Fundamentals of Mechatronics Engineering
INTRODUCTION
Dr. Ahmed Asker
Mansoura University
Course Contents
Introduction mechatronics design
Modelling using MATLAB and Simulink
Introduction to microcontrollers
Sensors
Actuators
DC motors
Modelling and simulation tools of Mechatronic systems
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Introduction to Mechatronics
The term “Mechatronics" was first assigned by Mr. Tetsuro
Mori, a senior engineer of the Japanese company Yaskawa, in
1969.
The word "mechatronics" was registered as trademark by the
company in Japan with the registration number of "46-32714" in
1971.
The word mechatronics composed of “mecha” from mechanics
and “tronics” from electronics.
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Mechatronics - definition
Mechatronics basically refers to mechanical electronic systems
and normally described as a synergistic integration of
mechanical engineering, electronics and intelligent computer
control in design and manufacture of products and processes.
In other words : synergistic integration of mechanical
engineering, electronic engineering, computer technology and
control engineering in development of electromechanical
products, through an integrated design approach.
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Mechatronics
Mechatronics is a multidisciplinary field of science that includes
a combination of mechanical engineering, electronics, computer
engineering, telecommunications engineering, systems
engineering and control engineering.
It specifically refers to multidisciplinary approach to product
and Manufacturing system design.
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Typical Components of a Mechatronics System
Actuators: Produce motion or cause some action. DC motor, Stepper motors,
servomotors, hydraulics, pneumatics
Sensors: detect the state of the system parameters, inputs and outputs.
Switches, Potentiometer, Strain gauge, Thermocouple, digital encoder
Input signal conditioning and interfacing: provide connection b/w the control
circuits and the I/P Discrete circuits, Amplifiers, Filters, A/D,D/D
Digital control architectures: Control the system. Logic circuits,
microcontroller, PLC
5. Output signal conditioning and interfacing : provide connection b/w the
control circuits and the O/P
D/A, D/D, Amplifiers, Power transisters.
Graphical Display : Provide visual feedback to users.LEDs, Digital displays,
LCD, CRT
Mansoura University Fundamentals of Mechatronics Engineering Dr. Ahmed Asker 6
Levels of mechatronics system
Stand-alone systems, for ex: washing machine, compact disk
player, auto focus camera, boat auto pilot, etc.
Systems with high level of distributed Sensor-microcontroller-
relationships, for ex: wire aircraft.
A large factory system that is also a distributed system but
which links a number of major subsystems such as machining
centers, robots for part handling, automated inspection stations
etc,
A system that incorporates intelligent control or artificial
intelligence, for ex: humanoid robot.
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Design Flow Diagram
RECOGNITION OF A NEED
MARKETING
SPECIFICATION
MARKETING FEED BACK
CREATIVE DESIGN SYNTHESIS
SPECIFICATION FEED BACK
ENGINEERING FEED BACK
PRELIMINARY DESIGN AND DEVELOPMENT
DETAIL DESIGN
PROTOTYPE BUILDING AND TESTING
DESIGN FOR PRODUCTION
PRODUCT RELEASE
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“Traditional” Product Development approach
HARD BOUNDARIES
MANUFACTURING
COMPUTING
PRODUCT BOUNDARY
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Mechatronics
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Mechatronic Design Process
Modeling/Simulation Prototyping Deployment/Life cycle
Recognition of the need
Software in the loop Deployment of
Conceptual Design and
simulation Embedded systems
Functional Specification
First principle modular Design Optimization Life cycle optimization
Mathematical Modeling
Sensor and Actuator
selection
Detailed modular
Mathematical Modeling
Control system Design
Design optimization
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Ways to Study a System
System
Experiment with actual Experiment with a
System model of the System
Physical Model Mathematical Model
Analytical Solution
Simulation
Frequency Domain Time Domain Hybrid Domain
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Mechatronics Systems Simulation
Why this topic is important?
Why simulation attract more attention recently?
Development of high-performance product
Complexity of the modern products
Availability of high-performance computational devices
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High-Fidelity Modeling Examples
Shuttle Vehicle Dynamics (SVD) was a computer simulation for
analyzing the separation dynamics between the Space Shuttle and its
solid rocket boosters
◦ SVD uses mathematical models for aerodynamic forces, propulsion
forces, spring and damper forces at interconnection points, etc
Shuttle Avionics Integration Lab (SAIL) at NASA Johnson Space
Center was used to simulate the dynamics of the entire Space Shuttle
mission profile
◦ SAIL was composed of “hardware in the loop” (such as sensors and
cockpit displays) mixed with mathematical models (such as
aerodynamic force models, gravity force models) and flight software
(such as guidance, navigation, and control functions)
◦ SAIL results compared very well with actual measured flight
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Balance: The Key to Success
Experimental
Modeling and Validation and
Simulation Hardware
implementation
Mechatronic System Design Process
System modelling and Computer Simulation Without Experimental
Verification Is At Best Questionable, And At Worst Useless!
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Advantages to Simulation
Can be used to study existing systems without disrupting the
ongoing operations.
Proposed systems can be “tested” before committing resources.
Allows us to gain insight into which variables are most
important to system performance.
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Disadvantages to Simulation
Model building is an art as well as a science. The quality of the
analysis depends on the quality of the model and the skill of the
modeler.
Simulation results are sometimes hard to interpret.
Simulation analysis can be time consuming and expensive.
Should not be used when an analytical method would provide for
quicker results.
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Engineering Modeling Procedure
Six Step Approach to Dynamic System Problems
1. Define the system and its components
2. Formulate the mathematical model and list the necessary
assumptions
3. Write the differential equations describing the model
4. Solve the equations for the desired output variables
5. Validate the solutions and the assumptions
6. If necessary, reanalyze or redesign the system
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Engineering Modeling Procedure
Understand the problem
◦ What are the factors and relevant relationships?
◦ What assumptions can be made?
◦ What equilibrium conditions exist?
◦ What should the result look like?
Draw and label an engineering sketch
◦ Free body diagram
◦ Hydraulic schematic
◦ Electrical schematic
Write the equilibrium equations (usually differential or difference)
◦ Newton 2nd Law
◦ Kirchoff Laws for current and voltages
◦ Flow continuity laws
Solve the equations for the desired result
Check the validity of the results
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Modeling of Dynamic Systems
Mathematical models are obtained by applying the appropriate
laws of physics to each element of a system
◦ Some system parameters (such as damping) may be unknown,
or these parameters are often determined through experiments
which lead to empirical relations
Engineering judgment must be used to trade model complexity
with accuracy of the analysis
◦ Nonlinearities (such as gear backlash) are often ignored in
preliminary design studies in order to derive linear models
◦ Sometimes, low-order linear models can be solved analytically
◦ Furthermore, simulations (e.g., MATLAB/Simulink) are easier
to construct with low-order linear models and therefore system-
analysis time is reduced
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Modeling of Dynamic Systems
Engineers must remember that the results from a model and/or
simulation are only approximate and are valid only to the extent of the
assumptions used to derive the model
The model must be sufficiently sophisticated to demonstrate the
significant features of the dynamic response without becoming too
cumbersome for available analysis tools
◦ Higher-order, complex nonlinear models typically require smaller
integration time steps to accurately solve the governing differential
equations, which increases computer run time
◦ Consequently, there is usually a trade-off between model complexity
and analysis time
◦ The validity of a mathematical model can often be verified by
comparing the model solution (i.e., simulation results) with
experimental results
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Control systems
A control system is an arrangement of physical components
connected or related in such a manner as to command, direct or
regulate itself or another system.
The basic functions of control systems are:
◦ to minimize the error b/w the actual and the desired output.
◦ to minimize the time response to load changes in the system.
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Examples of control system applications
Steering control of automobile.
Printwheel control system.
Industrial sewing machines.
Sun-tracking control of solar collectors.
Speed control systems.
Temperature control of an electric furnace.
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Open-loop Control Systems
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Closed-loop Control Systems
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