Introduction to Mechatronic Systems

Md. Faisal Rahman Badal

Assistant Professor
Dept. of Mechatronics Engineering, RUET
 Course Content
Introduction: Definitions of Mechatronics, Overview of different Mechatronic systems, Scope
and applications of Mechatronics.
Sensors and transducers: Basic principles of potentiometer, op-amps, Wheatstone bridge,
introduction to sensors and transducers, sensor terminologies, sensor characteristics, classification
of sensors, proximity sensors.
System Modeling and Control: Introduction to signals and systems, Modeling of Mechanical,
Electrical, Fluid and Thermal systems, Linearization of nonlinear systems, Rotational-
translational systems, Electro-Mechanical systems and Hydraulic-Mechanical System. Basic
components of Control system, Types of control system, System representation, System
responses, Time constant, Measurement of system performance, Transfer function, Block diagram
and Illustrative examples.
Actuation systems: Linear and rotary actuators. AC and DC motors, Solenoids, Stepper motor,
Fluid power actuators and Smart actuators.
Recent trends in Mechatronic systems.

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 Reference Books
Text Book:

1. William Bolton, Mechatronics: Electronic Control System in Mechanical and Electrical

Engineering.

Reference Book
1. R. K. Rajput, A Text Book of Mechatronics.
2. De Silva, Clarence W, Mechatronics : An Integrated Approach

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Learning Outcomes
1. Describe the importance of Mechatronics Engineering in this modern era
2. Describe the basic components to design an Mechatronic product
3. Explain the characteristics of different control scheme.

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 Mechatronics
The word mechatronics is composed of “mecha” from mechanical and the “tronics” from
electronics.

Mechanical + Electronics = Mechatronics

“Mecha” + “Tronics” = Mechatronics

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 Definition of Mechatronics System
➢ Mechatronic engineering is an interdisciplinary field that combines mechanical
engineering, electronics, computer science, and control engineering to design, build, and
maintain intelligent systems and automation technologies.
➢ These systems often have mechanical and electronic components that interact through
software and control algorithms, enabling complex functionalities that are adaptable and
efficient.
➢ A mechatronic system is not just a combination of electrical and mechanical systems and is
more than just a control system; it is a complete integration of all of them in which there is a
concurrent approach to the design.

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 Mechatronics System
❖ If we just combine mechanical systems, electrical systems, computer science and control system
together, then will it be a mechatronic system?

➢ Not quite- it’s more than just combining mechanical, electrical, computer, and control systems.
➢ A true mechatronic system is designed to integrate these elements seamlessly so they work together in a
cohesive, intelligent, and efficient way.
➢ To create a mechatronic system, engineers follow an integrated design approach where each component is
developed with the others in mind. The approaches are:
✓ System Integration – Mechatronics isn’t just about assembling parts but integrating them so they
interact and communicate seamlessly. For example, a robotic arm isn’t just mechanical parts with
electronics added; it’s designed so motors, sensors, and software control algorithms are interwoven to
respond to commands and adjust in real time.
✓ Feedback and Adaptability – Mechatronic systems often use sensors to gather data about their
environment or their own performance, which the system can then use to make adjustments. For
instance, an autonomous drone uses data from sensors (like GPS and accelerometers) combined with
control software to adjust its position and avoid obstacles.

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 Mechatronics System
✓ Precision and Control – Mechatronic systems are built to perform precise actions, often using
control theory to manage how they respond to inputs. For example, a 3D printer doesn’t just move
along preset paths; its software and control systems adjust movements to create a highly accurate
print layer by layer.
✓ Software-Driven Functionality – Software in mechatronic systems isn’t merely a background
feature; it’s a core part of how the system operates, adding intelligence and adaptability. For example,
in self-driving cars, the software interprets sensor data, decides on actions, and communicates
instructions to the mechanical components to control steering, acceleration, and braking.
✓ Human-Machine Interaction – Many mechatronic systems are designed with user interaction in
mind, such as medical devices with intuitive user interfaces or robotic systems that respond to human
commands in real-time. This involves not only physical controls but also user feedback mechanisms
to enhance safety and usability.

➢ So, a mechatronic system is much more than a simple combination of parts; it’s a fully integrated,
adaptive, and intelligent system where each component contributes to the overall functionality in a
coordinated way.

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 Mechatronics System
Mechatronics a combination of

➢ Mechanical
➢ Electronic
➢ Computer
➢ Software
➢ Control
➢ Artificial Intelligence
➢ Machine Learning
➢ Systems Design

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 Applications of Mechatronics System
➢ Robotics – Designing robots that automate tasks in manufacturing, healthcare, or service sectors.
➢ Automotive Systems – Developing intelligent car systems, including ABS brakes, adaptive cruise
control, and automated driving technologies.
➢ Home Automation – Creating smart home devices like robotic vacuum cleaners or thermostats that
learn from user behavior.
➢ Medical Devices – Designing devices like prosthetics, surgical robots, automated drug delivery
systems, where accuracy and safety are paramount for patient care.
➢ Drones and UAVs – Designing and optimizing drones for diverse uses, such as aerial photography,
delivery services, agriculture, and environmental monitoring.
➢ Automated Manufacturing Systems – Designing conveyor belts, robotic arms, and automated
assembly lines that work together with precise timing and coordination to improve productivity,
quality, and safety in production environments.
➢ Space Exploration Rovers and Probes – Mars rovers and space probes rely heavily on
mechatronics, integrating complex mechanical structures, sensors, power systems, and software that
enable remote operation and autonomy in extreme environments.

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Examples of Mechatronics System

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Area of Mechatronics System

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 Traditional Vs. Mechatronics Designs
Engineering design is a complex process involving interactions between many skills and
disciplines.

With traditional design, the approach was for the mechanical engineer to design the mechanical
elements, then the control engineer to come along and design the control system. This gives
what might be termed a sequential approach to the design.

However, the basis of the mechatronics approach is considered to lie in the concurrent
inclusion of the disciplines of mechanical engineering, electronics, computer technology and
control engineering in the approach to design. The inherent concurrency of this approach
depends very much on system modelling and then simulation of how the model reacts to inputs
and hence how the actual system might react to inputs.

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 Basic Elements of Mechatronics System
There are several elements of mechatronics system, such as:

➢ Sensor: Sensor is an element that convert the physical signal/quantities into electrical signal.
✓ Example: Thermocouple, Accelerometer, Infrared Sensor etc.
➢ Transducer: Transducer converts a signal from one form to another.
✓ Example: Strain Gauge, LVDT etc.
➢ Actuator: It converts the electrical signal into physical signal/quantities.
✓ Example: Electric Motor, Solenoid etc.
➢ Circuit Conditioner: It is use to amplify, filtering the input/output signal.
✓ Example: Filter, Amplifier, Converter etc.
➢ Controller: The controller is used to control the desire performance of the system.
✓ Example: Arduino, Microcontroller, Fuzzy Logic, PID etc.
➢ Display: It is used to display the signal of the system.
✓ Example: LCD, Recorder etc.

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 Benefits of Mechatronics System
➢ Enhanced Feature & Functionality
➢ More User Friendly
➢ Accuracy
➢ Increases Efficiency
➢ Cost Effective
➢ Flexible Design (Reprogrammable)
➢ Safe

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 System
A system can be thought of as a box or block diagram which has an input and an output and
where we are concerned not with what goes on inside the box but with only the relationship
between the output and the input that provides a special task.

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 Modelling

The term modelling is used when we represent the behavior of a real system by mathematical
equations, such equations representing the relationship between the inputs and outputs from the
system.

The relationship between the input and output for an spring can be represented as,

F=kx
Where,
F= force,
x= displacement
k= spring constant

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 Measurement System

A measurement system can be thought of as a box which is used for making measurements. It
has as its input the quantity being measured and its output the value of that quantity. For
example, a temperature measurement system, i.e. a thermometer, has an input of temperature
and an output of a number on a scale.

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 Measurement System
A measurement system consists of three basic elements:

1. Sensor
2. Signal conditioner
3. Display

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 Measurement System
1. Sensor: A sensor responds to the quantity being measured by giving as its output a signal
which is related to the quantity. For example, a thermocouple is a temperature sensor.

2. Signal Conditioner: A signal conditioner takes the signal from the sensor and manipulates
it into a condition which is suitable either for display or, in the case of a control system, for
use to exercise control. Thus, for example, the output from a thermocouple is a rather small
e.m.f. and might be fed through an amplifier to obtain a bigger signal. The amplifier is the
signal conditioner.

3. Display: A display system displays the output from the signal conditioner. This might, for
example, be a pointer moving across a scale or a digital readout.

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 Digital Thermometer System
Consider a digital thermometer. This has an input of temperature to a sensor, probably a
semiconductor diode. The potential difference across the sensor is, at constant current, a
measure of the temperature. This potential difference is then amplified by an operational
amplifier to give a voltage which can directly drive a display. The sensor and operational
amplifier may be incorporated on the same silicon chip.

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 Signal

A signal is an electrical or electromagnetic current that is used for carrying data from one
device to another.

There are two types of signals, such as:

1. Continuous
2. Discrete

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 Signal

1. Continuous Signal:
Continuous signals are the signals or quantities that can be defined and represented at any
instant of time in the sequence.

2. Discrete Signal:
Discrete signals are the signals or quantities that can be defined and represented at certain time
instants of the sequence.

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 Control System

A control system consists of subsystems and processes (or plants) assembled for the purpose
of obtaining a desired output with desired performance, given a specified input.

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 Types of Control System

There are two basic forms of control system,

➢ Open-loop control system

➢ Closed-loop control system

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 Open-loop Control System

➢ A control system in which the output does not produce any effect on the control action is
called open-loop control system.

➢ This output of this system is not measured or fed back to make a compression with the
reference signal.

➢ The feedback control element is absent in this control system.

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 Open-loop Control System

Consider an electric fire which has a selection switch which allows a 1 kW or a 2 kW heating
element to be selected. If a person used the heating element to heat a room, he or she might just
switch on the 1 kW element if the room is not required to be at too high a temperature. The
room will heat up and reach a temperature which is only determined by the fact that the 1 kW
element was switched on and not the 2 kW element. If there are changes in the conditions,
perhaps someone opening a window, there is no way the heat output is adjusted to compensate.

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 Open-loop Control System
Advantages:
➢ Easy to construct
➢ Easy to operate
➢ Less expensive
➢ Less maintenance is required

Limitations:
➢ Required proper calibration
➢ Low precession and accuracy
➢ Optimization is not possible
➢ Slow response
➢ Highly sensitive to disturbance

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 Closed-loop Control System

➢ A control system in which the controlled variable produces an effect on the control action is
called closed-loop or feedback control system.

➢ A closed-loop control system has one or more feedback path through which the output is
compared with the reference signal.

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 Closed-loop Control System
An automatic control system for the control of the room temperature could involve a
thermostatic element which is sensitive to temperature and switches on when the temperature
falls below the set value and off when it reaches it. This temperature-sensitive switch is then
used to switch on the heater. The thermostatic element has the combined functions of
comparing the required temperature value with that occurring and then controlling the
operation of a switch. It is often the case that elements in control systems are able to combine a
number of functions.

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 Closed-loop Control System
Advantages:
➢ Provides higher accuracy and precession
➢ Optimization is possible
➢ Higher reliable
➢ Higher flexible
➢ Less sensitive to noise and disturbance.

Limitations:
➢ Difficult to construct
➢ Difficult to maintain
➢ Difficult to install
➢ High expensive.

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 Basic Elements of a Closed-loop System

A closed-loop control system consists of five elements, such as:

1. Comparison element
2. Control element
3. Correction element
4. Process element
5. Measurement element

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 Basic Elements of a Closed-loop System
1. Comparison element:
This compares the required or reference value of the variable condition being controlled with
the measured value of what is being achieved and produces an error signal.
error signal = reference value signal - measured value signal

2. Control element:
This decides what action to take when it receives an error signal.

3. Correction element:
The correction element produces a change in the process to correct or change the controlled
condition.

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 Basic Elements of a Closed-loop System
4. Process element:
The process is what is being controlled.

5. Measurement element:
The measurement element produces a signal related to the variable condition of the process
that is being controlled.

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Example: Water Level Control in a Tank

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 Example: Water Level Control in a Tank
Consider a simple control system used to maintain a constant water level in a tank. The
reference value is the initial setting of the lever arm arrangement so that it just cuts off the
water supply at the required level. When water is drawn from the tank the float moves
downwards with the water level. This causes the lever arrangement to rotate and so allows
water to enter the tank. This flow continues until the ball has risen to such a height that it has
moved the lever arrangement to cut off the water supply.

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Example: Motor Control System

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 Example: Motor Control System
Consider a simple automatic control system for the speed of rotation of a shaft. A
potentiometer is used to set the reference value, i.e. what voltage is supplied to the differential
amplifier as the reference value for the required speed of rotation. The differential amplifier is
used both to compare and amplify the difference between the reference and feedback values,
i.e. it amplifies the error signal. The amplified error signal is then fed to a motor which in turn
adjusts the speed of the rotating shaft. The speed of the rotating shaft is measured using a
tachogenerator, connected to the rotating shaft by means of a pair of bevel gears. The signal
from the tachogenerator is then fed back to the differential amplifier:

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