Functional Block Programming:
Acting as the central brain of machinery and 1. Function Blocks (FBs)
processes, PLCs receive input from sensors, 2. Graphical programming
process the data through programmed logic, and 3. Blocks:
generate output signals to control devices like - Logic gates
motors and valves. They use a programming - Timers
language, often ladder logic, resembling - Counters
electrical relay diagrams. PLCs are ruggedized for - Math functions
harsh industrial environments and play a crucial - Analog functions
role in automating tasks and reducing 4. Data flow programming
manufacturing and energy. Their modular design
allows scalability, making them versatile
components in modern industrial control systems.
PLC Programming Languages:
1. Ladder Diagram (LD)
2. Function Block Diagram (FBD)
PLC Architecture:
3. Structured Text (ST)
1. Central Processing Unit (CPU)
4. Sequential Function Chart (SFC)
2. Memory (RAM, ROM, EEPROM)
5. Instruction List (IL)
3. Input/Output (I/O) Modules
4. Power Supply
PLC Manufacturers:
5. Communication Modules (optional)
1. Allen-Bradley (Rockwell Automation)
2. Siemens
Input/Output Processing:
3. Mitsubishi Electric
1. Inputs:
4. Schneider Electric
- Sensors (e.g., temperature, pressure)
5. Omron
- Switches (e.g., limit switches, push buttons)
- Analog inputs (e.g., 4-20mA, 0-10V)
Applications:
2. Outputs:
1. Industrial automation
- Actuators (e.g., motors, valves)
2. Process control
- Indicators (e.g., LEDs, displays)
3. Manufacturing
- Analog outputs (e.g., 4-20mA, 0-10V)
4. Power distribution
3. I/O Processing:
5. Building automation
- Reading inputs
- Executing logic
Benefits:
- Writing outputs
1. Increased productivity
2. Improved accuracy
Logic Ladder Programming:
3. Reduced downtime
1. Ladder Diagram (LD) programming
4. Enhanced safety
2. Rung-based programming
5. Flexibility and scalability
3. Logic functions:
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- AND
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
PLC architecture
It consists of a central processing unit (CPU) containing the system microprocessor, memory, and
input/output circuitry. The CPU controls and processes all the operations within the [Link] is supplied
with a clock that has a frequency of typically between 1 and 8 MHz.
Step 2: Choose IoT Devices and Sensors Components of a Single-Chip Embedded System
1. Select suitable devices (microcontrollers, 1. Microcontroller (MCU)
sensors, actuators) 2. Memory (RAM, ROM, Flash)
2. Consider factors: cost, power consumption, 3. Input/Output (I/O) peripherals
scalability 4. Analog-to-Digital Converter (ADC)
3. Ensure device compatibility and interoperability 5. Digital-to-Analog Converter (DAC)
6. Timers and Counters
Step 3: Design and Develop IoT Network
1. Plan network architecture and topology Types of Single-Chip Embedded Systems
2. Configure device connections and data 1. 8-bit Microcontrollers (e.g., Arduino)
transmission 2. 16-bit Microcontrollers (e.g., PIC24)
3. Ensure network security and authentication 3. 32-bit Microcontrollers (e.g., ARM Cortex-M)
4. System-on-Chip (SoC) devices
Step 4: Implement Data Analytics and 5. Field-Programmable Gate Arrays (FPGAs)
Processing
1. Choose data analytics platform and tools Applications of Embedded Systems
2. Develop data processing and visualization 1. Industrial Automation
algorithms 2. Medical Devices
3. Ensure data security and storage 3. Consumer Electronics
4. Automotive Systems
Step 5: Ensure Security and Authentication 5. IoT Devices
1. Implement encryption and secure data 6. Robotics and Control Systems
transmission 7. Smart Home Devices
2. Configure access control and authentication
3. Ensure device and network security Programming Languages for Embedded
Systems
Step 6: Integrate with Cloud or Edge Computing 1. C
1. Choose cloud platform (AWS, Azure, Google 2. C++
Cloud) 3. Assembly Language
2. Configure cloud connectivity and data storage 4. Python (for some microcontrollers)
3. Consider edge computing for real-time 5. Specialized languages (e.g., Verilog for FPGAs)
processing
Development Tools for Embedded Systems
Step 7: Test and Deploy IoT Solution 1. Integrated Development Environments (IDEs)
1. Conduct thorough testing and quality assurance 2. Compilers and Debuggers
2. Deploy IoT solution in controlled environment 3. Emulators and Simulators
3. Monitor and troubleshoot issues 4. Logic Analyzers and Oscilloscopes
5. Evaluation Boards and Development Kits
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Embedded Systems:
Definition: An embedded system is a
specialized computer system designed to
perform a specific task, often in real-time,
within a larger device or system.
Characteristics:
Real-time processing
Limited resources (memory, processing
power)
Specific functionality
Reliability and fault tolerance
Low power consumption
Small size
Types:
Microcontroller-based systems
System-on-Chip (SoC) systems
Field-Programmable Gate Array (FPGA)
systems
Digital Signal Processing (DSP) systems Development Tools:
Embedded Linux systems Compilers (GCC, Keil)
Debuggers (GDB, JTAG)
Components: Emulators (QEMU, Simulator)
Microcontroller (MCU) Integrated Development Environments
Memory (RAM, ROM, Flash) (IDEs) (Eclipse, Visual Studio)
Input/Output (I/O) peripherals Version Control Systems (Git, SVN)
Analog-to-Digital Converter (ADC)
Digital-to-Analog Converter (DAC)
Timers and Counters Challenges:
Communication Interfaces (UART, SPI, I2C) Resource constraints
Real-time requirements
Applications: Power consumption
Industrial Automation Reliability and fault tolerance
Medical Devices Security and data protection
Consumer Electronics
Automotive Systems
IoT Devices Trends:
Robotics and Control Systems IoT and connected devices
Smart Home Devices Artificial Intelligence (AI) and Machine
Learning (ML)
Programming Languages: Edge Computing and Real-Time Processing
C Security and Data Protection
C++ Energy Harvesting and Power Management
Assembly Language *************************************************
Python (for some microcontrollers)
Specialized languages (e.g., Verilog for
FPGAs)
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
UNIT – IV CONTROLLERS
Foundation topics: Programming Languages: C++ and Python - The Linux Operating System. Arduino:
The
Arduino Boards - Arduino Peripherals- Arduino IDE – ESP8266 Wi-Fi module. Raspberry Pi: The
Raspberry
Pi Boards - The Raspberry Pi Peripherals - The Raspberry Pi Operating System. (typical peripherals)
Interfacing and Controlling I/O devices by Arduino and Raspberry Pi: LEDs - Push buttons - Light
intensity
sensor - Ultrasonic distance sensor – Temperature sensor- Humidity sensor - Sensor and Actuator
interactions
: Arduino:
Arduino IDE
1. The Arduino Boards
2. Arduino Peripherals 1. Features:
- Code editor
3. Arduino IDE
- Compiler *Uploader
Arduino Boards - Serial monitor
- Debugger
1. Arduino Uno (most popular)
2. Arduino Mega 2. Supported operating systems:
3. Arduino Nano - Windows
- macOS
4. Arduino Micro
5. Arduino Due - Linux
3. Programming languages:
6. Arduino Leonardo
7. Arduino ESP32/ESP8266 (Wi-Fi enabled) - C++
8. Arduino Industrial 101 -C
- Arduino-specific syntax
9. Arduino MKR1000
10. Arduino Zero
.
Arduino Programming Concepts
Arduino Peripherals
1. Sensors:
1. Variables (int, float, char, etc.)
- Ultrasonic
- Infrared 2. Data types (arrays, structs, etc.)
- Temperature 3. Control structures (if/else, for, while, etc.)
4. Functions (custom reusable code)
- Humidity
- Light 5. Interrupts (event-driven programming)
6. Analog and digital input/output
- Sound
2. Actuators:
- LEDs Arduino Applications
- Motors (DC, Stepper, Servo)
- Relays 1. Robotics
- Solenoids 2. Home automation
3. IoT projects
3. Displays:
- LCD 4. Wearable technology
5. Art and design installations
- OLED
- LED Matrix 6. Educational projects
4. Communication: 7. Environmental monitoring
8. Medical devices
- Wi-Fi modules (ESP8266/ESP32)
- Bluetooth modules Vices
- RFID readers
5. Power:
- Batteries
- Power adapters
- Solar panels
*************************************************
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Raspberry Pi
Interfacing and Controlling I/O devices
LEDs
People use the Raspberry Pi all across the
1. Arduino:
world to learn programming, develop hardware
- DigitalWrite() function
projects, automate their homes, implement
- AnalogWrite() function (PWM)
Kubernetes clusters and Edge computing, and
2. Raspberry Pi:
even employ them in industrial applications.
- GPIO library (Python)
1. Pi Boards
- WiringPi library (C++)
a. The Raspberry Pi Peripherals
b. The Raspberry Pi Operating System.
Push Buttons
(typical peripherals)
1. Arduino:
2. Interfacing and Controlling I/O devices by
- DigitalRead() function
Arduino
- Interrupts
3. and Raspberry Pi: LEDs –
2. Raspberry Pi:
4. Push buttons –
- GPIO library (Python)
5. Light intensity
- WiringPi library (C++)
Raspberry Pi Boards
Light Intensity
1. Raspberry Pi 4 Model B
1. Arduino:
2. Raspberry Pi 3 Model B+
- AnalogRead() function
3. Raspberry Pi 2 Model B
- Light-dependent resistor (LDR)
4. Raspberry Pi Zero W
2. Raspberry Pi:
5. Raspberry Pi Zero
- ADC (Analog-to-Digital Converter)
- I2C interface
Raspberry Pi Peripherals
1. Displays:
Other I/O Devices
- HDMI monitors
1. Motors (DC, Stepper, Servo)
- Touchscreens
2. Relays
- LCD displays
3. Sensors (temperature, humidity, ultrasonic)
2. Cameras:
4. Displays (LCD, OLED)
- Raspberry Pi Camera Module
5. Keyboards and mice
- USB cameras
3. Audio:
Interfacing Examples
- HDMI audio
1. Arduino:
- USB speakers
- Blinking LED
- Audio jack
- Button-controlled LED
4. Networking:
- Light-intensity sensor
- Wi-Fi
2. Raspberry Pi:
- Ethernet
- LED control using Python
- Bluetooth
- Button-controlled LED using Python
5. Storage:
- Light-intensity sensor using Python
- MicroSD cards
- USB drives
Programming Languages
1. Arduino: C++, Arduino-specific syntax
Raspberry Pi Operating System
2. Raspberry Pi: Python, C++, Java
1. Raspbian (official OS)
2. Ubuntu MATE
Resources
3. Linux Mint
1. Official Raspberry Pi website
4. Kodi
2. Arduino website
5. Windows 10 IoT
3. Raspberry Pi forums
4. Arduino forums
5. Online tutorials and courses
************************************************
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Sensors
1. Ultrasonic Distance Sensor Sensor and Actuator Interfaces
- Measures distance using high-frequency sound 1. Analog-to-Digital Converter (ADC)
waves 2. Digital-to-Analog Converter (DAC)
- Examples: HC-SR04, Ultrasonic Sensor Module 3. Pulse Width Modulation (PWM)
- Applications: Obstacle detection, distance 4. Inter-Integrated Circuit (I2C)
measurement, robotics 5. Serial Peripheral Interface (SPI)
2. Temperature Sensor 6. Universal Asynchronous Receiver-Transmitter
- Measures temperature using thermistors or (UART)
thermocouples
- Examples: DS18B20, TMP36, LM35 Programming Sensors and Actuators
- Applications: Environmental monitoring, 1. Arduino
temperature control, medical devices 2. Raspberry Pi
3. Humidity Sensor 3. Python
- Measures relative humidity using capacitive or 4. C++
resistive sensing 5. Java
- Examples: DHT11, DHT22, HIH6130
- Applications: Environmental monitoring, weather Applications
stations, agricultural automation 1. Robotics
2. Automation
Other Types of Sensors 3. IoT (Internet of Things)
1. Light Sensor (photodiode, phototransistor) 4. Environmental monitoring
2. Sound Sensor (microphone, sound level meter) 5. Medical devices
3. Pressure Sensor (barometer, pressure transducer) 6. Automotive systems
4. Accelerometer (measures acceleration, orientation) 7. Aerospace engineering
5. Gyroscope (measures angular velocity) 8. Consumer electronics
6. Magnetometer (measures magnetic field)
7. GPS (Global Positioning System)
8. Infrared Sensor (IR receiver, IR transmitter)
Actuators
1. LED (Light Emitting Diode)
- Outputs light, used for indication or illumination
- Examples: LED strip, LED module
- Applications: Lighting systems, indicator lights,
display panels
2. Motor (DC, Stepper, Servo)
- Outputs rotational motion or torque
- Examples: DC motor, Stepper motor, Servo motor
- Applications: Robotics, automation, CNC machines
3. Relay
- Outputs electrical signal to control devices __________________________________________________________
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
UNIT – V
MECHATRONICS AND IoT CASE STUDIES
Mechatronics Systems
Definition: Mechatronics is an interdisciplinary field Control Algorithms:
combining principles from mechanical, electrical, and 1. PID (Proportional-Integral-Derivative) Control:
software engineering to design, develop, and control Stabilize attitude and position
intelligent systems. 2. Model Predictive Control (MPC): Optimize trajectory
planning and control
Key Components: 3. Feedback Control: Respond to sensor data and adjust
1. Sensors (input devices) actuation
2. Actuators (output devices) 4. Machine Learning (ML) and Artificial Intelligence
3. Microcontrollers/Microprocessors (control units) (AI): Adaptive control and decision-making
4. Power Electronics (power management)
5. Software (programming and algorithms) Drone Control Components:
1. Flight Controllers (e.g., PX4, ArduPilot)
Types of Mechatronics Systems: 2. Motor Controllers (e.g., ESCs, Motor Drivers)
1. Robotics and Automation 3. Power Distribution Boards (PDBs)
2. Automotive Systems 4. Radio Transmitters and Receivers (e.g., FrSky,
3. Aerospace and Defense Spektrum)
4. Medical Devices and Healthcare 5. Sensors and Sensor Fusion Algorithms
5. Consumer Electronics and Appliances
6. Industrial Control Systems Drone Types and Applications:
7. Smart Buildings and Home Automation 1. Quadcopters: Aerial photography, surveillance, and
8. Wearable Technology and IoT Devices delivery
2. Hexacopters: Heavy-lift, industrial, and agricultural
Applications: applications
1. Industrial Automation 3. Fixed-Wing Drones: Long-range surveillance and
2. Robotics and Machine Learning mapping
3. Autonomous Vehicles 4. Rotary-Wing Drones: Search and rescue, medical
4. Medical Imaging and Diagnostics transport
5. Smart Homes and Buildings 5. Swarm Drones: Entertainment, research, and
6. Consumer Electronics (e.g., smartphones, laptops) environmental monitoring
7. Aerospace and Defense Systems
8. Energy and Power Systems
Control Systems:
1. Flight Control Computers (FCCs): Process sensor
data and control actuators
2. Autopilot Systems: Stabilize and navigate the drone
3. Remote Control Systems: Manual control via radio
frequency (RF) or Wi-Fi
4. Sensors: Accelerometers, Gyroscopes, GPS, ………………………………………………………………………………..
Barometers, and Cameras
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
Automotive Applications
1. Advanced Driver Assistance Systems (ADAS):
- Lane Departure Warning
- Adaptive Cruise Control
- Automatic Emergency Braking
2. Autonomous Vehicles:
- Level 3-5 Autonomy
- Sensor Fusion
- Motion Planning
3. Driver Monitoring:
- Facial Recognition
- Emotion Detection
- Attention Analysis
Key Components
1. Microcontrollers (MCUs)
2. Field-Programmable Gate Arrays (FPGAs)
3. Graphics Processing Units (GPUs)
4. Computer Vision Software
5. Machine Learning Frameworks
JAYAM COLLEGE OF ENGINEERING TECHNOLOGY, NALLANUR, DHARMAPURI,TAMIL NADU.
THANK YOU .