Introduction to the Development and Design of a Mechatronic System

Home , Control engineering

Ebinezaru Babu Gollamudi 1 ,Venkata Ramesh Mamilla 2, Tippa Bhima Sankara Rao 3 1Assistant Professor, 2Associate Professor, 3Professor

Department of Mechanical Engineering 1PACE Institute of Technology & Sciences, Ongole 2QIS College of Engineering &Technology, Ongole 3Nimra Institute of Science & Technology,Vijayawada Andhra Pradesh ,India

Abstract The purpose of this interdisciplinary engineering Mechatronics is a way of combining the field is the study of automata from an engineering classical engineering disciplines for perspective and serves the purposes of controlling mechanical, electrical engineering and advanced hybrid systems. The word itself is a computer science. The objective is to build combination of 'Mechanics' and 'Electronics'. smart products and “intelligent” machines. This paper presents about the 1.1 Description architecture of mechatronic system and its key Engineering cybernetics deals with the elements. This main objective of this paper is question of control engineering of mechatronic the development and design of mechatronic systems. It is used to control or regulate such a systems. The major objective of mechatronics system. Modern production equipment consists of is the design and implementation of mechatronic modules that are integrated mechatronic systems as a new type of system according to a control architecture. There are in which mechanical, electro, and electronic many systems in the existing world that require a subsystems are naturally designed into a whole synergy of these expertise areas including systems system . in automotive aerospace, medical, material Keywords : Mechanical, Electronics, processing, manufacturing and the consumer Development, Design, Mechatronic system. products application sector. Some examples of mechatronics system include air craft light control 1.0 Introduction and navigation systems, automobile fuel injection Mechatronics is a system-level approach and anti-break systems, automated manufacturing to designing electromechanical systems that equipments (e.g...Robots).The field of robotics merges mechanical, electrical, control and can be considered to be a subfield of embedded software design. Explore these mechatronics.The typical of a robotic system mechatronics resources and learn how to lower includes the actuator, communicator, control your development costs, reduce risk, and produce element, end-effector, manipulator, power supply higher-quality products. as well as sensors. An excellent example of a IT is the fusion of the technologies of mechatronic system is the photocopy machine. electronics and mechanics. Examples include Analog circuits are used to control the lamp, numerically controlled machine tools, industrial heater and power. Digital system controls the Robots, digital clocks, and electronic calculators. digital displays and the indicator lights. Buttons Mechatronics (or Mechanical and and switches are used for the user interface. All of Electronics Engineering) is the synergistic these complex interactions are transparent to the combination of mechanical engineering, eventual user of the system; typically a electronic engineering, controls engineering and mechatronics design goal for any mechatronic computer engineering to create useful products. system. www.ijera.com 542 | P a g e

2.0 Key elements of a Mechatronic system 2.1 Microprocessors and integrated circuits : It is a general-purpose programmable logic device. It is a digital device which receives information in digital form. According to stored programs this information is processed. A microprocessor is a semiconductor device having electronic logic circuits manufactured by using LSI (Large Scale Integration) or VLSI (Very Large Scale Integration) technique. It is a chip capable of performing arithmetic and logic functions according to a defined program. A controller and computer designed using microprocessor is called Fig:1 Key elements of a Mechatronic system a micro-computer and micro-controller respectively. It consists of memory and I/O 3.0 Designing for Mechatronics devices besides microprocessor. Microcomputer Engineers are grappling with how to more is able to carry out complicated control operations effectively design products that have mechanical, due to its memory. Microprocessors are present in electronics and software components. But this not various mech. applications such as Automobiles, your father’s systems engineering approach When Washing machines, Process instrumentation etc. an average vehicle boasts more than 1 million 2.2 Interfacing Devices : Mechatronic systems lines of software code and dozens of ECUs essentially consist of energy and information (engine control unit) and common household domains. Data processing is done in digital appliances like dishwashers and refrigerators devices while physical detection in sensors and come standard with mini on-board computers, it power output in actuator requires analog doesn’t take a rocket scientist to see something capability. Hence appropriate devices for Digital about the traditional engineering process has to to analog and vice-versa are necessary. give. 2.3 Sensors : It is a sensing device that converts The complexity of today’s products has physical phenomena and chemical composition added another dimension to product development into electric, pneumatic or hydraulic output as companies from car manufacturers to appliance signals. Some of modern sensors developed for makers struggle to integrate mechanical, electrical mechatronics applications are Disposable blood and software components into their products and, pressure sensors, Pressure sensors for automotive at the same time, uphold their business goals of manifold air pressure, Accelerometers for airbag improving time-to-market and meeting ever- systems etc higher quality standards. Unlike traditional design 2.4 Actuators: The actuator performs task of processes where electrical engineers worked on converting control signal into action on the their components relatively unconnected to the control element. The actuator often supplies large design efforts of mechanical engineers or the force or torque to manipulate some control software development team, this new kind of element such as valve, switch etc. Conventional product development — mechatronics as it’s actuators use electric motors and fluid power as sometimes called — demands a wholesale shift to their energy source. Modern actuators for a more concurrent, systems engineering approach mechatronic applications use novel technology where all the disciplines collaborate early on in such as ultrasonic motors, micromotors, the process. The reason for this cross-discipline piezoelectric and magnetostrictive forces and collaboration is simple: With companies facing shape memory alloys to derive necessary energy. fierce competitive pressures, they can no longer Some of the common types of devices are listed afford to bump up against possible design flaws in figure below: or incompatibilities between systems at the end of www.ijera.com 543 | P a g e

Ebinezaru Babu Gollamudi, Venkata Ramesh Mamilla, Tippa Bhima Sankara Rao/ International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 1, Issue 3, pp.542-545 the design cycle when making changes is expensive and an impediment to shipping 4.2 Precision Control products in a timely manner. Flow rate, speed, position, and any 3.1 Diagram of a Mechatronic System number of other variables can be controlled Diagram of a Mechatronic System preciselywith a microcontroller. In many provides insight into the design process for a applications, purely mechanical solutions are not mechatronic system as efficient, nor as precise as mechatronic 1) Select elements in each of the areas solutions. Cruise control in an automobile is a 2) Model/Analyze/characterize behavior of the great example of how a mechatronic solution elements allows for precise control. A microcontroller 3) Account for interactions between modules based solution will factor in many different 3.2 Design of Mechatronic Systems variables (i.e. velocity, acceleration, cumulative Stages in Design Process changes in velocity) in order to give the car a • The need smooth acceleration to the desired speed as well • Analysis of problem as maintaining a constant velocity over varying • Preparation of Specification load conditions. • Generation of possible solutions 4.3 More Efficient • Selection of a suitable solution The efficiency of a system can be • Production of a detailed design improved by adding intelligence to the design. Certain portions of the system can be shut-off • Production of working drawings when not in use or a microcontroller can make 3.1 Goals and specific objectives The life cycle for mechatronic design requires: better use of the energy available by offering the precision control described previously. • Delivery parameters such as time, cost Techniques such as Pulse Width Modulation and medium; (PWM) can be used instead of resistive elements Reliability issues such as failure rates, • to vary the voltage and current to a load, thereby materials and tolerance; increasing the efficiency of the system. • Maintainability, whish necessitates 4.4 Lower Cost modular design; In some cases, a mechatronic solution • Upgradeability costs less than the alternative mechanical solution. • Disposability processes including A complex mechanical solution may be simplified recycling and hazardous materials. using a microcontroller-based approach. Design The key to success for any mechatronics system time, product size, and reliability can all be is to strike a balance between: improved with a mechatronic solution. All these • Modeling, analysis, control design, factors impact the cost over the lifetime of a computer simulation of dynamic system product. • Experimental Validation of models, 4.5 Flexible Design analysis and understanding key issue of Design flexibility is a huge advantage to hardware implementation designing with a microcontroller. The specifications of a product can change during the 4.0 More Features course of its design. When a PIC MCU 4.1 More User-Friendly is used, the timing of a signal, the sequence of Mechatronics solutions also appeal to events, or any number of software controlled consumers because they are more user-friendly. parameters can be changed quickly without the The improvements in automotive technology over need for a product redesign. the past decades are evidence of this fact. Power This flexibility also allows the same hardware to windows, power door locks, keyless entry, and be used in different products. The software is numerous other conveniences testify to the fact simply changed to meet the needs of each that consumers prefer mechatronic solutions. product. www.ijera.com 544 | P a g e

cost/size-effectiveness of computers, mechatronic 4.6 Increased Reliability systems are becoming common in any Mechanical designs are prone to wear and engineering discipline dealing with the tear over time. In many situations a mechatronic modulation of physical power. solution is more reliable. A good example of this 7.0 References is the odometer in your car. Mechanical 1. G. Schweitzer: Mechatronics - basics, odometers use a direct drive system that consists objectives, examples. Journal of Systems of a flexible cable running from the transmission and Control Engineering, Proc. IMechE Vol to the odometer gage. The solution is unreliable 210, (1996), 1-11. because the cable is prone to failure. The modern 2. J.R. Hewit: Advancements and Applications of mechatronic solution consists of an optical Mechatronics Design in Textile encoder and digital display, which increases Engineering. system reliability. 3. D.A. Bradley, D. Dawson, N.C. Burd, A.J. 4.7 Smaller Size Loader: Mechatronics - Electronics in Adding a microcontroller to a system may Products and Processes. Chapman and Hall, result in space savings. Motor drive circuits, for 1991. instance, traditionally had to have over-sized 4. D. Shetty, R.A. Kolk, 1997. “ Mechatronics drive stages to handle in-rush current. In-rush System Design”. Boston: PWS Publishing current can be limited and the size of the drive Company. (An International Thomson stage can be reduced by Publishing Company). implementing soft-startup using a 5. Bolton.W, Mechatronics, Electronic Control microcontroller. System in Mechanical and Electrical 4.8 Safer Engineering, Second edition, Pearson Adding intelligence to a system makes it Education Limited ,Boston(2001). safer. Whether you add an automatic shutdown to 6. Mikell P.Groover, Automation ,Production a coffee pot or sense when a system is Systems and Computer Integrated overheating, numerous safety checks can be Manufacturing, Second Edition, Prentic Hall of easily added to a system when a microcontroller India Ltd.,(2003). is controlling the system. 7. Hmt Limited, Mechatronics, Tata McGraw-Hill 5.0 Application Areas of Mechatronics company limited, New delhi • Automation, and in the area of robotics (2000). • Servo-mechanics 8. R.B.Chadge, S.L.Bankar, Introduction of • Sensing and control systems Mechatronics System in Mechanical • Automotive engineering, in the design of Engineering in National Conference on Recent subsystems such as anti-lock braking Trends & Challenges in Mechanical systems Engineering On 5th - 6Th October, 2009, • Computer engineering, in the design of mechanisms such as computer drives 6.0 Conclusion Mechatronics plays a vital role in different applications of mechanical engineering, In many applications, purely mechanical solutions are not as efficient, nor as precise as mechatronic solutions. It is concerned with generating motions in machinery in a controlled way. Today’s engineering systems requires multi-disciplinary design teams. In addition, the computer tends now to be an integral component of these complex systems. With the explosively increasing www.ijera.com 545 | P a g e