Unit VI

Mechatronics Systems in Automobile

 CONTENTS

• (Treatment with Block Diagram

Approach) Boat Autopilot
• High Speed tilting trains
• Automatic car parking systems
• Engine Management systems
• Antilock Brake systems (ABS)
• CNC Machines(Only Black Diagram and
explanation)
 Boat Autopilot
Autopilots are self-steering devices for power or
sailboats.
In early days, ships carry compasses to help navigate
when conditions required a reference aboard the ship to
provide orientation.
At night, or otherwise out of sight of familiar landmarks, a
compass provides vital information for the navigator.

They can hold your vessel on a pre-set compass

course (even the most basic pilots do this) and
sophisticated pilots that connect to GPS receivers or
gather data from your boat's instruments can handle a
lot more advanced tasks.
Compass

Control Error Transmitt Steering

Receiver
Unit amplifier er Gear
Course
set
control

Rudder
A classic example of a control system is the negative
feedback loop.

It's called a negative feedback loop because the result of

a certain action inhibits further performance of that
action.

All negative feedback loops require a receptor, a control

center and an effector.

In the example above, the receptor is the thermometer

that measures air temperature.

The control center is the processor inside the thermostat.

And the effector is the air conditioning unit.
As computers become smaller and more powerful, adaptive learning (or a
sort of artificial intelligence) is what drives today’s best autopilots to guide
boats more efficiently.
In rough conditions, a well-tuned autopilot will sense small changes in
heading before the captain does.
An autopilot comprises a computer chip, head display, drive unit, and
compass.
When the captain plots a waypoint on the display, the computer, and
compass signal the drive unit which powers the electric/hydraulic ram or
rudder.

On most recent boats,

the autopilot is
networking facility.
 Boat Autopilot takes the existing learning algorithm and watches
the performance of the boat over time and then optimizes the
performance.

The cockpit autopilots that have a separate control/display unit.

To get the most out of such units you need to integrate them with
a compatible GPS or chartplotter, and a wind instrument either
mounted at the masthead or at the stern of the boat. This gives
three main operating modes:~
Auto - the autopilot is locked onto a heading;
Track - the autopilot is locked onto a track between two
waypoints;
Wind Vane - the autopilot maintains a course relative to the
apparent wind. However, in practice if there's much of a swell
running, neither a masthead instrument nor a stern-mounted one
will give a particularly satisfactory result. The masthead unit will
suffer from the motion of the boat, and a stern-mounted unit will
be operating in a disturbed airflow. The resulting impulses have to
be damped and processed to obtain a useful signal.
All sorts of data display and functionality is now available on the
display unit - cross-track error, off-course alarm, waypoint
proximity alarm, windshift alarm and so on.
 High Speed tilting trains
A tilting train is a train that has a mechanism enabling
increased speed on regular rail tracks.
As a train (or other vehicle) rounds a curve at speed,
objects inside the train experience centrifugal force. This
can cause packages to slide about or seated passengers to
feel squashed by the outboard armrest, and
standing passengers to lose their balance. Tilting trains are
designed to counteract this by tilting the carriages
towards the inside of the curve, thus compensating for
the g-force. The train may be constructed such that
inertial forces cause the tilting (passive tilt), or it may have
a computer-controlled powered mechanism
A high-speed tilting train is a tilting train that operates at high
speed, typically defined as by the European Union to include 200
km/h (124 mph) for upgraded track and 250 km/h (155 mph) or
faster for new track.
So, the APT was designed to tilt as it went into curved track sections,
rather like a motorbike on a winding road, allowing it to go up to
40% quicker than non-tilting trains.
The high-speed train is named ‘Pendolino’, meaning small pendulum
in Italian, due to its mechanism to tilt at the bends.

The trains use Tiltronix technology, and feature hydraulic tilting

bogies. The tilting rods installed in the bogies activate the tilting. The
train’s wheel forces have been minimised by reducing suspended
masses. The bodyshell sits centred with the use of active lateral air
suspension system.
The new Pendolino trains are claimed to be 95% recyclable. The
electric brake systems save up to 8% of energy consumed. Alstom
says 97% of the power is recycled and fed back into the catenary
system.
Sound insulation under the body and optimised aerodynamic
design reduce sound penetration through the roof. A shock
absorber dumping system vibration under the wheels also
contributes to decrease noise pollution.
Pl REFER SPRINGER
PAPER
 Automatic car parking systems
How it works: Drivers take their cars to the entrance of the
automatic parking system where all occupants exit the
vehicle. From here, the vehicle is moved by mechanical
maneuvers to an available space where it is automatically
parked or parked by an attendant.
An automated (car) parking system (APS) is a mechanical system
designed to minimize the area and/or volume required for parking
cars. Like a multi-story parking garage, an APS provides parking for
cars on multiple levels stacked vertically to maximize the number of
parking spaces while minimizing land usage.
A typical Car parking System have the following features:
• The system uses state-of-the-art servo drives and laser
based guidance system.
• The typical parking time is less than 1 minute.
• Horizontal carts in each level optimizes the parking and
retrieval time.
• Based on the parking frequency, additional car lifts can
be provided to speedup parking and retrieval.
• The system is very modular to suit the space availability
at site.
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 Engine Management systems (EMS)
An EMS is a self, custom-built device that regulates an engine’s
operation by regulating its speed, load, and temperature,
supplying the ignition spark at the appropriate time for the
conditions, and metering the fuel engine in the precise amount
needed.

EMS consisting of a wide range of electronic and electrical

components such as sensors, relays, actuators, and an Engine
Control Unit.
They work together to provide the Engine Management System
with vital data parameters.
These are essential for governing various engine functions
effectively.
Furthermore, modern-day engine technologies incorporate the
EMS.
These include MPFi & GDi systems in Petrol engines and CRDi
systems in diesel engines for improved performance.
 Engine Management System (EMS) Main Components
Sensors, relays, actuators, and an Engine Control Unit make up the
EMS which comprises various electronic and electrical parts.
These are needed for the efficient control of various engine
functions.
They work collaboratively to supply valuable data parameters to the
Engine Management System.

ECU stands for Engine Control Unit and ECM for Engine Control
Module. Both are the same.
Engine Control Unit/Module:
The Engine Control Unit is a central part of the Engine Management
System, virtually the ‘Brain’ of the engine.

It plays a vital role in collecting, analyzing, processing, and

executing the data it receives from various sub-systems.
Furthermore, an ECU comprises a computer that uses a microchip
to process the inputs from multiple engine sensors in real-time.
The Electronic Control Unit contains hardware and
software.
The ECU’s printed circuit board (PCB) consists of a micro-
controller chip or the CPU (Central Processing Unit).

The micro-controller or chips on the PCB store the

software.
It is possible to re-program the ECU by updating the
software or replacing chips.

All the engine sensors send data inputs through electrical

signals to the ECU.

In turn, the ECU controls various actuators, ignition

timing, variable valve timing, etc.
 How an ECU Works?
Based on this data input, the ECU precisely calculates and
delivers the ideal air-fuel mixture.

It also regulates the engine’s idle speed and limits the top speed
of a vehicle.

This system is also widely referred to as an ”Electronic Engine

Management System” or the EMS.

Furthermore, it is possible to customize the modern-day ECUs to

suit different vehicular applications and varying customer
demands.
Also, some cars have an individual’ ‘Control Module” for all major
systems.
For example, a modern car has the following individual Control
Modules that control the respective systems.

An Engine Control Unit connects to all the individual Electronic Control

Modules (ECMs). A modern-day car consists of more than one Control
Modules, each exclusive for every primary system, which improves
performance. However, the manufacturers seldom refer to these systems as car
computers since they are multiple computers instead of one.
 Modern Engine Management Systems
Modern engine management systems are excellent at ensuring that engines
operate cleanly and effectively under a wide range of environments.
They are generally reliable and need little to no maintenance.

The EMS system is made up of many sensors (which send data to the ECU) and
actuators (which receive their inputs from the ECU).

The fuel or injection system and the ignition system are two separate sub-
systems that operate within the EMS.

Ignition Mapping
Inside the EMS, there will usually be a map for injector timings (fuel map) and a
separate map for ignition timing settings (ignition map).

The engine’s fuel and ignition timing specifications can differ when running,
depending on the engine’s operating conditions.
Engine speed and engine load are the two most important factors.
A map is nothing more than a lookup table organized by engine speed and
load that displays the acceptable fuel or timing set for each speed and load
state.

What are the ECU and ECM?

An engine control unit (ECU), also known as an engine control module (ECM),
is an electronic control unit that ensures optimum engine output by
controlling a series of actuators on an internal combustion engine.

The Engine Control Unit is a critical component of the Engine Management

System, which functions as the engine’s ‘brain.’ It collects, analyses,
processes, and executes data received from various sub-systems. An ECU also
includes a computer that processes data from various engine sensors in real-
time using a microchip.
 Antilock Brake systems (ABS)
An anti-lock braking system is a system which is used to avoid
skidding of the wheel by rapid braking action.

Generally, in vehicles without ABS, when a driver presses the brake

pedal,‌due to braking, the wheel immediately gets locked.

Hence wheel skids on the road.

So in such case, if suddenly a big rock comes in front of the vehicle,

the driver presses the brake pedal & then due to skidding of a
wheel, the driver losts control over the vehicle.
Therefore by Antilock Brake systems ABS, if suddenly a big rock
comes in front of the vehicle, then with ABS, the driver can easily
reduce the vehicle speed and also change the direction of the vehicle.

In easy language, ABS helps to stop the constant locking of a vehicle

wheel, hence resulting in vehicle stops without the skidding of a
wheel.
ABS system consists of the following key components:-

• Master cylinder

• Hydraulic control unit (Shown as an orange color box in the above diagram)
• Electronic control unit (ECU)
• Tooth wheel & speed sensor
1) Master cylinder:-

It is a device that is used to pump the brake fluid and it consists of a piston, brake fluid, and
return spring.

The piston rod is connected to the brake pedal hence when the driver presses the brake
pedal, the piston presses the brake fluid inside the master cylinder.

The oil reservoir is connected to the master cylinder, which maintains the oil quantity inside
the system. The outlet of the master cylinder is connected to the hydraulic control unit.
2) Hydraulic control unit (HCU):-

It is a control unit that works as per signals received from an electronic control unit (ECU). So, as
per ECU signals, the Hydraulic control unit (HCU) sends the brake fluid through the input line or
stops the flow or take returns the brake fluid from the return lines to apply and release the
brake to prevent the wheel from constant locking during braking.

HCU consists of the following components:-

i) Pump
ii) Accumulator
iii) Solenoid Valves

i) Pump:- The Inlet of the pump is connected to the master cylinder & outlet is connected to the
accumulator. The pump pressurizes the brake fluid received from the master cylinder & sends it
to the accumulator.

ii) Accumulator:- It is a storage device, which is used to store the pressurized brake fluid. The
outlet of the accumulator is connected to the solenoid valves.

iii) Solenoid valves:- Solenoid valves work as per signal received from the ECU to – Supply
pressurizes brake fluid to apply the brake, To stop the supply of brake fluid, To take return flow
of brake fluid to release brake force on the wheel.
3) Electronic control unit (ECU):-
It is a control unit, which receives a signal from the speed sensor & sends signals to
components (Accumulator, Solenoid valves, Pump, Master cylinder) to perform
required operations when a brake is applied.

4) Tooth wheel & speed sensor:-

These devices help ECU to know about the wheel speed. The tooth wheel is
connected to the wheel & rotates with the wheel.

The speed sensor is also located behind the tooth wheel. It senses the rotation of the
tooth wheel & sends the signal to the ECU. So ECU gets data about the vehicle speed
through the speed sensor
The ABS works as per the following steps:-

STEP-1:-
When the driver presses the brake pedal, the piston presses the brake fluid & then ECU sends a
signal to the solenoid valve & pump to start the flow of brake fluid towards the brake drum.

Hence Brake fluid flows from – Master cylinder -> Pump -> Accumulator -> Solenoid valves ->
Brake drum and wheel stops.

STEP-2:-
When the wheel stops due to a brake, the speed sensor sends a signal to ECU. ECU sends a
signal to the pump & solenoid valve to stop brake fluid flow & release pressure on the wheel (by
returning the brake fluid through the return line).

Therefore brake fluid flows from the Brake drum -> Solenoid valves -> Accumulator and the
resulting wheel again starts to rotate.

STEP-3:-
Again speed sensor sends a signal to the ECU about wheel speed. Again ECU sends a signal to
the solenoid valve & pump to start the flow, Hence Again brake fluid flows from – Pump ->
Accumulator -> Solenoid valves -> Wheel Drum

This step occurs rapidly till vehicle speed reduces or the vehicle stops without skidding.
Advantages:
The advantages of using the Anti-lock braking system are as follows:-

• Less braking distance

• Good steering control, so the vehicle can turn in the desired direction
• Avoids accidents.

Anti-lock braking system applications:

The ABS has the following applications:-

• Bike
• Car
 CNC Machines (Only Black Diagram and explanation)
CNC stands for Computer Numerical Control.
When computers are used to control a Numerical Control (NC) machine tool
than the machine is called CNC machine.
In other words, the use of computers to control machine tools like lathe,
mills, slotter, shaper etc is called CNC machine.

The cutting operations performed by the CNC is called CNC machining.

The Various machining services in which CNC machine is used are known as
CNC machining services.

In CNC machine shops, programs are designed or prepared first, and then it
is fed to the CNC machine.

According to the program, the CNC controls the motion and speed of the
machine tools.
 Main Parts of CNC Machine
The main parts of the CNC machine are
(i) Input Devices: These are the devices which are used to input the part
program in the CNC machine.
There are three commonly used input devices and these are punch tape reader,
magnetic tape reader and computer via RS-232-C communication.

(ii) Machine Control Unit (MCU): It is the heart of the CNC machine. It
performs all the controlling action of the CNC machine, the various functions
performed by the MCU are:

• It reads the coded instructions fed into it.

• It decodes the coded instruction.
• It implements interpolation ( linear, circular and helical ) to generate axis motion
commands.
• It feeds the axis motion commands to the amplifier circuits for driving the axis
mechanisms.
• It receives the feedback signals of position and speed for each drive axis.
• It implements the auxiliary control functions such as coolant or spindle on/off
and tool change.
(iii) Machine Tool: A CNC machine tool always has a slide table and a spindle to
control of the position and speed. The machine table is controlled in X and Y axis
direction and the spindle is controlled in the Z axis direction.

(iv) Driving System: The driving system of a CNC machine consists of amplifier
circuits, drive motors and ball lead screw. The MCU feeds the signals (i.e. of
position and speed) of each axis to the amplifier circuits. The control signals are
than augmented (increased) to actuate the drive motors. And the actuated drive
motors rotate the ball lead screw to position the machine table.

(v) Feedback System: This system consists of transducers that act as sensors. It is
also called a measuring system. It contains position and speed transducers that
continuously monitor the position and speed of the cutting tool located at any
instant. The MCU receives the signals from these transducers and it uses the
difference between the reference signals and feedback signals to generate the
control signals for correcting the position and speed errors.

(vi) Display Unit: A monitor is used to display the programs, commands and other
useful data of CNC machine.
How CNC Machine Works?
• First, the part program is inserted into the MCU of the CNC.
• In MCU all the data process takes place and according to the
program prepared, it prepares all the motion commands and sends
it to the driving system.
• The drive system works as the motion commands are sent by MCU.
The drive system controls the motion and velocity of the machine
tool.
• The feedback system records the position and velocity
measurement of the machine tool and sends a feedback signal to
the MCU.
• In MCU, the feedback signals are compared with the reference
signals and if there are errors, it corrects it and sends new signals
to the machine tool for the right operation to happen.
• A display unit is used to see all the commands, programs and other
important data. It acts as the eye of the machine.
Advantages
• It can produce jobs with the highest accuracy and precision than any other manual
machine.
• It can be run for 24 hours a day.
• The parts produced by it have the same accuracy. There is no variation in the parts
manufactured.
• A highly skilled operator is not required to operate it. A semi-skilled operator can also
operate accurately and more precisely.
• Operators can easily make changes and improvements and reduce the delay time.
• It has the capability to produce complex designs with high accuracy in minimum possible
time.
• The modern design software, allows the designer to simulate the manufacturer of
his/her idea. And this removes the need for making a prototype or model and saves
time and money.
• Fewer workers are required to operate a CNC and save labor costs.
Disadvantages
Despite of having so many advantages, It has some disadvantages too. And
these are:

• The cost of the CNC machine is very high as compared with a manually
operated machine.
• The parts of the CNC machines are expensive.
• The maintenance cost in the case of CNC is quite high.
• It does not eliminate the need for costly tools.

Application

• Almost every manufacturing industry uses CNC machines.

• With an increase in the competitive environment and demands, the
demand for CNC usage has increased to a greater extent.
• The machine tools that come with the CNC are lathe, mills, shaper,
welding, etc. The industries that are using CNC machines are the
automotive industry, metal removing industries, industries of fabricating
metals, electrical discharge machining industries, wood industries, etc.