Mechatronics 2

CCE 354

Lecture (1)
Introduction to Mechatronics
Dr. Bikheet Mohamed Sayed
Course contents

❑ Introduction (Mechatronics vs. Electromechanics) (One lecture)

❑ Mechanical design (One Lecture)
❑ Measurement (One lecture)
❑ Actuation systems (Two lectures)
❑ Advanced system modeling and control (One Lecture)
❑ Analysis of Nonlinear mechatronic system One Lecture)
❑ Kalman filtering and applications (One Lecture)
❑ Automatic control (Programmable Logic Control) (Three lectures)
❑ Mechatronics design project (One Lecture)
Definitions

Electromechanics
• Electromechanics is a combination of electrical and mechanical engineering,
where it studies the integration of electrical and mechanical systems, and their
interaction.

• Electromechanical systems were first developed in 1822 (Electric motor by

Faraday) until the development of transistors in 1950.
Examples

▪ Motors/Generators

▪ Relay/Solenoid valve

▪ MEMs (Micro Electro-Mechanical devices)

▪ Piezoelectric devices
 Historical Background

• ‘Mechatronics’ term was introduced by

a Japanese engineer in 1969 as a
combination of ‘mecha’ for
“mechanisms” and ‘tronics’ for
“electronics”.

• The inclusion of different engineering

disciplines occurs concurrently (rather
than sequentially) since the early stages
of the design process.
The development timeline
 Embedded systems

• Microprocessors are embedded in mechatronic systems to control its

behavior and operation.

• Microprocessors are programmable (not by the user) unlike logic

gates with fixed-wiring.

• More elements (as memory, input/output ports..etc) are needed to enable

microprocessors to process signals from/to the outside world.

 Programmable Logic Controller (PLC)

• PLC is a microprocessor-based controller which uses programmable

memory to store instructions and to implement functions (ex: logic,
sequence, arithmetic, timing..etc) and can be readily reprogrammed for
different tasks.
• PLCs are widely used in industry where on/off control is required.
Mechatronic system main blocks
Examples

• Home appliances such as washing machine

• Intelligent measuring devices like calibration devices

• Medical applications such as ultrasonic probes

• Robots and autonomous systems

 Mechatronic systems

Advantages:

● Enhanced functionality and features

● Higher efficiency and reliability

● Results in automation in production, assembly and quality control.

● Less design time and product size

● Reduced cost

● Simplified mechanical design

 Mechatronic systems

Disadvantages:

● Increase in the components failures

● More complex safety issues

● The initial cost is high (not suitable for small scale industry)

● Multi-disciplinary engineering background is required to design and

implementation.

● Self-heating may affect the accuracy of the system.

The design process
 The design process
2- Analysis of Problem:
is the process of defining the main concerns or exact
specification of the client
3- Preparation of a specification:
● State the problem,
● Find constraints placed on the solution,
● Specify Criteria which may be used to judge the quality of
the design.
● In stating the problem, specify all the functions required
from the design together with any desirable features.

4- Generation of possible solutions

● This is often termed the conceptual stage.
● Outline solutions are prepared which are worked out in sufficient detail to indicate the means of
achieving each of the required functions.
5- Selections of a suitable solution: The various solutions are evaluated and the most suitable one should
be selected.
6- Production of detailed design: This might require the production of prototypes in order to determine
the optimum details of a design.
7- Production of working drawing: The selected design is then translated into working drawings, circuit
diagrams, etc.
8- Implementation of design
 Modeling systems

● Basically, to study a certain system, we need to learn a mapping from

inputs to outputs (linearity) of this system, including the transient and
steady-state responses.
 Connected systems

• Systems usually consist of simpler system (subsystems) connected together.

• This can be represented as a series of interconnected block, with each block

having a specific function.

 Conventional vs Mechatronic design

• Conventionally, each subsystem is designed separately and then

connected together finally.

• The mechatronic design considers the dynamic interaction between

the subsystems and hence the design is carried out concurrently rather

than sequentially.
Design examples

Weight scale
Conventional design Mechatronic design
Design examples

Temperature control

Conventional design Mechatronic design

 Measurement systems

● The basic elements of a measurement system are:

1- Sensor: responds to the quantity being measured by giving an output

signal which is related to the quantity.

2- Signal conditioner: takes the signal from the sensor and manipulates

it into a condition which is suitable either for display, or as an input to

control system.

3- Display system: where output from signal conditioner is displayed

 Control Systems

• A control system can be thought of as a system which can be

used to:
1) Control some variable to some particular value (ex: A/C)

2) Control the sequence of events (ex: washing machine)

3) Control whether an event occurs or not (ex: safety lock)

• A control system can be either an open-loop or closed-loop

based on how it make use of the feedback data.
Open-loop vs closed-loop control
Open-loop system

• Relatively simple and consequently low cost with generally good

reliability.

• However, they are generally inaccurate since there is no correction for

error.
Closed-loop system

● Relatively accurate (match the actual to the required values)

● More complex and costly with a greater chance of breakdown)

Basic elements of a closed-loop system

1) Comparison element:

• error signal = reference value signal – measured value signal

• Negative feedback subtracts from the input signal, while positive

feedback adds to it.
Basic elements of a closed-loop system

2) Control element:
• Decides what action to take when it receives an error signal.
• A control plan can be simple (ex: on/off switching at a threshold
value) or more complex based on the system designed.
• Control plan may be hard-wired (fixed) or programmable
systems.
Basic elements of a closed-loop system

3) Correction element:
• Produces a change in the process to correct or change the
controlled condition.
• Can be a switch or a valve … etc (i.e. an actuator)
• Actuator: the element of a correction unit that provides the
power to carry out the control action.
Basic elements of a closed-loop system

4) Process element:
• Process is what is being controlled.
Ex:. It could be a room in a house or a tank of water being filled.
Basic elements of a closed-loop system

5) Measurement element:

• Produces a signal related to the variable condition of the process

that is being controlled.
Example of a closed-loop system
Example of a closed-loop system
Advanced Mechatronics
Applications
 Mechatronics Systems
Smart Robotics Application

Big Dog Walked Robot

System Can
•Carry up to 150 kg Advantages
•Run 6.5 km/h •Robot with rough-terrain mobility that could
•Climb, run, and walk carry equipment to remote location.
•Move over rough terrain
 Mechatronics Systems

Automotive Applications
Anti-Lock Braking System (ABS)
Anti-Lock Braking System (ABS)
Hydraulics

Hydraulic cylinder
on brakes
Mechanical
Dynamics of car

Oil Flow Wheel speed

Control Signal sensor

ABS Control
Wires
Unit
Electronic Wires
Mechatronics Systems
Manufacturing Applications

CNC Machining

Advantages
• Deliver the highest accuracies
• Can create very complex shapes
 Mechatronics Systems
Manufacturing Applications

Micro Factory

• Desktop sized Factory

• Build small parts with a small factory
• Greatly reduces space, energy, and materials
 Mechatronics Systems
Medical Applications
Prosthetics

• Arms, Legs, and other body parts can

be replaced with electromechanical
ones.
 Mechatronics Systems
Medical Applications
Pace Maker
• Used by patients with slow or
erratic heart rates. The pacemaker
will set a normal heart rate when it
sees an irregular heart rhythm.

Implantable Defibrillation
• Monitors the heart. If heart
fibrillates or stops completely it will
shock the heart at high voltage to
restore a normal heart rhythm.
 Mechatronics Systems
Sanitation Applications
System Uses
• Proximity sensors
• Control circuitry
• Electromechanical valves
• Independent power source

Advantages
• Reduces spread of germs by making device
hands free
• Reduces wasted water by automatically
turning off when not in use
 Mechatronics Systems
Sanitation Applications
Systems Uses
• Motion sensors
• Control circuitry
• Electromechanical actuators
• Independent power source

Advantages
• Reduces spread of germs by making
device hands free
• Reduces wasted materials by controlling
how much is dispensed
Measurement
Physical measurements as input
Physical measurements as input
 International Prototype kilogram (IPK)

An alloy of platinum-iridium (Pt-Ir)

Platinum: 90 % Iridium: 10 %

D = L = 39 mm
Treatability chain
Treatability chain
Sensors
• Sensor is a device that when exposed to a physical phenomenon
(temperature, displacement, force, etc.) produces a proportional
output signal (electrical, mechanical, magnetic, etc.).
• The term transducer is often used with sensors.
• However, ideally, a sensor is a device that responds to a change in the
physical phenomenon.
• On the other hand, a transducer is a device that converts one form of
energy into another form of energy.
• Sensors are transducers when they sense one form of energy input and
output in a different form of energy.
• For example, a thermocouple responds to a temperature change
(thermal energy) and outputs a proportional change in electromotive
force (electrical energy). Therefore, a thermocouple can be called a
sensor or transducer.
Sensors and Transducers

Transducers: are generally sensors, but generate a signals of usable

forms.

OR: Is an element that convert signals from one form to

another form, usually from unusable to usable form.

Examples: Thermocouples generate an electric mV relating to the

measured temperature.
OR An electronic circuit designed to convert R
signals to V or I signals.

Sensor-Transducer: Is a sensor provided with a transducer element to

change its unusable output signal into a usable one.
 Sensor and Transducer Specifications
Various specifications of a sensor/transducer system are:

• Stability
• Range • Accuracy
• Hysteresis • Dead band/time
• Span • Sensitivity
• Resolution • Repeatability
• Error • Nonlinearity
• Response time
 Sensor and Transducer Specifications
Range
• The range of a sensor indicates the limits between which the input can vary. For
example, a thermocouple for the measurement of temperature might have a
range of 25-225 °C.
Span
• The span is difference between the maximum and minimum values of the input.
Thus, the above mentioned thermocouple will have a span of 200 °C.
Error
• Error is the difference between the result of the measurement and the true value
of the quantity being measured. A sensor might give a displacement reading of
29.8 mm, when the actual displacement had been 30 mm, then the error is –0.2
mm.
Sensitivity
• Sensitivity of a sensor is defined as the ratio of change in output value of a
sensor to the per unit change in input value that causes the output change. For
example, a general purpose thermocouple may have a sensitivity of 41 μV/°C.
 Sensor and Transducer Specifications
Accuracy
• The accuracy defines the closeness of the agreement between the actual
measurement result and a true value of the measurand.
• It is often expressed as a percentage of the full range output or full–scale deflection.
Resolution
• Resolution is the smallest detectable incremental change of input parameter that can
be detected in the output signal. Resolution can be expressed either as a proportion
of the full-scale reading or in absolute terms.
• Example: if a LVDT sensor measures a displacement up to 20 mm and it provides
an output as a number between 1 and 100 then the resolution of the sensor device is
0.2 mm.
Stability
• Stability is the ability of a sensor device to give same output when used to measure
a constant input over a period of time. The term ‘drift’ is used to indicate the change
in output that occurs over a period of time. It is expressed as the percentage of full
range output.
 Sensor and Transducer Specifications
Dead band/time
• The dead band or dead space of a transducer is the range of input values for
which there is no output. The dead time of a sensor device is the time
duration from the application of an input until the output begins to respond
or change.
Repeatability/Precision
• It specifies the ability of a sensor to give same output for repeated
applications of same input value. It is usually expressed as a percentage of
the full range output:

Response time
• Response time describes the speed of change in the output on a step-wise
change of the measurand. It is always specified with an indication of input
step and the output range for which the response time is defined.
Sensor and Transducer Specifications

Accuracy vs. Resolution

True value

measurement
Sensor and Transducer Specifications

Accuracy vs. Precision

Precision without Accuracy without Precision and

accuracy precision accuracy
 Sensor and Transducer Specifications
Hysteresis
• The hysteresis is an error of a sensor, which is defined as the maximum
difference in output at any measurement value within the sensor’s
specified range when approaching the point first with increasing and then
with decreasing the input parameter.
Sensor and Transducer Specifications

Nonlinearity
• The nonlinearity indicates the maximum
deviation of the actual measured curve of a
sensor from the ideal curve.
• Linearity is often specified in terms of
percentage of nonlinearity, which is defined
as:

• The static nonlinearity is dependent upon

environmental factors, including temperature,
vibration, acoustic noise level, and humidity.
• Therefore it is important to know under what
conditions the specification is valid.
• Measurement

• Sources of error
Definitions

• Measurement
Set of operations having the object of determining a value of a
quantity

Note: all measurements are subject to error

Definitions

Error (of measurement)

Result of a measurement minus a true value of the measurand

value.
NOTE
Since a true value cannot be determined, in practice a
conventional true value is used e.g. assigned value, best estimate,
reference value etc.

errors are subject of uncertainty.

 Errors in measurement systems

• It is extremely important in any measurement system to reduce errors to the

minimum possible level.
• What will happen if errors are not reduced?

DEFINITIONS

▪ Absolute Error (maximum possible limiting error)

▪ Relative Error (a) is the ratio of the absolute error to the nominal measurand value.

▪ Percentage error
Errors in measurement systems
Example: For a resistor of (200 )Ω
While the reference value is 201.5 Ω

Estimate
(a) Absolute error
(b) Relative error
(c) Percentage error

a) Absolute error

b) Relative error

c) Percentage error
 Errors in measurement systems

Example: A voltage has a nominal value of 1.5 V. An analog indicating

instrument with a scale range of 0 − 2.5 𝑉 shows a 1.46 𝑉 What are the
voltage values of absolute and relative errors?

Solution

• Absolute error

• Relative error is
0.0267
• Percentage error
= 2.67%
 Errors in measurement systems
In the calibration process of the temperature sensor, the followings
Example:
are the reading of the sensor V and the reference value.

Reference 40.2 80.5 120.6 161.0 201.5 242.3

value (oC)
Measured 40 80 120 160 200 240
value(oC)
Estimate
(a) Absolute error
(b) Relative error
(c) Percentage error
(d) If the accuracy of the sensor is 1%
Specify the maximum permissible error of the sensor
 Errors in measurement systems

Reference Measured Absolute Relative Percentage Maximum

Value (oC) Value (oC) error (oC) error error (%) error (oC)
40.2 40 0.2 0.005 0.5 0.4

80.5 80 0.5 0.00625 0.625 0.8

120.6 120 0.6 0.005 0.5 1.2

161.0 160 1.0 0.00625 0.625 1.6

201.5 200 1.5 0.0075 0.75 2.0

242.3 240 2.3 0.0096 0.96 2.4

Max
 Errors in measurement systems

Example: A 0 − 150 𝑉 voltmeter has accuracy of 1% of full scale reading. The

voltage measured by this instrument is 75 𝑉. Calculate the max
permissible error and relative error

Solution
Maximum permissible error at the measured point = 0.01×75 =0.75 V

Maximum permissible error at the full range = 0.01×150 =1.5 V

The relative error =

 End of Lecture

Thank you for attention!

Any questions?

Dr. Bikheet Mohamed Sayed

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