Mechatronics and Automation
ZC324
BITS Pilani
Pilani Campus
S.S.Mujumdar- WILP Faculty
Session I
Type
Content
Ref.
Topic Title
Study/HW
Resource
Reference
During Introduction Introduction
Mechatronics systems-examples
CH
Introduction to automation,
Key issues,
Approach to Mechatronics and automation
Some typical applications of experimental
design
Measurement systems
Examples of mechatronic systems
Problems:
Identifying, a product is a mechatronic product
or not.
Discussion on creating a mechatronics
(“smart”) product with add-on functions
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T1: Chapter
1, R1:
Chapter 1
2
Mechatronics
Sensor
Signal
Conditioning
Actuators
Control
Automation – what / types/ industrial manipulators/ robots - system
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Evaluation Scheme
Evaluation
Component
Weight
Duration
Assignment/Qu Individual /
iz
Take-home
10%
2 Weeks
5-5 Marks 1
pg
assignments
pre and post
midsem
Lab /
Assignment
Online
20%
2 Weeks
Virtual Lab12M / Remote
Lab – 8M
EC - 2
Mid-Semester
Examination
Closed Book
30%
2 Hrs.
Sessions – 1
to 8 syllabus
EC - 3
Comprehensive Open Book
Examination
40%
3 Hrs.
EC - 1
Name
Type
Schedule
Sessions – 1 to
16 syllabus
weightage will
be more to
BITS
Pilani,
Pilani Campus
9to16
session
Books and references
1. W. Bolton, Mechatronics, 3rd Ed., Pearson, 2004
2. M.P. Groover, “Automation, Production systems, and
Computer-Integrated Manufacturing”, PHI, 2008
3. Anthony Esposito : Fluid Power with Applications
4. Lecture slides
BITS Pilani, Pilani Campus
Lab
• 16 session – theory – S.S.Mujumdar
• Lab session –myself
• Lab – Virtual lab – simulation software –
AS – ACTUATOR PART/PLC
• Remote lab – 2 control boards – h/w –
Hyderabad/ access through server –
Mathematic modelling of systems
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Industrial
revolution
Industry 4.0 –
AI/Telematics/ automation /IOT
http://www.apriso.com
BITS Pilani, Pilani Campus
Introduction to Mechatronics and
Automation
• Integration of electronics,
mechanical engineering
control
engineering,
Mechatronics- MTMSIZC324 BITS Pilani
and
35C
Current temp
Input given to set
the temp. at
23C
Room variable
parameters –
disturbances in the room
Air Conditioning – compressor will be
given instruction to adjust it to 23C
Output air with certain tem
23C
Control
System
Working inside AC – Sensor And actuator
– Fan with a motor/ solenoid valve or
light LED display – Mechanical+
Electronic Components
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Mechatronics & Automation is…
•
•
•
•
•
Communication
Senses
Analyses
Acts
Controls
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Introduction to Mechatronics
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Mechatronics
• The term mechatronics was invented by a
Japanese
engineer
in
1969
as
combination of MECHA from mechanical
and tronics from electronics.
• Concurrently developed integration of
electronics and mechanical engg. Along
with intelligent computerized control in the
design of products and processes.
Mechatronics- MTMSIZC324 BITS Pilani
• https://www.youtube.com/watch?v=_ge5zs
x5-8o
• https://www.youtube.com/watch?v=K8Qbi
SR347Q
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What it contains?
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Introduction to Mechatronics
• Mechatronics is the synergistic integration of
–
–
–
–
sensors, actuators, signal conditioning,
power electronics,
decision and control algorithms, and computer hardware and
software to manage complexity, uncertainty, and communication
in engineered systems.
Mechatronics- MTMSIZC324 BITS Pilani
Disciplinary Foundations of
Mechatronics and Automation
1. Digital/Analogue actuators
2. Mechanical system
3. Sensors Digital/Analogue
4. Microprocessor system for control
Mechatronics- MTMSIZC324 BITS Pilani
Example…
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• https://www.youtube.com/watch?v=uaeADiep
fXk
• https://www.youtube.com/watch?v=ylWNQrIWAk
• https://www.youtube.com/watch?v=lsYaVHKf
KZI
• https://www.youtube.com/watch?v=irVEYvEIb
6o
• BOSCH IOT ads
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Key elements of mechatronics system
Mechatronics- MTMSIZC324 BITS Pilani
System
•
•
•
•
Input
Disturbances
Output
Noise/Disturbance
Input
Resources
System
(desired output)
Types of system
• Open loop system
• Interconnected system
• Closed loop system
Resources
Mechatronics- MTMSIZC324 BITS Pilani
Output
Examples (Open loop)
Input
Output
Motor
Electrical power
Rotation
Input
Output
Electrical power
Electrical Heater
temperature
Mechatronics- MTMSIZC324 BITS Pilani
Interconnected open loop system
Feed forward system
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Closed loop system
C
A
Mechanical System
Feed back system
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23
Measurement System
– linear/rotary
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Control Systems
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Modeling a System
• It is expressing the relationship between
the input and the out put
• Generally described by a differential
equation
Mechatronics- MTMSIZC324 BITS Pilani
Control systems as measurement
system
Sensors
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Signal
Conditioner
Display
Mechatronics- MTMSIZC324 BITS Pilani
Comparison
and Control
27
• https://www.youtube.com/watch?v=1Feroo
tGwQc
• https://new.siemens.com/global/en/product
s/automation/pc-based.html
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Building blocks – Open , Closed loops
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Uses of control system
1. Control of variables to some particular
value
e.g. temperature control up to 35 degrees
2. Control sequence of events
e.g. washing machine
3. Control whether event occur or not eg: a
safety lock on a machine where it cannot be
operated until a guard is in position
Mechatronics- MTMSIZC324 BITS Pilani
Open loop control system and close
loop control system
• Domestic toaster. Controller is exercised
by a timer. Brownness of the toast is
determined by time. There is no feed back
to control the degree of browning
• In open loop system the output has no
effect on the input.
• Open loop: simple by construction and
less costly
Mechatronics- MTMSIZC324 BITS Pilani
• https://www.youtube.com/watch?v=lsYaVH
KfKZI
• https://www.youtube.com/watch?v=irVEYv
EIb6o
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Control systems as measurement
system
Filtering noise
Amplification
AtoD or DtoA
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Control systems as measurement
system – Speed measurement
Measuring device
1440rpm
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Mechatronics Applications
• Smart consumer products:
– home security, camera, microwave oven,
toaster, dish washer, laundry washer-dryer,
climate control units, Refrigerator.
• Medical:
– implant-devices, assisted surgery, BioMechanics with chip assistance.
• Defense:
– unmanned air, ground, and underwater
vehicles, smart munitions, jet engines, etc.
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications
• Manufacturing:
– robotics, machines, processes, etc.
• Automotive:
– climate control, antilock brake, active
suspension, cruise control, air bags, engine
management, safety, etc.
• Network-centric, distributed systems:
– distributed robotics, tele robotics, intelligent
highways, etc.
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics products
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Washing
machine
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Mechatronics Applications- Washing
machine
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Mechatronics Applications- Dish washer
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Examples on Control systems
(Automatic camera)
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Mechatronics Applications- Camera
Autofocus
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Mechatronics Applications- CNC machine
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Mechatronics Applications- FMS
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Automotive Functions - SW and HW
Network
Software components
6
Embedded Software is different from general purpose SW!
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Automotive
Five major technology transitions in the auto industry in
the next five to ten years:
1.Gasoline to hybrid to fuel cell to electrical vehicle.
2.Mechanical connection to “Drive-by-wire”
3.Proprietary electrical/hardware/software system to
standardized “architectures”
4.Adoption and implementation of IT standards in the
technology of the car (XML, Web Services, etc.)
5.“On-demand” to “Always-on” vehicle connectivity
to the Internet
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Automotive
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Mechatronics Applications- Automotive
The role of software and electronics
Comfort - Diagnosis – Braking –
Active & Passive Safety - Telematics
- Anti-Theft Systems - ...
Electronic components and software will, to a large
extent, shape tomorrow‘s vehicles (90% of vehicle
innovations)
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Medical
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Mechatronics Applications- Sanitation
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Mechatronics Applications- Household
Hair Dryer
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Mechatronics Applications- Automotive
Drive-by-Wire replaces mechanical connections – push rods,
rack & pinion, steering columns, overhead cams, cables – by
Mechatronics connections – sensors, actuators, embedded
microprocessors, control software
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Automotive
EMS
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Automotive
EMS
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Automotive
Second Example: Camless Engines
Cams replaced by actuators and embedded controls
What is the advantage?
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Smart
Robotics
The Robot is, of course, the ultimate Mechatronic System
Mechatronics- MTMSIZC324 BITS Pilani
Mechatronics Applications- Robotics
The CSL Air Hockey Playing Robot
•Combines Intelligence Control, Real-Time Vision Sensing and
Vision Processing, and Machine Learning
Mechatronics- MTMSIZC324 BITS Pilani
Examples are Everywhere Smart Skis
Application- Personal Transportation
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Automation
P - productivity
Q – Quality and Quantity
C – Cost red.
D - delivery
S - safety
M - Morale
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Automation Levels
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Automation in production
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Manufacturing Systems
Types of Automated systems -
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Types of Automated systems -
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Manufacturing Systems
Manual Work system
Worker machine system
Automated system
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Automation Principles and Strategies
1. The USA Principle
2. Ten Strategies for Automation and Process Improvement
3. Automation Migration Strategy
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U.S.A Principle
1. Understand the existing process
–
–
–
Input/output analysis
Value chain analysis
Charting techniques and mathematical modeling
2. Simplify the process
–
Reduce unnecessary steps and moves
3. Automate the process
–
–
Ten strategies for automation and production systems
Automation migration strategy
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Ten Strategies for Automation and
Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing
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Automation Migration Strategy
for Introduction of New Products
1. Phase 1 – Manual production
–
–
Single-station manned cells working independently
Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
–
–
Single-station automated cells operating independently
As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
–
Multi-station system with serial operations and automated transfer of work units
between stations
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Automation Migration Strategy
Mechatronics- MTMSIZC324 BITS Pilani
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