MECHATRONICS

TE –A, 2019 Pattern

A.Y. 2025-26

PROF. JAYASHRI CHOPADE

CAD/CAM (PHD PURSUING)
 UNIT-1

INTRODUCTION TO MECHATRONICS,
SENSORS AND ACTUATORS
Actuators: Servo motor; Hydraulic and Pneumatic
(must be restricted to classification and working of one
type of linear and rotary actuator); linear electrical
actuators Selection of Sensor & Actuator
ACTUATOR:

An actuator is a device that makes something move or operate.

It receives a source of energy and uses it to move something.
Everyday Examples
1. Grocery Store Door: When we go to the grocery store, the door opens
automatically for us. An actuator makes the door open.
2. Car Seat
We can move the car seat forward or backward before we drive away in our car.
An actuator makes the seat move.
Types of Actuators
1. Linear Actuator: An actuator can move something in a straight
line, also referred to as linear.
2. Rotary Actuator
Also, An actuator can make something move in a circular motion, also referred
to as rotary.
Actuators receive a source of energy and use it to move something. To put
it another way, the actuator converts a source of energy into a
physical-mechanical motion.

A butterfly valve is operated by turning the Handwheel connected to the

rotary actuator. In industrial applications, the Handwheel could be replaced
by one of three typical sources of energy, which can operate the rotary
actuator:

– Electric actuators use some form of electric energy to operate.

– Hydraulic actuators use a variety of liquids as a source of energy.

– Pneumatic actuators are operated by compressed air.

Hydraulic actuators:
Principle of Hydraulic Actuator System

• Hydraulic actuator system uses the concept proposed by Pascal

generally known as Pascal’s Law or Pascal’s Principle.

• Pascal’s Law states that the pressure applied at a specific point to a

confined fluid in a container is transmitted equally in all the
directions within the fluid as well as the walls of the container
without any loss.
Hydraulic Actuator System
Working of Hydraulic Actuator
• The major component of the unit is pilot valve also known as spool valve and main
cylinder (or power cylinder).
• It operates in a way that difference in pressure created at the two regions of the
main cylinder leads to the occurrence of translational motion of the piston.
• These two regions are obtained by dividing the main cylinder with a main piston.
Thus, there are two chambers of the main cylinder.
• Initially, the spool is present at the neutral position say x = 0 and at this position,
there will be no flow of fluid inside the main cylinder. The assembly of the
hydraulic actuator is such that the load will move according to the fluid flow.
• Thus, when input displacement, x is 0 then the output displacement y will also be 0.
• As soon as a certain input displacement is provided, then the spool moves towards
the right. The movement of spool towards the right causes the fluid from the
high-pressure source to move towards the left chamber of the main cylinder.
• Thus, the pressure on the left chamber of the cylinder rises comparatively more than
that present on the right chamber. This results in the generation of accelerating force
that causes movement of the load.
• In this way, the direction in which fluid flows corresponds to the direction in which
the load moves.
• This acts as power amplification because the force supplied to displace the valve is
comparatively very small than the force generated that actually displaces the load.
Advantages of Hydraulic Actuators
A number of advantages in comparison with mechanical and electric transfers explains
such their wide application
∙ Infinitely variable control of gear-ratio in a wide range and an opportunity to create the
big reduction ratio
∙ Small specific weight, i.e. the weight of a hydro actuator is in ratio to transmitted
capacity(0,2…0,3 kg / kWt)
∙ Opportunity of simple and reliable protection of the engine from overloads
∙ Small sluggishness of the rotating parts, providing fast change of operating modes
(start-up, dispersal, a reverser, a stop)
∙ Simplicity of transformation of rotary movement into reciprocating one
∙ Opportunity of positioning a hydraulic engine on removal(distance) from an energy
source and freedom in making configuration.
Disadvantages of hydraulic actuators
• Efficiency of a volumetric hydraulic actuator is a little bit lower, than
efficiency of mechanical and electric transfers, and during regulation it is
reduced.
• Conditions of operation of a hydraulic actuator (temperature) influence its
characteristics.
• Efficiency of a hydraulic actuator is a little reduced in the process of
exhaustion of its resource owing to the increase in backlashes and the
increase of outflow of liquid (falling of volumetric efficiency).
• Sensitivity to pollution of working liquid and necessity of high culture
service.
Applications
• Hydraulic jack
• Hydraulic brake
• Hydraulic ram
• Used as sensor
• Close loop velocity controlling
• Highly precise positioning for heavy loads
 Pneumatic actuators
Pneumatic actuators are devices that convert the energy of compressed air or
gas into a mechanical motion that regulates one or more final control
elements. Pneumatic actuators are devices that convert the energy of
compressed air or gas into a mechanical motion that regulates one or more final
control elements.

More specifically, pneumatic actuators are devices that change the pressure
obtained by compressing the air into mechanical energy.

https://youtu.be/vF61cZerj2M
Operating Principle:
• A pneumatic actuator operates in a way that it converts the pressurized air applied to it into
displacement. The two major units of these actuators are piston and diaphragm.

In this type of actuator, these two units create the motive power from the supplied air. More
simply, air power is used to create motion.
Pneumatic Actuator is generally of two types:
•Linear and
•Rotatory

• The above classification of pneumatic actuators is based on the type of motion produced by
it.
• If the device generates linear motion then it is said to be linear pneumatic actuator. While, if
the conversion from air to motion is rotational in nature then it is said to be rotatory
pneumatic actuator.
• The fluid energy is changed into mechanical energy for
driving the system.
• The functioning of the system shown above is such that
the fresh air is compressed by the compressor and is
stored in the storage reservoir.
• The direction, rate of flow along with the pressure of the
fluid is controlled by a flow control valve. The spring
unit manages to carry the air from one location to another
and provides return stroke to the piston.
• Initially, in the absence of any supplied air, the control
valve remains open and the diaphragm is pulled upwards
by the action of the spring.
• However, when the air is drawn from the atmosphere then it is filtered by a filter and is
provided to the compressor. The compressor now compresses the air that causes an increase
in the pressure level.
• It is to be noted here that with the increase in pressure level of the air, its temperature also
increases. So, to maintain the temperature to a moderate range, air coolers are used.
• Now, the pressurized air is stored in a storage reservoir so that the pressure level can be
maintained.
• Furthermore, the pressurized air inside the system applies force on the diaphragm of the
actuator.
• When the force due to pressurized air overcomes the force of the spring that keeps the
diaphragm at the top then the this causes downward movement of the diaphragm thereby
closing the control valve.
• With the increase in the pressure of supply air, the diaphragm continuously moves in the
downward direction and this completely closes the control valve at a certain point of time.

• While once this supply pressure decreases, then the force that is applied by the spring on
the diaphragm overcomes the force due to supplied pressure. This causes motion in the
upward direction of the diaphragm thereby opening the control valve.

• It is to be noted here that the position of the control valve depends on the air pressure.
Thus, opening and closing of the control valve is related to the movement of the diaphragm
so with the air pressure.
• The actuators are present after a controller that provides a control signal for the desired
action to take place.
• According to the obtained control signal, the air pressure varies and this simultaneously
varies the position of the control valve.
• In this way, the assembly inside the actuator operates according to the received control
signal and drives the process.
Advantages

• Pneumatic actuators offer operation up to a wide temperature

range generally, 0 to 200 °C.
• It offers ease of construction and requires less maintenance.
• These actuators are fire and explosion-proof.
• Pneumatic actuators are less costly and low weight devices.
Disadvantages:
• The output power delivered by the pneumatic actuator is lesser than
the hydraulic actuator.
• The internal machine parts are not lubricated due to the use of air as
the fluid.
• The accuracy of the produced output is somewhat less in
low-velocity operations.
• These work efficiently only when used for specific applications.
Pneumatic Rotary Actuators
• Pneumatic rotary actuators spin rather than move linearly, hence the name
rotary. To generate the energy to rotate, they use compressed air or gas.

There are three main types of pneumatic rotary actuators.

• Scotch yoke,
• Vane
• Rack-and-pinion.
Vane

• Vane pneumatic actuators create the rotary force directly from the compressed air by
having a moveable vane in an air chamber.
• As air pressure increases on one side of the movable vane, it rotates the shaft, which is
connected to the stem of the valve.
• Vane type actuators are almost always double-acting and require pressure on the other side
of the movable vane to rotate it back, but they can be single acting as well.
• However, vane actuators often have a leakage in the vane and a very limited range of
oscillation when compared to rack-and-pinion actuators.
• However, they are cost effective for low-medium torque ranges and can have precise
positioning.
Electric Actuator
• The electrical actuator is an electromagnetic device that converts electrical energy
into mechanical movement.
• Electric valve actuators are mounted on valves that automatically move to the desired
position using an external power source in response to a signal.
• AC or DC voltage and duty cycle are important factors when selecting electrical
actuators.
• Electric actuators are devices capable of creating motion of a load, or an action that requires
a force like clamping, making use of an electric motor to create the force that is necessary.
• As the spindle or rotor rotates, rotary motion is created by an electric motor. In the structure
of an electrical actuator, there is a helical screw to which the motor spindle is coupled via
the drive shaft. This will rotate in a ball screw nut.
Function of Electric Actuator
• The electric motor creates a rotary motion during the rotation of the spindle or
rotor. The motor spindle rotates in a ball screw nut.
• This motor spindle is coupled directly to a helical screw via the shaft of the
drive.
• The ball screw nut is driven forward or backward during the rotation of the spindle, along
the helical screw.
• There is an attachment of a hollow piston rod to the ball screw nut and this generates the
linear motion into, or out of the linear actuator during the clockwise or anti-clockwise
rotary motion of the motor.
• An electric drive controls the motor, and allows the varying of the speed of rotation, and
hence the actuator's linear speed.
• A mechanism for feedback provides positional information and the linear actuator is
capable of being programmed to move a certain position, stop the position and then move
on again, or return to its position of rest.
• The torque that can be generated is determined by the power of the motor. Hence the
power will also determine the force that can be put to useful motion through the actuator.
Applications: Electric Actuators
Electric actuators appear in a number of industries. Typically, they’re used
in industrial applications associated with manufacturing valves, pumps, and
motors.
They most commonly automate industrial valves, and many types of
technical process plants use them, including:
• Upstream, midstream, and downstream oil and gas plants
• Wastewater treatment plants
• Power plants
• Food and beverage plants
• Farming and agricultural plants
• Pulp and paper plants
Selection of Sensors:
1) Range:
Difference between Maximum and Minimum value which can be sensed by the sensor.
2) Resolution:
The smallest change which can be sensed by the sensor. High is good but not always. If it is
too high, it would pickup even very minute fluctuations which would then require additional
processing.
3) Sensitivity:
Ratio of change in output to a unit change in the input. Again, high is good, but too high could
be a problem. Also, higher the sensitivity, more will be the cost in most cases.
4) Error:
Difference between the Measured Value and True Value.
5) Accuracy:
It is inversely proportional to Error, i.e. How close the sensor reading is to the True Value.
(Should be high).
6) Precision:
Ability to give/reproduce accurate value repeatedly. If a sensor is giving different values for
the same physical conditions.

7) Response Time:
Time lag between the Input and Output. (Should be Minimum)

8) Signal-to-noise Ratio:
Ratio between the magnitude of the signal and the noise at the output.

9) Calibration:
As sensors need frequent calibration, so it should be easy to calibrate.

10) Cost:
It shouldn’t be expensive.
11. Nature of Output:
Need Analog output or Digital output, it should be clear.

12) Environment:
It is one of the most important parameters because not all sensors can work in extreme
conditions. Sensors can get affected due to the non-ideal conditions(like temperature,
humidity, etc.) which may affect the output of the sensor.

13) Flexibility:
check whether the sensor can adapt to changes in the product.

14) Interfacing:
It should be compatible to use with a wide range of instruments.

15) Size and Weight:

Sensors should be compact and lightweight.
Selection of Actuator
1) Continuous power cut:
The maximum force/ torque attainable continuously without exceeding the temperature limit.

2) Range of Motion:
The range of linear/rotary motion.

3) Resolution:
The minimum increment of force/torque attainable.

4) Accuracy:
Linearity of the relationship between input and output.

5) Peak force/torque:
The force/torque at which the actuator stalls.
6) Heat dissipation:
Maximum weightage of heat dissipation in continuous operation.

7) Speed characteristic:
Force/torque versus speed relationship.

8) No load Speed:
Typical operating speed/velocity with no external load.

9) Frequency response
The range of frequency over which the output follows the input faithfully,
applicable to linear actuators.

10) Power requirement:

Type of power (AC or DC),number of phases, voltage level and current
capacity.
Servomotor:
• A servomotor (or servo motor) is a simple electric motor,
controlled with the help of servomechanism.
• If the motor as a controlled device, associated with
servomechanism is DC motor, then it is commonly known as a DC
Servo Motor. If AC operates the controlled motor, it is known as a
AC Servo Motor.
• A servomotor is a linear actuator or rotary actuator that allows for
precise control of linear or angular position, acceleration, and velocity.
• It consists of a motor coupled to a sensor for position feedback.
• The servo motor is usually a simple DC motor controlled for specific angular
rotation with the help of additional servomechanism (a typical closed-loop
feedback control system).
• Nowadays, servo systems are used widely in industrial applications.
• Servo motor applications are also commonly seen in remote-controlled toy cars
for controlling the direction of motion, and it is also very widely used as the
motor which moves the tray of a CD or DVD player.
• Besides these, there are hundreds of servo motor applications we see in our daily
life.
• The servomotor consists DC
motor, potentiometer, and a control circuit.
• The motor is attached by gears to the control
wheel.
• As the motor rotates, the potentiometer's
resistance changes, so the control circuit can
precisely regulate how much movement there
is and in which direction
• When the shaft of the motor is at the desired position, power supplied to the motor is
stopped. If not, the motor is turned in the appropriate direction.
• The desired position is sent via electrical pulses through the signal wire.
• The motor's speed is proportional to the difference between its actual position and desired
position.
• So if the motor is near the desired position, it will turn slowly, otherwise it will turn fast.
This is called proportional control.
• This means the motor will only run as hard as necessary to accomplish the task at hand, a
very efficient little guy.