Addis Ababa Science and Technology University

Electromechanical Engineering Department

Introduction to Mechatronics
Lecturer: Bereket Walle (MSc in Mechatronics Engineering)
 Chapter I

Introduction to Mechatronics
 1.1 Introduction
• Even though development of automated mechanical systems
occurred long before, the term automation was not popular since
1940s.
• The term automation was introduced by Ford Motor Company to
denote a process in which a machine transferred a sub-assembly
item from one station to another and then positioned the item
precisely for additional assembly operations.
• But the early applications of automatic control systems appeared in
Greece from 300 to1 B.C.

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 Definition of Mechatronics
• The word "mechatronics" was registered as trademark by the
Yaskawa Electric Corporation company in Japan with the registration
number of in 1971.
• However, afterward the company released the right of using the word
to public, and the word "mechatronics" spread to the rest of the
world.
• The Mechatronics is composed from Mechanism and electronics.
• Mechatronics is the application of complex decision making to the
operation of physical systems.
• Mechatronics is a methodology used for the optimal design of
electromechanical products.
 Def. Cont..
• A mechatronic system is not just a marriage of electrical and
mechanical systems and is more than just a control system;
it is a complete integration of all of them.
• Mechatronics is a multidisciplinary field of science that
includes a combination of mechanical, electronics,
computer, systems and control engineering .
• However, as technical systems have become more and more
complex the definition has been broadened to include more
technical areas.

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 Def. Cont..
• All of these definitions and statements about mechatronics are accurate and
informative, yet each one in and of itself fails to capture the totality of
mechatronics.
• Nowadays, the word is translated in each language and essential term for
industry.
• Mechatronics is the synergistic integration of mechanics, electronics, control
theory, and computer science within product design and manufacturing, in
order to improve and/or optimize its functionality.
• The measurement result expressed by a pointer deflection over a predefined
scale or a number representing the ratio between the unknown quantity and
the standard.

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 Key Elements of Mechatronics

• The study of mechatronic systems can be divided into the

following areas of specialty:
1. Physical Systems Modeling
2. Sensors and Actuators
3. Signals and Systems
4. Computers and Logic Systems
5. Software and Data Acquisition
The key elements of mechatronics are illustrated in Figure bellow
As the field of mechatronics continues to mature, the list of
relevant topics associated with the area will most certainly expand
and evolve.

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 Key Elements Cont…

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 Mechatronic system components
• To replace the mechanics of this mechanical system with an equivalent mechatronics
based system, we need to have the basic controlling element, a microprocessor.
• Microprocessor processes or utilizes the information gathered from the sensor system
and generates the signals of appropriate level and suitable kind (current or voltage)
which will be used to actuate the required actuator .

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 Mechatronic system components
• These sensors generate either digital signals (0 or 1) or analogue signals (milli-volts or
milli-amperes).
• These signals are then converted into right form and are attenuated to a right level which
can properly be used by the microprocessor to take generate the actuation signals.
• Analogue-to-Digital Converter (ADC), Digital-to-Analogue Converter (DAC), Op-amps,
Modulators, Linearization circuits, etc. are used to condition the signals which are either
received by the microprocessor from the sensors or are sent to the actuators from the
microprocessor.
• Piezo-electric sensor having analog brings analog signals as an input for the ADC and The
digital actuation signals generated by the microprocessors are converted into appropriate
analogues signals. This process is called Signal conditioning.
• These analogue signals operate the hydraulic pump and control valves to achieve the
desired displacement of the piston-rod.
Assignment 1: Identify a mechatronics system being used by you in your daily routine.
Analyze its elements and state its importance in the functioning of that system.
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 Mechatronic system components
• A Mechatronics system integrates various technologies involving sensors, measurement
systems, drives, actuation systems, microprocessor systems and software engineering.

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 Mechatronic cont…

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 Applications of Mechatronics
Mechatronics has a wide range of applications.
1. Design and Modelling
• Design and modelling are simplified to a large extent by the use of mechatronic systems.
• Basically, design involves drawing, analysis, and documentation.
• The computer is used to complete processes of design faster.
• The virtual modelling of a manufacturing plant gives an idea of the time taken for a
particular component to be manufactured and also shows virtually how the operations
will be performed.
• The mechatronic systems Digitizers, drum plotter, x-y plotter, printer, CD drives etc.
Give complete documentation of design drawings.

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 Applications Cont…
2. Manufacturing automation
Mechatronics has a variety of applications as products and systems in the area of ‘manufacturing
automation’.
Some of these applications of mechatronics in manufacturing are as follows:
1. Computer numerical control (CNC) machines
• Efficient operation of conventional machine tools dependent on operator skill and training.
• It is time consuming in work part setting, tool setting and controlling the process parameters
2. Tool monitoring systems : Offline methods are time consuming
3. Advanced Manufacturing Systems: such as FMS , CIM, CAD CAM
4. Industrial robots: robots used in Parts handling, Parts processing and Product building:
5. Automatic quality control and inspection systems
Supply of a good quality product or a system to the market is the basic aim of the manufacturing
industry. A number of sensors and systems have been developed that can monitor quality continuously
with or without the assistance of the operator.

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 Applications Cont…
Assignment 2
Visit to your nearby tool room or CNC work shop and prepare a case study on
a real life example on tool wear monitoring system employed.

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 Applications cont…
Operations involved in design and manufacturing of a product

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 Applications Cont…
2. Software Integration
• Different kinds of real time application and system soft wares are used in manufacturing
industry for designing, testing, monitoring, and control of the manufacturing process.

3. Actuators and Sensors

• Mechanical, electrical, hydraulic, and pneumatic actuators are widely used in the industry.
• Toggle linkage and quick return mechanics are typical examples of mechanical actuators.
• Switching devices, solenoid-type devices, ac/dc motors can be used as electrical actuators.
• The term sensor is used for an element which produces a signal relating to the quantity being
measured.
• For example, an electrical resistance temperature device transforms the input of temperature
into change in resistance

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 Applications Cont…

4. Intelligent Control
• Feedback control systems are widespread not only in nature and the
home but also in industry.
• There are many industrial processes and machines which control
many variables automatically.
• Temperature, liquid level, fluid flow, pressure, speed, etc. are
maintained constant by process controllers.
• Adaptive control and intelligent manufacturing are the areas where
mechatronic systems are used for decision making and controlling the
manufacturing environment.

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 Applications Cont…
5. Robotics
• Robot technology uses mechanical, electronic, and computer systems.
A robot is a multifunctional reprogrammable machine used to handle
materials, tools, or any special items to perform a particular task.
• Manipulation robots are capable of performing operations, assembly,
spot welding, spray painting, etc.
• Service robots such as mail service robots, household servant robots,
nursing robots in hospitals are being used nowadays.

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 Advantages and Disadvantages of Mechatronics
• The objectives of mechatronics are the following
1 To improve products and processes
2 To develop novel mechanisms
3 To design new products
4 To create new technology using novel concepts
• Earlier the domestic washing machine used cam-operated switches in order
to control the washing cycle. Such mechanical switches have now been
replaced by microprocessors.
• The application of mechatronics has helped to improve many
• mass-produced products such as the domestic washing machine,
dishwasher, microwave oven, cameras, watches, and so on.

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 Advantages and Disadvantages of Mechatronics
• Mechatronic systems are also used in cars for active suspension,
antiskid brakes, engine control, speedometers, ABS, TCS, vehicle
collision avoidance systems etc.

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 Advantages and Disadvantages of Mechatronics
• Future mechatronic systems on automobiles may include a fog-free windshield
based on humidity and temperature sensing and climate control, self-parallel
parking, rear parking aid, lane change assistance, fluid less electronic brake-
by-wire, and replacement of hydraulic systems with electromechanical servo
systems
• Mechatronic systems are not without their disadvantages. One disadvantage is
that the field of mechatronics requires a knowledge of different disciplines.
• The design cannot be finalized and safety issues are complicated in
mechatronic systems.
• Such systems also require more parts than others, and involve a greater risk of
component failure

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 1.2 Review of Measurement system
• A fundamental part of many mechatronic systems is a measurement system.
• Its main function is to collect the information on system status and to feed it to the
micro-processor(s) for controlling the whole system.
• It is composed of the three basic parts i.e Sensor, signal processor and recorder .
• Sensor is a sensing device that converts a physical input into an output, usually a
voltage.
• Transducer is a device that converts a signal from one form of energy to
another form. It may be sensor or actuator.

• Signal processor is performs filtering, amplification, or other signal conditioning on

the transducer output.
• Recorder is an instrument, a computer, a hard-copy device, or simply a display that
maintains the sensor data for online monitoring or subsequent processing.
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 1.2 Measurement system Cont…

• For a mechatronics system designer it is quite difficult to choose suitable

sensors/transducers for the desired application(s).
• It is therefore essential to learn the principle of working of commonly used
sensors/transducers.
• Sensors in manufacturing are basically employed to automatically carry out the
production operations as well as process monitoring activities.
• Sensor technology has the following important advantages in transforming a
conventional manufacturing unit into a modern one .
1. Sensors alarm the system operators about the failure of any of the sub units of
manufacturing system. It helps operators to reduce the downtime of complete
manufacturing system by carrying out the preventative measures.
2. Reduces requirement of skilled and experienced labors.
3. Ultra-precision in product quality can be achieved.

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 1.2 Measurement system Cont…
Sensor/transducers specifications
• Transducers or measurement systems are not perfect systems.
• Mechatronics design engineer must know the capability and shortcoming of a transducer or
measurement system to properly assess its performance.
• There are a number of performance related parameters of a transducer or measurement
system.
• These parameters are called as sensor specifications.
• Sensor specifications inform the user to the about deviations from the ideal behavior of the
sensors.
• Following are the various specifications of a sensor/transducer system.
1. Range: indicates the limits between which the input can vary.
2. Span: The span is difference between the maximum and minimum values of the input

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 1.2 Measurement system Cont…
3. Error: is the difference between the result of the measurement and the true value.
4. Accuracy: is the closeness of the agreement between the actual measurement result and a true
value of the measurand.
5. Precision: Is the closeness of repeated measurement values.
6. 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
7. Nonlinearity: The nonlinearity indicates the maximum deviation of the actual measured curve of a
sensor from the ideal curve.

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 1.2 Measurement system Cont…

8. 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.

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 1.2 Measurement system Cont…

9. Resolution: Resolution is the smallest detectable incremental change of input parameter

that can be detected in the output signal.
10. 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.
11. Dead band: The dead band or dead space of a transducer is the range of input values
for which there is no output.
12. Dead time: 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.
13. Repeatability : It specifies the ability of a sensor to give same output for repeated
applications of same input value.
14. Response time: describes the speed of change in the output on a step-wise change of
the measurand.

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 1.2 Measurement system Cont…
Example of measurement system
• Thermocouple is the transducer/sensor that convert the temperature in to small voltage.
• The amplifier increase the magnitude of the voltage.
• The ADC is a device that changes the analog signal to the coded digital signal.
• The LED record/display the scaled value of the temperature.

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 1.2 Measurement system Cont…
Classification of sensors based on their application in manufacturing.
• Sensors can be classified into various groups according to the factors such as
measurand, application fields, conversion principle, energy domain of the measurand
and thermodynamic considerations.

A. Displacement, position and proximity sensors

1. Potentiometer sensors
The output voltage is proportional to the displacement of the slider over the wire.
Then the output parameter displacement is calibrated against the output voltage VA.

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 1.2 Measurement system Cont…
Applications of potentiometer

• These sensors are primarily used in the control systems with a feedback
loop to ensure
that the moving member or component reaches its commanded position.
• These are typically used on machine-tool controls, elevators, liquid-level
assemblies,
forklift trucks, automobile throttle controls.
• In manufacturing, these are used in control of injection molding machines,
woodworking machinery, printing, spraying, robotics, etc.
• These are also used in computer-controlled monitoring of sports equipment.

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 1.2 Measurement system Cont…
Capacitive element based sensor
Capacitive sensor is of non-contact type sensor and is primarily used to measure the
linear displacements from few millimeters to hundreds of millimeters.
• It comprises of three plates, with the upper pair forming one capacitor and the lower pair
another. The linear displacement might take in two forms:
a. One of the plates is moved by the displacement so that the plate separation changes
b. Area of overlap changes due to the displacement

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 1.2 Measurement system Cont…
• The capacitance C of a parallel plate capacitor is given by

• As the central plate moves near to top plate or bottom one due to the movement of the
element/work piece of which displacement is to be measured, separation in between
the plate changes.

Capacitive elements can also be used as proximity sensor.

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 1.2 Measurement system Cont…
Applications of capacitive element sensors

• Feed hopper level monitoring

• Small vessel pump control
• Grease level monitoring
• Level control of liquids
• Metrology applications to measure shape errors in the part being produced
• Assembly line testing to test assembled parts for uniformity, thickness or
other design
features

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 1.2 Measurement system Cont…
Linear variable differential transformer
• Linear variable differential transformer (LVDT) is a primary transducer used for
measurement of linear displacement with an input range of about ± 2 to ± 400 mm
in general.
• The working principle of LVDT sensor is as shown bellow
• LVDT exhibits good repeatability and reproducibility.

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 1.2 Measurement system Cont…
Applications of LVDT sensors

• To measure the spool position in a wide range of servo valve applications

• To provide displacement feedback for hydraulic cylinders
• To control weight and thickness of medicinal products viz. tablets or pills
• For automatic inspection of final dimensions of products being packed for dispatch
• To measure distance between the approaching metals during Friction welding process
• To continuously monitor fluid level as part of leak detection system
• To detect the number of currency bills dispensed by an ATM

Note; Let you have a read about the rest of the displacement and position sensor, Velocity, motion,
force and pressure sensors

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 1.2 Measurement system Cont…
Temperature and light sensors

Temperature conveys the state of a mechanical system in terms of expansion or

contraction of solids, liquids or gases, change in electrical resistance of conductors,
semiconductors and thermoelectric emfs

Temperature sensors such as bimetallic strips, thermocouples, thermistors are widely used
in monitoring of manufacturing processes such as casting, molding, metal cutting etc.
1. Bimetallic strips

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 1.2 Measurement system Cont…
Bimetallic strips working principle:
• Bimetallic strips are used as thermal switch in controlling the temperature or heat in a
manufacturing process or system.
• It contains two different metal strips bonded together.
• The metals have different coefficients of expansion.
• On heating the strips bend into curved strips with the metal with higher coefficient of
expansion on the outside of the curve.
• As the strips bend, the soft iron comes in closer proximity of the small magnet and
further touches.
• Then the electric circuit completes and generates an alarm.
• In this way bimetallic strips help to protect the desired application from heating above
the pre-set value of temperature.

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 1.2 Measurement system Cont…
2. Resistance temperature detectors (RTDs)
• RTDs work on the principle that the electric resistance of a metal changes due to
change in its temperature.

where Rt is the resistance at temperature T (⁰C) and R0 is the temperature at 0⁰C and α
is the constant for the metal termed as temperature coefficient of resistance.

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 1.2 Measurement system Cont…
• It has a resistor element connected to a Wheatstone bridge.
• The element and the connection leads are insulated and protected by a sheath.
• A small amount of current is continuously passing though the coil.
• As the temperature changes the resistance of the coil changes which is detected at the
Wheatstone bridge.
applications areas:

• Air conditioning and refrigeration servicing, Food Processing, Stoves and grills
• Textile production, Plastics processing, Petrochemical processing, Micro electronics
• Exhaust gas temperature measurement

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 1.2 Measurement system Cont…
3. Thermistors:
Thermistors follow the principle of decrease in resistance with increasing
temperature.

4. Thermocouple:
Thermocouple works on the fact that when a junction of dissimilar metals heated, it
produces an electric potential related to temperature.

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 1.2 Measurement system Cont…
Light sensors

• A light sensor is a device that is used to detect light.

• There are different types of light sensors such as photocell/photoresistor and photo
diodes being used in manufacturing and other industrial applications.
1. Photoresistor is also called as light dependent resistor (LDR).
• It has a resistor whose resistance decreases with increasing incident light intensity.
• It is made of a high resistance semiconductor material, cadmium sulfide (CdS).
• The resistance of a CdS photoresistor varies inversely to the amount of light incident
upon it.
• Photoresistor follows the principle of photoconductivity which results from the
generation of mobile carriers when photons are absorbed by the semiconductor material.

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 1.2 Measurement system Cont…
Applications of photo resistor
• Computers, wireless phones, and televisions, use ambient light sensors to
automatically control the brightness of a screen
• Barcode scanners used in retailer locations work using light sensor technology
• In space and robotics: for controlled and guided motions of vehicles and robots.
• The light sensor enables a robot to detect light. Robots can be programmed to have a
specific reaction if a certain amount of light is detected.
• Auto Flash for camera
• Industrial process control
2. Photo diodes
Photodiode is a solid-state device which converts incident light into an electric
current.

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 1.2 Measurement system Cont…
Signal Conditioning Devices

• Transducers sense physical phenomenon such as rise in temperature and convert the
measurand into an electrical signal viz. voltage or current.
• However these signals may not be in their appropriate forms to employ them
to control a mechatronics system.

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 1.2 Measurement system Cont…
1. Amplification/Attenuation
• Various applications of Mechatronics system such as machine tool control unit of a
CNC machine tool accept voltage amplitudes in range of 0 to 10 Volts. However
many sensors produce signals of the order of milli volts.
• This low level input signals from sensors must be amplified to use them for further control
action.
• Operational amplifiers (op-amp) are widely used for amplification of input signals.
• Operational Amplifier is a basic and an important part of a signal conditioning system.

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 1.2 Measurement system Cont…
• op-amp amplifies the difference between input voltages (V+ and V-). The
output of an operational amplifier can be written as

2. Filtering
• Output signals from sensors contain noise due to various external factors like
improper hardware connections, environment etc.
• Noise gives an error in the final output of system.
• Therefore it must be removed.
• In practice, change in desired frequency level of output signal is a commonly noted
noise.

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 1.2 Measurement system Cont…
Following types of filters are used in practice:
1. Low Pass Filter
Low pass filter is used to allow low frequency content and to reject high frequency
content of an input signal

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 1.2 Measurement system Cont…
2. High Pass Filter
These types of filters allow high frequencies to pass through it and block the lower
frequencies.

3. Band Pass Filter

4. Band Reject Filter

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 Design project Proposal (Reading)
• Project proposal is a pre-project plan in which the presenter will show or justify the
feasibility and visibility of the project work.
• Sometimes project proposal may have different structure while keeping the the existence of
major skeleton depend on the project type, the institution , etc
• According to AASTU the project proposal should contain or discuss the following major
issues;
1. Project Title: The title should accurately reflect the scope and content of the study
It should be short, clear and descriptive
1. Project Theme: The university or country may identify different active
project/research thematic areas. So the thematic area the project will focus on should be
explained well.
2. Executive Summary/Abstract:
It should contain the short summery of the proposal including the statement of problem,
methodology you will follow and the expected output or result you are looking for.
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 Design project Proposal
4. Introduction/Background : Here the existing system or literature should be revised well with
proper citation.
5. Statement of the Problem: Here The main problem that ignite someone to work the project
should be stated well.
6. Objective of the Project :
General; The expected outcome of the project and its advantage will bee explained here.
Specific; The task or approach that we will follow for the accomplishment of the project will be
stated here.
7. Materials and Methods
Materials; Here we have to list down and put short description about the working principle and
usage of materials we are planned to use in the project work.
Methods it is the way that will follow to accomplish the project and it shall be put with flowchart
8. Expected Outcomes : It deals with the significant of the project for the customer.

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 Design project Proposal
5. Beneficiaries; Here who will be beneficial from the project should be listed.
6. Ethical Considerations; If the project violet some ethical or economical benefit of some
one/group it should be stated here
7. Budget Breakdown and funding mechanism
Here the budget the project work needs should be justified.
8. Time table/ schedule
Here the duration of the project will take and detail task breakdown should be stated.

9. Reference
All references we have cited in the proposal should be put here with proper format.

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 End of Chapter I

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