introduction to mechatronics system

10 Department of Mechanical Engineering

Vol. 1, 2006

INTRODUCTIONTO MECHATRONICS SYSTEMS

J.K. GeraDeptt. of Mechanical Engineering

BackgroundThe current technological designs are highly complex and interdisciplinary in nature involvingsynergistic integration of many aspects of engineering knowledge base. The integration of varioustheories, principles , techniques, methodologies and standards to cater to the pressing needs have longbeen emerging as new multi-disciplinary subject in the name of mechatronics, which has been attractingnot only manufacturers but also engineers, developers, researchers and academicians.

Advanced technological designs are highly complex and interdisciplinary nature involving synergisticintegration of mechatronics, photonics, computronics and communication. Technological designs havebecome a high risk endeavor due to the lack of knowledge and experience on interdisciplinary subjectsand methods. Synergetic integration is solitarily logic based integration. Combined action andcooperation increases effectiveness and productivity.

DefinitionMechatronics is “the synergistic integration of Mechanical Engineering with Electronics and intelligentcontrol algorithms in the design and manufacture of products process”. Synergistic integration meansthe mechatronic engineers have to study the aspects of engineering that are vital for the design andmanufacture of products, process. A graphical representation of Mechatronics is shown Fig. 1

The main technical areas under the research and development domain mechatronics are:• Motion control• Robotics• Automotive systems• Intelligent control

11Department of Mechanical Engineering

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• Actuators and sensors• Modeling and design• System integration• Manufacturing• Micro devices and optoelectronics• Vibrations and noise control

Figure 2 provides an abstract view of the mechatronic discipline. The square like block represents thesubject areas the discipline includes and the semicircular projections represent that there existsinteraction among the subjects emphasizing multidisciplinary scenario.

Figure 2-Detailed layout of basic Mechatronics

Evolution of MechatronicsMechatronics has evolved through the following stages:• Primary Level Mechatronics: Integrates electrical signaling with mechanical action at the

basic control level for e.g.fluid valves and relay switches• Secondary Level Mechatronics: Integrates microelectronics into electrically controlled devices

for e.g. cassette tape player.• Tertiary Level Mechantronics: Incorporates advanced control strategy using microelectronics,

microprocessors and other application specific integrated circuits for e.g. microprocessor basedelectrical motor used for actuation purpose in robots.


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• Quaternary Level Mechatronics: This level attempts to improve smartness a step ahead byintroducing intelligence ( artificial neutral network and fuzzy logic ) and fault detection andisolation ( F.D.I.) capability into the system.

Scope of MechatronicsThe definition of mechatronics is elusive, as is the definition of computer. The scope of Mechatronicsis vast and can be enclosed within the following domain of activities:• Marketing: Signifies market research, identification of user needs, information analysis and

formulation of product specification.• Manufacturing: Looks into process development, production planning, material handling and

quality control.• Design: The concentration is on studying fundamental aspects of sensors, actuators, control

and integration methods. Broadly the core of a mechatronics system incorporates Mechanical,Electronics, Control and Information system engineering.

Mechatronic SystemsMechatronic system have become increasingly popular because of their versality, functionality andhigh integration level. Examples of mechatronic system are :• An aircraft flight control and navigation system, weapon system• Automobile electronic fuel injection, antilock brake systems, collision detection, global

positioning system, camless valve operation, active suspension, by wire systems etc.• Automated manufacturing equipment such as robots and numerically controlled (NC) machine

tools., autonomous guided vehicles ( A.G.V.).• Smart kitchen and home appliances such as bread machines and clothes washing machines, and

even toys.

Photocopying machine , automatic cash machine , music system, and video player.

Figure 3 – Scope of Mechatronics


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Fig. 4 Mechatronic System

Fig. 5 Elements of Mechatronic System

The elements of a typical Mechatronics system are shown in Fig. 5


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• The actuators produce motion or cause some action.• The sensors detect the state of system parameters, inputs, and outputs devices• Digital devices control the system.• Conditioning and interfacing circuits provide connections between the control circuits and the

input/output devices.• Graphical displays provide visual feedback to users.

Mechatronics as Design PhilosophyIt is “a design philosophy” where mechanical, electrical, electronics components, and it should beconsidered together in the design stage to obtain an compact, efficient, and economic product designrather than designing the components in stages separately. This is illustrated in fig. 6

Fig. 6 Conventional and Modern Design Approaches

Design trends in mechatronics are oriented to reduction of hardware parts of the systems and increasingthe software option volume to improve of the system functionality and system reliability. Typicalaspects of the mechatronics area are the applications of new physical principles, (smart) materials,electronic and microelectronic systems, complex computing and controlling technologies andprogressive production processes.


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Future results of these special mechatronics aspects are the smart or intelligent systems suitable for allapplications areas of the human life necessity and human interactions to the nature.

Smart devices, while the term smart is elusive in precise definition, in the engineering sense we meanthe inclusion of elements such as logic, feedback, and computation that in a complex design mayappear to simulate human thinking processes.

Mechatronic systems are to be built, designed, monitored, controlled and simulated using hardwareand software tools(modularity), work bench(platforms) and techniques, considering harware softwareintegration parameters such as modularity, scalability, extendability, flexibility, interoperability,interchangeability etc.

Measurement SystemsA fundamental part of many mechatronic system is a measurement system composed of the three basicparts:

• The transducer is a sensing device that converts a physical input into an output, usually avoltage.

• The signal processor performs filtering, amplification, or other signal conditioning on thetransducer output.

• The recorder is an instrument, a computer, a hard-copy device, or simply a display that maintainsthe sensor data for online monitoring or subsequent processing.

Fig.7Examples of Measurement Systems – Digital Thermometer is shown in Fig. 7.

Micro MechatronicsThe system integration has another view point by combining micro sensor and actuator technologies,which is defined as “micro-mechatronics”. Micro-mechanics is viewed as giving new birth to anotherbranch of mechatronics showing precision engineering and system integration. This filed introduced


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the bottoms-up approach from semiconductor technology based on photolithography, and thedownsizing/miniaturizing approach from conventional mechatronics, emerging into a new filed asmicro-mechatronics. Microsensors are good examples of micro-mechatronics with the developmentof microprocessors and micro actuators.

Modelling and simulationThe behavior of engineering system is studied through modeling and simulation.state of the artsimulation, measurement and test technique enable us to accurately predict performance.

In a conventional design approach, components of a physical system are designed in isolation and testits feasibility physical prototypes are made. Based on the prototype test results modifications are carriedout. Using such approach, several prototypes are required before a satisfactory design is achieved.Since making physical prototypes is time consuming and expensive, a large investment is required,particularly.

Alternatively, with the advent computers researchers are able to solve complex equations. Hence, insteadof viewing components of a physical system in isolation the whole system equations of motions arederived based on the fundamental principles of the individual components., this is called modelling.Modeling shapes the foundation for understanding, studying and manipulating the behaviour of thesystems. The total system equations are then solved using a computer, which is referred to as simulation.The simulation results provide the nature of the system behaviour. Since changing the model parametersand re-running the simulation does not take much time (only in minutes or hours), the number of realprototypes are reduced, and a new product can be brought to the market much quicker than in theconventional approach. This modelling and simulation together is also referred as virtual prototyping,as it serves the purpose of physical prototypes without really making one.

The challenges in modelling and simulation or in virtual prototyping are:1. The methods and ways to write the system equations of motions so that computers take less time

to solve; and2. The numerical methods used to solve the equations so as to obtain realistic results without large

numerical errors, which have nothing to do with the physical systems.

Application of modeling and simulation• Concept design : a new idea to be examine / discussed / communicated.• Design refinement : re-run program with change input data.• Design verification : study performance.• Test planning : predict behaviour before a real test.• System re-construction : study a failure.• Teaching and training : useful tool for teaching and training.


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Future TrendsThe future has much to offer. The reduction in component sizes is providing new types of actuator andsensors, which are being increasingly utilized in complex systems such as the provision of low costradar sensors for autonomous robot systems and automotive uses.

Mechatronics allows both to achieve increased functionality for the same dimension of a system, andto reduce its size for the same functionality.

As examples, today’s intelligent washing machines incorporate a wide variety of sensors (turbidity,conductivity, temperature, humidity, waster-level, position, torque sensor), in order to optimize thewashing cycles and the final washing quality.

ConclusionThe knowledge of mechatronics is a prime requirement and is considered as fundamental to engineersof all fields.

The concept of mechatronics is very important today to meet the customers’ ever increasing demandsand still remain competitive in the global market. Very often a mechanical engineer without themechatronics background is considered equivalent to a mechanical engineer without the engineeringdrawing knowledge.

The growing importance of mechatronics, a truly multidisciplinary approach to engineering, isbecoming increasingly apparent. New products and systems based on the integrated application ofmechanics, electronic and computing engineering technologies are demonstrating reduced mechanicalcomplexity, increased performance, and often, previously impossible capabilities.

Mechatronics system has become increasingly popular because of their versatility, functionality andhigh integration level. These advantages have been stimulated by factors including developments inmicroprocessors, new and improved sensors and actuators, advances in design and analysis methods,simulation tool and novel software techniques. To improve communication, control capabilities,implementation simplicity, efficiency, reliability and safety system design.

Mechatronics is the challenge for future intelligent tools. An expansion of today technologies is expectedin application of nanoelectgronics, bio and molecular technologies. Future is in micromechatronics toreach the unique quality of the system for new application areas. Mechatronic has a bright future andwill grow steadily in the 21st century.

References1. David G Alciatore, M B Histand “Introduction to Mechatronics and Measurement System”2. D Mecrulescu “Mechatronics3. J W Gardener “Microsensor”4. N P Mahalik “ Mechatronics Principle Concept & Application”5. W Bolton “Mechatronics”.

introduction to mechatronics system

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