Introduction to Mechanical Engineering

MODULE-5 IME-22ESC144

Introduction to Mechatronics and Robotics

Mechatronics is defined as a multidisciplinary field of engineering that includes a combination

of systems engineering: mechanical engineering, Electric/Electronic Engineering, control
engineering, and computer engineering.

Open loop & Closed loop mechatronic systems (Control systems)

1. Open loop (control) system
2. Closed loop (control) system
1. Open Loop Systems
Open loop systems have no access to the real time data about the performance of the system and
therefore no immediate corrective action can be taken in case of system disturbance.
i.e. open loop systems are systems in which input to the system is not controlled by the present
output.

Block Diagram of an Open Loop System.

 In open loop systems the slide (Work table) may overshoot or may not reach desired
position because of inertia, wear and tear and friction, hence inaccurate machining.
Advantages:
- Simple design and easy to construct.
- Economical.
- Easy for maintenance.
- Highly stable operation.
- Convenient when output is difficult to measure.
Dis-advantages:
- Not accurate
- Recalibration of the parameters are required time to time.

Examples of Open Loop Control System

1. Electric Hand Drier – Hot air (output) comes out as long as you keep your hand under the
machine, irrespective of how much your hand is dried.
2. Automatic Washing Machine – This machine runs according to the pre-set time irrespective
of washing is completed or not.

2. Closed Loop Systems

A closed loop system automatically regulates a process variable to a desired state or set
point without human interaction. i.e. in a closed loop system, feedback devices closely monitor
the output and any disturbance will be corrected in the first instance.

Block Diagram of a Close Loop System

 In closed loop systems the position sensors are used to correct slide (work table)
movements and achieve higher accuracy and repeatability.
Advantages:
• More accurate operation than that of open-loop control system.
• Can operate efficiently when system parameters are variable in nature.
• There is facility of automation.
• Time to time recalibration of the parameters are not required.
Dis-advantages:
• Complex design and difficult to construct.
• Expensive than that of open-loop control system.
• Complicate for maintenance.
• Sometimes becomes unstable
Examples of Closed Loop Control System
Automatic Electric Iron – Heating elements are controlled by output temperature of the
iron.
An Air Conditioner – An air conditioner functions depending upon the temperature of
the room.

Comparison between open loop and closed loop systems

Examples of Mechatronic Systems
1. Airbag deployment systems
2. Automatic washing machines
3. The automatic bread toaster
4. Flight control system
5. Factory robots (for welding, spray painting, assembly, inspection, etc.)
6. Modern computer-numerical control (CNC) machine
7. Dishwashers
8. Space vehicles

Example 1: Working principle of an Airbag deployment systems

The airbag is a typical mechatronic system. It consists of three main parts: a sensor, a
controller and an actuator. The acceleration sensor registers a sudden change in acceleration
and transmits a corresponding signal to the controller. The controller in turn sends signals
to activate an initiator. This results in the chemical propellant inside the inflator to undergo
a rapid chemical reaction. This reaction produces nitrogen gas that fills the air bag and
inflates it in front of the person seated in the car.
Example 2: Working principle of an Automatic washing machines
Automatic washing machines have integrated sensors, controllers and a programmer to
measure the load, fill with water and adjust the temperature. Various program are executed to
agitate, wash, rinse and spin dry. In some cases they will even use hot air drying. The washing and
wringing cycle time is set on a timer and the washer is energized. When the cycle is completed, the
machine switches itself off.

Robotics
Definition:
A robot is a reprogrammable multifunctional manipulator designed to move material, parts,
tools, or specialized devices through variable programmed motions for the performance of a variety
of tasks.
Advantages of robots
1. Robots can perform operations with precision & repeatability every time. This level of
consistency can be difficult to achieve with human labours.
2. Robots have the ability to work continuously at constant speed without breaks. This makes
them suitable for mass production applications.
3. Robots increase workplace safety. They are complete replacements for human labours
working under harsh and hazardous environments.
4. Reduces production costs, time, and material waste thereby helping in financial savings.
5. Can be programmed to perform variety of tasks.
6. Robots can process multiple tasks simultaneously, humans can process only one at a time.
7. Robots and their sensors can have capabilities beyond that of humans

Disadvantages of robots
1. High initial investment and maintenance costs resulting in increased costs.
2. Robots are incapable of performing task outside of their predefined programming.
3. Cannot handle unexpected situations. Hence they cannot completely replace human
labours.
4. Cannot move easily. They have some degrees of freedom
5. Require considerable human intervention to perform some complex tasks.
6. Use of robot can lead to increases in unemployment.

ROBOT APPLICATIONS
1. Material-handling applications
Involve the movement of material or parts from one location to another. It includes part
placement, palletizing and/or de-palletizing, machine loading and unloading.
2. Processing Operations
Robot performs a process on the part. The robot is equipped with some type of process tooling
as its end effectors. Manipulates the tooling relative to the working part during the cycle. Industrial
robot applications in the processing operations include:
 Welding
 Spray painting
 Metal cutting operations
 Various machining operations like drilling, grinding, laser and water jet cutting, and
riveting.

3. Part-Placement:
The basic operation in this category is the relatively simple pick-and-place operation. This
application needs a low-technology robot of the cylindrical coordinate type.
4. Palletizing and/or De-palletizing

The applications require robot to stack parts one on top of the other, that is to palletize them, or to
un-stack parts by removing from the top one by one that is de-palletize them. Example: process of
taking parts from the assembly line and stacking them on a pallet or vice versa.

5. Machine loading and/or unloading

Robot transfers parts into and/or from a production machine.

There are three possible cases:
 Machine loading in which the robot loads parts into a production machine, but the parts are
unloaded by some other means.
Example: a press working operation, where the robot feeds sheet blanks into the press, but the
finished parts drop out of the press by gravity.
 Machine loading in which the raw materials are fed into the machine without robot
assistance. The robot unloads the part from the machine assisted by vision.
 Machine loading and unloading that involves both loading and unloading of the work parts
by the robot. The robot loads a raw work part into the process ad unloads a finished part.
Example: Machine operations

6. Stacking and insertion operation

In the stacking process the robot places flat parts on top of each other. In the
insertion process robot inserts parts into the compartments of a divided carton.

Robot Configuration:
Industrial robots come in a variety of shapes and sizes. They are capable of various arm
manipulations and they possess different motion systems. Robot configuration specifies the
possible movements provided by different robots
Classification based on robotics configuration
1. Cartesian configuration robot
2. Cylindrical configuration robot
3. Polar (or spherical) configuration robot
4. Jointed-arm robot.

1. Cartesian configuration robot

Cartesian co-ordinate robot consists of three perpendicular slides designed to move parallel to
the X, Y and Z axis of a Cartesian coordinate system.. By moving these three slides relative to one
another the robot is capable of operating within a rectangular work area. It robot is also called as
XYZ robot, rectilinear robot (or) Box configuration robot.

No need to
draw this Draw these two figures
figure

Advantages, disadvantages & applications of Cartesian configuration robot

Advantages
1. Simple controls due to linear movements and also easy to visualize
2. High degree of mechanical rigidity, accuracy and repeatability
3. Can carry heavy loads
4. Since movement can start and stop simultaneously along all three axis, motion of the wrist
end is smoother.

Disadvantages
1. The arm movement is limited to a small rectangular work space.
2. Occupy large area.
Applications
1. Assembly
2. Welding
3. Machine loading and unloading
4. Surface finishing
5. Inspection

2. Cylindrical configuration robot

Cylindrical configuration robot is so called because the arm movement of the robot is designed
to move according to the cylindrical coordinate system. A robot designed with this type of
configuration consists of a vertical column and a slide that can move up and down long the
column as shown in the fig. The column can rotate about a vertical axis and hence is capable of
achieving a work space similar to cylinder.

No need to
draw this
figure Draw these two figures

Advantages, disadvantages & applications of cylindrical configuration robot

Advantages
1. Larger work space than Cartesian configuration
2. Relatively easy to program
Disadvantages
1. Overall mechanical rigidity is reduced
2. Robot’s repeatability and accuracy also reduced in the direction of rotary movement
3. Requires a more sophisticated control system than the Cartesian configuration.
Applications
1. Assembly
2. Machine loading and unloading
3. Forging operations
4. Investment casting
5. Conveyor pellet transfer
6. Coating applications

3. Polar configuration robot (Spherical Coordinate robot)

This configuration also goes by the name “spherical coordinate” because the workspace
within which it can move its arm is a partial sphere. It consists of a rotary base and a pivot
 that can be used to raise and lower a telescopic arm similar to the formation of an arc
movement as shown in fig. The sliding arm can be extended or retracted to provide reach.

No need to Draw only this figure

draw this
figure

Advantages, disadvantages & applications of polar (spherical) configuration

robot
Advantages
1. Can generate large working space
2. Simple in design and hence easy to program
3. Provides good weight lifting capabilities
Disadvantages
1. Has reduced mechanical rigidity
2. Need for sophisticated control system
3. Limited vertical movement

Applications
1. Die casting,
2. Injection moulding,
3. Forging,
4. Dip coating
5. Material transfer

4. Jointed-arm configuration robot

This is similar in appearance to the human arm, as shown in above fig. The arm consists of
straight members connected by joints which are analogous to the human shoulder, elbow, and
wrist. The robot arm is mounted to a base which can be rotated to provide the robot with the
 capacity to work within a quasi-spherical space. The workspace within which this robot can
move it’s arms is irregular.

No need to Draw only this figure

draw this
figure

Advantages, disadvantages & applications of jointed arm configuration

robot
Advantages
1. Most flexible configuration that enables the robot arm to move in all directions
2. Large working envelope(space)
3. Versatile configuration
Disadvantages
1. Requires complex programming
2. Control actions are difficult
3. Less stable as the arm approaches maximum reach

Applications
1. Painting
2. Welding
3. Pick and place operations involving light parts

Automation in industry
Definition of automation:
It is the technology by which a process or procedure is accomplished without human
assistance. It is a technology concerned with the application of mechanical, electronics and
computer based systems to operate and control production.
Types of automation
1. Fixed (or) Rigid automation
2. Programmable automation
3. Flexible automation

1. Fixed (or) Rigid automation

As the name suggests in this automation the sequence of operations are fixed and easier to
perform. It is used when the volume of production is high and product variety is low. This kind of
automation is mostly suitable for mass production.
Here the equipment is specially designed to produce a particular product. If the product
changes the same equipment cannot be used.
Fixed automation has very high production rates. Overall investment is less when compared
to other types of automation.
Ex: Oil refineries, chemical processing, Assembly lines

2.Programmable automation
In this type of automation sequence of operations can be interchanged. The sequence of
operations are controlled by program of instructions. If the product is changed only program of
instructions are changed but not the equipment. It used when production volume is low.
 This kind of automation is more suitable for batch production. The product variety will be
high compared to fixed automation. If the product changes, the same equipment can be used
with minimal changes. High investment in general purpose equipment.
Ex: NC machines, Industrial robots

3. Flexible automation
It is an extension of programmable automation. A flexible automation system is capable of
producing a large variety of parts with virtually no time lost for change over from one part style
to the next. Changing the program is accomplished by preparing the program off line and
electronically transmitting the programs so, programming does not interrupt on the current job.
It covers advantages of both fixed and programmable automation. The production rates are
medium. It can deal with variety of products but less than that of programmable automation.
High investment.
Ex: Flexible manufacturing systems for performing machining operations
 Basic elements of automation

An automated system consists of three basic elements:

1. Power: To accomplish the process and operate the system
2. Program of instructions: To direct the process
3. Control systems: To actuate the instructions
The relationship amongst these elements is illustrated in Figure. All systems that qualify as
being automated include these three basic elements in one form or another.
Power:
An automated system is used to operate some process, and power is required to drive as well
as to control. The principal source of power in automated systems is electricity. Electric power has
many advantages in automated as well as non - automated processes.
Modern industrial controllers are based on digital computers, which require electrical power
to read the program of instructions, make the control calculations, and execute the instructions by
transmitting the proper commands to the actuating devices.

Program of Instructions
The actions performed by an automated process are defined by a program of instructions.
Each part or product style made in the operation requires one or more processing steps that are
unique to that style, These processing steps are performed during a work cycle. A new part is
completed during each work cycle (in some manufacturing operations, more than one part is
produced during the work cycle; e.g., a plastic injection molding operation may produce multiple
parts each cycle using a multiple cavity mold). The particular processing steps for the work cycle
are specified in a work cycle program. Work cycle programs are called part programs in numerical
control.
Control System
The control element of the automated system executes the program of instructions. The
control system causes the process to accomplish its defined function.
The controls in an automated system can be either closed loop or open loop. A closed loop
control system, also known as a feedback control system automatically regulates a output variable
to a desired state or set point.
A closed loop control system consists of six basic elements: (I) input parameter, (2) process, (3)
output variable, (4) feedback sensor. (5) controller (6) actuator.
The input parameter often referred to as the set point
A sensor is used to measure the output variable and close the loop between input and output.
Sensors perform the feedback function in a closed loop control system. The controller compares the
output with the input and makes the required adjustment in the process to reduce the difference
between them.

Advantages of automation
1. To increase productivity:
The automation of processes can increase productivity by reducing the time to perform the
repetitive tasks. Since increased productivity with less time and labour cost means increase
in profit.
2. To reduce labour cost/ Overheads:
Cost savings are also made by reduction of training that staff will require. Less training, so
less overheads.
3. To eliminate routine work:
A work force who does not do repetitive tasks and worry about achieving high degree of
accuracy each time will actually be a happier workforce because automation solves all these
problems

4. To improve worker safety: By implementing automation, workers can be safe guarded from
hazardous environment.

5. To improve product quality: Automated processes will reduce defects, which lead to increase
in the product quality.

6. To reduce manufacturing lead time: Automation helps to reduce the time taken from the
customer order to the delivery of product.

7. Fewer accidents: Automation results in elimination of labour and therefore reduced number
of accidents.
 8. To reduce the effect of high cost of raw materials: Reduces the wastage of raw materials
during processing thereby most of the raw materials can be converted into products.

Introduction to Internet of Things (IoT)

Definition of IoT:
It is a dynamic global network infrastructure with self-configuring capabilities based on
standard and interoperable communication protocols where physical and virtual “things” have
identities, physical attributes and virtual network and use intelligent interfaces.
The internet of things (IoT) is a web connected system in which physical objects are being
connected to the internet and being able to identify themselves to other devices

Characteristics of IoT
Various characteristics of IoT are:
• Dynamic and self-adapting
• Self-configuring
• Interoperable Communication protocols
• Unique identity
• Integrated into information network
Dynamic and self-adapting:
The IoT devices can dynamically adapt with sensed environment, their operating conditions,
and user’s context and take actions accordingly. For ex: Surveillance System.
Consider a surveillance system where cameras are installed for monitoring a location.
Whenever there are no objects in front of the camera, the camera will be in a low power mode.
Whenever an object is detected, the camera resumes its activity of monitoring that object.
This is the dynamic behaviour. The cameras also respond to changes in the environment. If it is
night time, the cameras might shift to infrared mode and vice versa during day time. Also, the
cameras can adjust their picture clarity based on the environment. Thus IoT devices can self adapt
to changes in the environment.

Self-configuring:
- IoT devices can upgrade the software with minimal intervention of user, whenever they are
connected to the internet.
- They can also setup the network i.e a new device can be easily added to the existing
network. For ex: Whenever there will be free wifi access one device can be connected
easily.
Interoperable Communication:
IoT allows different devices (different in architecture) to communicate with each other as
well as with different network. For ex: MI Phone is able to control the smart AC and smart TV of
different manufacturer.

Unique identities:
- The devices which are connected to the internet have unique identities i.e IP address
through which they can be identified throughout the network.
- The IoT devices have intelligent interfaces which allow communicating with users. It
adapts to the environmental contexts.
- It also allows the user to query the devices, monitor their status, and control them
remotely, in association with the control, configuration and management
infrastructure.
Integrated into information network:
- The IoT devices are connected to the network to share some information with other
connected devices. The devices can be discovered dynamically in the network by other
devices. For ex. If a device has wifi connectivity then that will be shown to other nearby
devices having wifi connectivity.
- II. The devices ssid will be visible though out the network. Due to these things the
network is also called as information network.
- The IoT devices become smarter due to the collective intelligence of the individual
devices in collaboration with the information network. For Ex: weather monitoring
system. Here the information collected from different monitoring nodes (sensors,
arduino devices) can be aggregated and analysed to predict the weather.

Physical design of IoT (General Block Diagram of IoT)

Things in IoT
The word “Things” refers to IoT devices which have unique identities and can perform
remote sensing, actuating and monitoring capabilities.

IoT devices
- can exchange data with other connected devices and applications (directly or indirectly),
- Collect data from other devices and process the data locally or send the data to centralized
servers to process the data
- Perform some tasks locally and other tasks within the IoT infrastructure, based on temporal
and space constraints

The IoT devices consists of several interfaces for connection to other devices both wired and
wireless which includes
1. I/O interfaces for sensors
2. Interfaces for internet connectivity
3. Memory and storage
4. Audio and video interface

Logical design of IoT

Logical design of IoT refers to an abstract representation of entities and the processes
without going into the details of the implementations.
The logical design includes
(1) Functional block of IoT
(2) Communication model of IoT(Communication APIs )
1. IoT functional Block :
The functional block of the system provides the capabilities for identification, sensing,
actuation, communication and management.
 Various components of IoT functional block are as follows.
• Device
• Communications
• Services
• Management
• Security
• Application

Device:
- IoT i.e Internet of things, where things refer to the IoT devices which have unique
identities and can perform remote sensing, actuating and monitoring capabilities (ex:
combination of sensors, actuators, Arduino, relay, non IoT devices).
- The IoT devices can share information with as well as collect information from other
connected devices and applications (directly and indirectly).
- They can process the data locally or in the cloud to find greater insights and put them
into action based on temporal and space constraints (i.e space memory, processing
capabilities, communication latencies and speeds and deadlines).
- IoT devices can be of varied types. For ex: wearable sensors, smart watches, LED
lights, automobiles and industrial machines.
Communications:
It refers to various communication protocols which allows different devices to communicate
with each other by sharing some information. It also allows interoperability among different
devices.
Services:
IoT system provides various services such as device monitoring, device control services, data
publishing services, device discovery services.
Management: Various management functions to govern the IoT system.
Security: It secures the IoT system by providing authentication, authorization, message and
content integrity and data security.
Application:
- IoT applications provide an interface that the users can use to control and monitor
various aspects of the IoT system.
- It also allows viewing the system status and view or analysing the processed data.

2. IoT Communication model

To provide communication to various IoT devices, there are various communication
models. Such as
 • Request-Response communication model
• Publisher-subscriber communication model
• Push-pull communication model
• Exclusive-pair communication model

Request-Response communication model

- In this communication model client will send request to server. Server will receive the
request then decides how to respond, fetches the data according to client’s request, retrieves
resource representations, prepares the response and then sends the response to client.
- Request-response model is a stateless communication model i.e each request-response pair
is independent of others. Ex: HTTPs requests to log in some secure sites like IRCTC.
- Here only client can request to the server. i.e request is unidirectional but data transfer is bi-
directional.
- IoT devices act as client. Cloud act as server or local server serves as server.

Publish-Subscribe communication model:

- This communication model comprises of publisher, broker, and consumer.

- Publishers are the source of data i.e the devices or applications which generate data. Publisher
publishes the data to the requested topic by the client or consumer into the server.
- Broker manages the topics in server. Broker receives the data from the client or publisher and
forwards the message to topics on the topics subscribed by the clients.
- Consumer or clients (applications that process the data) subscribe to various topics present
inside server. When the publisher publishes the data to the requested topics they will receive
it from the broker.
- The publisher doesn’t know about the client, but knows about the broker. Likewise client does
not know about the publisher but knows about the broker.
- Ex-when one user subscribe to any channel in you-tube.

Push-Pull communication model:

- Push-pull is a communication model in which the data producers push the data to the
queues and the consumers pull the data from the queues.
- Producers do not need to be aware of the consumers.
- Queues act as buffer which helps in situations when there is a mismatch between the
rate at which the producers push the data and the rate at which the consumers pull the
data.
Exclusive pair communication model:

- Exclusive pair is a bi-directional, full duplex communication model.

- It uses state-full protocols i.e we don’t need to log in again and again.
- It uses a single http connection i.e persistent connection between the client and the
server i.e once the connection is set up it remains until the client sends the request to
close the connection.
- It also supports client-server architecture.
- It is a stateful communication model and the server is aware about all the open
connection.
IoT Protocols
Link Layer
This protocol determines how the data is physically sent over the network layer (e.g.
copper wire, coaxial cable or a radio wave). It determines how the packet are coded and signaled
by the hardware device over the medium to which the host is attached. Example:-
1. IEEE 802.3--Ethernet (wired connection) 2. 802.11 –Wi-Fi 3. 802.16—WiMax
4. 2G/3G/4G—Mobile communication
Network/Internet Layer
The network layers are responsible for sending of IP datagram’s from the source
network to the destination network. It performs host addressing and packet routing. The
datagram’s consists of source and destination addresses where host identifies using IP schemes
as IPV4 and IPV6.
IPV4:- It is used to identify the devices on a network using hierarchical addressing scheme. It
uses 32- bit address that allows total 2^32 or 4 billion devices 128
IPV6:- It is the new version of internet protocol which uses 128-bits address that allows 2^128
or 3 X 10^38 address.
Transport Layer
The transport layer protocols provide end to end message transfer capability
independent of the underlying network. The function of the transport layer is to provide functions
such as error control, segmentation, flow control and congestion control.
TCP (Transmission Control Protocol): - It is most widely used for data transmission in
communication network such as internet. It provides process to process communication using port
numbers. It uses port number for communication which keeps track of segments that are received
and transmitted.
UDP (User Datagram Protocol) - It is the simplest protocol that involves minimum amount of
communication mechanism. It is connectionless, unreliable transport protocol. It does not provide
guaranteed delivery of the message.
Application Layer
An application layer protocol defines how application processes (clients and servers),
running on different end systems, pass messages to each other. In particular, an application layer
protocol defines:
• The types of messages, e.g., request messages and response messages.
• The syntax of the various message types, i.e., the fields in the message and how the fields are
delineated.
• The meaning of the information that the field is supposed to contain.
• Rules for determining when and how a process sends messages and responds to messages.