Department of

Automation and Robotics

Unit No.2:
Block Diagram Representation

Presented by: Prof. D. P. Patil

 Introduction to Mechatronic System Design; Identification
of key elements of Mechatronic systems and represent into
Block Diagram;
 Open and Closed loop Control System;
 Concept of Transfer Function;
 Block Diagram & Reduction principles;
 Applications of Automation and Robotics: Household,
Automotive, Industrial shop floor.
 Transfer Function based modeling of Mechanical, Thermal
and Fluid system;
 Concept of Poles & Zeros; Pole zero plot,
 Stability Analysis using Routh Hurwitz Criterion (Numerical
Approach)
 Mechatronics is synergistic integration of mechanical
engineering, electronics and intelligent computer control
in design and manufacture of products and processes.
 “mecha” from mechanism and the “tronics” from
electronics.

 technologies and developed products will be incorporating

electronics more and more into mechanisms

 MTX is defined as the interdisciplinary field of engg. for

designing a product relies on the integration of mechanical
& electronic components coordinated by control system.
•A voice coil actuator, also known as a non-commutated DC linear actuator,
is a type of direct drive linear motor. The name “voice coil” comes from one
of its historically first applications: vibrating the paper cone of a
loudspeaker.
•They are currently used for a wide range of applications, including moving
much larger masses.
• A non-commutated DC linear actuator, typically referred to as a voice coil,
is capable of a displacement of up to 5 in., whereas most actuators have
displacements up to 2 in.
•Voice coil actuators are typically used in focusing applications, oscillatory
systems, mirror tilting, and miniature position control.
Mechatronics System
(a)Sensors and actuators

• Sensors and actuators mostly come under mechanical systems.

• The actuators produce motion or cause some action.
• The sensors detect the state of the system parameters, inputs, and
outputs.
• The various actuators used in the mechatronic system are pneumatic and
hydraulic actuators, electro-mechanical actuators, electrical motors such
as DC motors, AC motors, stepper motors, servomotors, and piezoelectric
actuators.
• The various types of sensors used in the mechatronic system are linear
and rotational sensors, acceleration sensors, force, torque and pressure
sensors, flow sensors, temperature sensors, proximity sensors, light
sensors.
(b) Signals and conditioning
• The mechatronic systems deal with two types of signals and
conditioning such as – input and output.
• The input devices receive input signals from the mechatronic systems
via interfacing devices and sensors. Then it is sent to the control
circuits for conditioning or processing.
• The various input signal conditioning devices used in the
mechatronic system are discrete circuits, amplifiers, Analog-to-Digital
(A/D) converters, Digital-to-Digital (D2D) convertors.
• The output signals from the system are sent to output/display
devices through interfacing devices.
• The various output signal conditioning devices used in the
mechatronic system are Digital-to-Analog (D/A) converters, Display
Decoders (DD) converters, amplifiers, power transistors, and power
op-amps.
(c) Digital logic systems

• Digital logic devices control overall system operation. The various

digital logic systems used in the mechatronic system are logic circuits,
microcontrollers, programmable logic controllers, sequencing and
timing controls, and control algorithms.
(d) Software and data acquisition systems

• The data acquisition system acquires the output signals from sensors
in the form of voltage, frequency, resistance etc. and it is inputted
into the microprocessor or computer.
• Software is used to control the acquisition of data through DAC
board. The data acquisition system consists of a multiplexer,
amplifier, register, control circuitry and DAC board. The various data
acquisition systems used in the mechatronic system is data loggers,
computer with plug-in boards, etc.
(e) Computers and display devices

• Computers are used to store a large number of data and process

further through software.
• Display devices are used to give visual feedback to the user.
• The various display devices used in the mechatronic system are LEDs,
CRT, LCD, digital displays, etc.
Examples of Mechatronics system

 Auto focus camera

 Robotics
 Washing Machine
 Engine management system
 Microwave ovens
 Camcorders
 Aircraft flight control & navigation system
 Numerically control M/C tools
 Photocopiers
 Barcode readers etc.
A control system is a system, which provides the desired response by
controlling the output. The following figure shows the simple block diagram of
a control system.

Here, the control system is represented by a single block. Since, the output is
controlled by varying input, the control system got this name. We will vary this
input with some mechanism. In the next section on open loop and closed loop
control systems, we will study in detail about the blocks inside the control
system and how to vary this input in order to get the desired response.

Examples − Traffic lights control system, washing machine

 Control Systems can be classified as open loop control
systems and closed loop control systems based on
the feedback path.
 In open loop control systems, output is not fed-back to
the input. So, the control action is independent of the
desired output.

Traffic lights control system is an example of control

system. Here, a sequence of input signal is applied to this
control system and the output is one of the three lights that
will be on for some duration of time. During this time, the
other two lights will be off. Based on the traffic study at a
particular junction, the on and off times of the lights can be
determined. Accordingly, the input signal controls the
output. So, the traffic lights control system operates on time
basis.
 Here, an input is applied to a controller and it produces
an actuating signal or controlling signal. This signal is
given as an input to a plant or process which is to be
controlled. So, the plant produces an output, which is
controlled. The traffic lights control system which we
discussed earlier is an example of an open loop control
system.
 In closed loop control systems, output is fed back
to the input. So, the control action is dependent on
the desired output.
 The following figure shows the block diagram of
negative feedback closed loop control system.
 The error detector produces an error signal, which
is the difference between the input and the
feedback signal. This feedback signal is obtained
from the block (feedback elements) by considering
the output of the overall system as an input to this
block. Instead of the direct input, the error signal is
applied as an input to a controller.
 So, the controller produces an actuating signal
which controls the plant. In this combination, the
output of the control system is adjusted
automatically till we get the desired response.
Hence, the closed loop control systems are also
called the automatic control systems. Traffic lights
control system having sensor at the input is an
example of a closed loop control system.
 Open Loop Control Closed Loop Control
Systems Systems
Control action is Control action is
independent of the dependent of the desired
desired output. output.
Feedback path is not Feedback path is present.
present.
These are also called These are also called
as non-feedback control as feedback control
systems. systems.
Easy to design. Difficult to design.
These are economical. These are costlier.
Inaccurate. Accurate.
Concept of
Transfer Function
Block Diagram &
Reduction principles
Applications of Automation and Robotics:
Household, Automotive, Industrial shop floor
Household Applications:
• Automatic Washing Machine
• Automatic Dishwashing Machine
Automatic Washing Machine
Automatic Dishwashing Machine
• Basically, a dishwasher is a robot that cleans and rinses dirty
dishes. Humans have to load the dishes, add detergent, set the
proper washing cycles and turn it on, but the dishwasher
accomplishes a whole series of functions by itself.

A dishwasher:

•Adds water
•Heats the water to the appropriate temperature
•Automatically opens the detergent dispenser at the right time
•Shoots the water through spray arms to get the dishes clean
•Drains the dirty water
•Sprays more water on the dishes to rinse them
•Drains itself again
•Heats the air to dry the dishes off, if the user has selected that
setting
• In this system consists of three sections first is scrubbing, second is
rinsing, and third is cleaning.
• A conveyor belt mechanism is used to execute the dish washing process
• Scrubber is attached to a motor which rotates and cleans the dishes.
• A spray pump is used to wash the dishes after scrubbing process.
• A cleaner or sponge is attached to a dc motor along conveyor line to dry
the dishes.
• Thus the cleaning gets complete.
• Conveyor passes the washed dishes while waste water is collected
separately.
• All the water gets collected at one place because of innovative collector
design.
• The IR sensor along with its signal conditioning circuit is used for
counting the number of dishes and also it is used for monitor of dishes
whether it comes under specific section or not. If dish is undetected
that particular section is in off state.
• The number of dishes cleaned shall be shown on LCD, this is done with
help of IR sensor.
Automotive Applications:

• Antilock Brake System

• Automotive Engine Management System
Antilock Brake System

• ABS or Anti-lock braking system is a car safety feature which

kicks in when the driver pushes hard on the pedal preventing the
wheels from locking up or skidding uncontrollably.
• It using a system of gradual braking, which can apply or release
the brakes 15 times a second. This pulsating brake reduces the
chance of skidding or wheel locking during a sudden panic brake.
Antilock Brake System (ABS)
ABS Working Principle:
 Automotive Engine Management System

• The objective of the system being to ensure that the engine is

operated at its optimum settings.
• The system consists of many sensors for observing vehicle
speed, engine temperature, oil and fuel pressure, airflow etc.
• These sensors are supplying input signals to the micro
controller after suitable signal conditioning and providing
output signals via drivers to actuate corresponding actuators.
• The various drivers such as fuel injector drivers, ignition coil
drivers. solenoid drivers are used to actuate actuation according
to the signal by various sensors.
Automotive Engine Management System
 An Engine Control Unit connects to all the individual
Electronic Control Modules (ECMs).
 A modern-day car consists of more than one Control
Modules, each exclusive for every primary system,
which improves performance. However, the
manufacturers seldom refer to these systems as car
computers since they are multiple computers instead
of one.
 Bosch, Delphi, and Hitachi are some of the world’s
leading Engine Management System manufacturers
Industrial shop floor
• CNC Machine
• Conveyer Belt System
CNC Machine
• The term CNC stands for ‘computer numerical control, and the
definition of CNC machining is that it is a substandard
manufacturing process that typically employs computerized
controls and machine tools to remove layers of material from
stock grinding which is Known as a blank or workpiece and
produces a custom-designed part.
• The process is suitable for wide ranges of materials, including
metals, plastics, wood, glass, foam, & composites, & finds
applications in a variety of industries, such as large CNC
machining, prototyping for parts machining and
telecommunications, & CNC machining Aerospace parts, which
require stricter tolerances than other industries.
The main parts of CNC machine are, and The following
represent the various CNC machine parts:-

1. Input Device
These are the device that is used to input part programs in a CNC
machine. There are three commonly used input devices, & these are
punch tape readers, magnetic tape readers, and computers via RS-
232-C communication.
2. Machine Control Unit (MCU)
• This is the heart of the CNC machine. It performs all the control
functions of the CNC machine, the various tasks performed by the
MCU are, It reads the coded instructions givens in it. It decodes the
coded instruction. This axis applies interpolation (linear, spherical,
and helical) to generate motion commands.
• It feeds the axis speed order to the amplifier circuit to drive the
spindle mechanism. It receives feedback signals of position and
speed for each drive axis. It implements auxiliary control functions
such as coolant or spindle on / off and tool change.
3. Machine Tools
A CNC machine tool always has a sliding table & a spindle
to control position and speed. The machine tables are
controlled in the X and Y-axis direction, & the spindle is
controlled in the Z-axis direction.
4. Driving System
The driving system of the CNC machine consists of an
amplifier circuit, drive motors, and ball lead screws. The
MCU feeds the signals (i.e., position and speed) of each
axis into the amplifier circuit.
The control signals are then amplified to activate the drive
motors. And actuated drive motors rotate the ball lead
screw to position the machine table.
5. Feedback System
• The system consists of transducers that act as sensors.
It is also called a measurement system. It consists of
position and motion transducers that continuously
monitor the position and speed of the cutting tool located
at any given moment.
• The MCU receives signals from these transducers, and it
uses the difference between reference signals and
response signals to generate control signals to correct
position and motion errors.
6. Display Unit
• A monitor is used to display programs, commands, and
other useful data of the CNC machine.
7. Bed
On CNC machine, this part bear all the weight of the
machine; this means that all other components are mounted
on it. The bed component is made of hardened materials
such as cast iron because the tool turret passes over them in
CNC lathe machines.
8. Headstock
The headstock is one of the main component of the CNC
lathe machine due to the fact that the workpieces are fixed
to it. The CNC lathe features motors help to drive the main
axle.
9. Tailstock
This lathe provides additional grip to the workpiece when
performing operations such as noodling, threading, and
turning, part of a CNC machine. Support is provided on the
end surfaces of the workpiece.
10. Tailstock Quill
The tailstock quill helps to centralize the workpieces
between the headstock and the tailstock.
11. Footswitch or Pedal
The pedal is used to open & close the chuck while trying
to hold the component, such as the tailstock quill is
moved to the forward and reversed positions.
12. Chuck
The chuck is mounted on the main axle, which gives the
tool space to fix.
13. Control Panel
Control panels are also one of the important parts of
CNC machines that are used to set or feed programs for
the operation to be performed on the workpieces. It is
also called the brains of the CNC machine.
Advantages of CNC Machine:
• It can generate employment with the highest accuracy and
precision than any other manual machine.
• It can be run for 24 hours.
• The parts produced by it have the same accuracy. There is no
variation in manufactured parts.
• It does not require a highly-skilled operator to operate. A semi-
skilled operator can also work more accurately and accurately.
• Operators can easily make changes and corrections and reduce
delay times.
• It has the ability to design complex designs with high accuracy in
the shortest possible time.
• Fewer workers are required to operate CNC and save labor costs.
Application of CNC Machine:

• Almost every manufacturing industry uses CNC machines.

With the competitive environment and increasing demands,
the demand for CNC usage has increased substantially. The
machine tools that come with CNC are Lathe, Mills, Shaper,
Welding, etc.
• The industries using CNC machines are the automotive
industry, metal removal industry, metal forming industry,
electrical discharge machining industry, wood industry, etc.
 The Mechatronics system is designed to transport
components that are placed on the conveyor through
the different “modules” of the complete system to: do
quality assurance on the specific component using
image processing, weigh the component, direct the
component to the correct exit, pick the component
from the exit area and place it on Automatic Guided
Vehicles using a Cartesian robot to transport the
component to a permanent storage area.
 A graphical representation of the conveyor system is
shown below.
Heat Flow Rate:
1

3
 4

5
6

7
Transfer function based modeling
of Fluid system
Example of Liquid Level System:

• A simple liquid level system is shown in the below figure with

steady flow rate, Q and steady state head, H.
• Let Q = Steady state flow rate( before any change has occured)
qi = Small deviation of inflow rate from its steady-state value
qo = Small deviation of outflow rate from its steady-state
value
H = Steady state head (before any change has occured)
h = Small deviation of head from its steady state value
 Poles: Poles of a Transfer Function are the frequencies
(values of s) for which the denominator of the Transfer
Function becomes zero.

 Zeros: Zeros of a Transfer Function are the frequencies

(values of s) for which the numerator of the Transfer
Function becomes zero.