Industrial Automation System

U NIVERSITY OF S USSEX
D EPARTMENT OF E NGINEERING AND D ESIGN
Course: H7121: Industrial Automation Systems

MECHATRONIC DESING

1. Mention what are the steps in the V model for mechatronic system design.

Rta: The V-model for mechatronic system design breaks down the development process into two
major halves, mirroring each other in a V-shape. Here's a breakdown of the typical steps involved:

Left Side (Top-Down): Decomposition

1. System Requirements Definition: This involves capturing the needs and functionalities expected
from the overall mechatronic system.
2. Functional Breakdown: Here, the system requirements are translated into specific functions that
the mechanical, electrical, and software sub-systems will need to perform.
3. Logical Design: This stage focuses on defining the logical architecture of each sub-system,
outlining how they will achieve their functionalities. This might involve creating block diagrams or
flowcharts.
4. Physical Design: In this step, the logical designs are translated into concrete physical
specifications. This includes selecting components, materials, and defining their specifications.

Right Side (Bottom-Up): Verification & Validation

5. Component Verification: Individual components (mechanical, electrical, software modules) are

tested to ensure they meet their designated specifications.
6. Subsystem Integration & Verification: Subsystems are integrated, and their functionalities are
tested together to verify they work as intended.
7. System Integration & Verification: The complete mechatronic system is assembled, and its overall
performance is evaluated against the initial system requirements defined in step 1.
8. System Validation: This is the final stage where the entire system is tested in a realistic
environment to confirm it meets the actual user needs and objectives.

2. Using the Functional Analysis System Technique (FAST), perform

the analysis of a robotic lawnmower (present minimum 3 sub-
functions and specifications).

FAST Analysis of a Robotic Lawn Mower

Function: Mow lawn

Sub-Function 1: Cut Grass

 Specifications:
o Cutting height adjustable (1 inch to 3 inches)
o Minimum blade width of 18 inches
o Mulch or collect clippings (user selectable)

Sub-Function 2: Navigate Terrain

 Specifications:
o Obstacle detection and avoidance (within reason, e.g., avoid flower beds, trees)
o Ability to handle slopes up to 20 degrees
o Rain sensor to return to charging station when rain detected

Sub-Function 3: Maintain and Schedule Operations

 Specifications:
o Self-docking and charging
o Programmable mowing schedule (e.g., specific days/times)
o Low battery notification with automatic return to charging station

Note: This is a basic FAST analysis focusing on core functionalities. Additional sub-functions can be
included depending on the complexity of the robotic lawnmower. Examples include:

 Anti-theft security measures

 Smartphone app control for remote operation and adjustments
 Integration with smart home systems for scheduling based on weather forecasts

3. Using the Functional Analysis System Technique (FAST), perform

the analysis of the Festo MPS solution used in lab sessions.

Unfortunately, without specific details about the Festo MPS solution used in your lab sessions, it's
impossible to provide a completely accurate FAST analysis. However, based on general knowledge
of the Festo MPS (Modular Production System), here's a possible FAST analysis focusing on a
potential lab exercise:

Function: Assemble a specific product (replace "Product X" with the actual product assembled in
your lab)

Sub-Function 1: Pick and Place Components

 Specifications:
o Pick specific components from designated feeders (based on type, size, etc.)
o Precise placement of components at designated assembly points (accuracy within +/- 0.5 mm)
o Gripper force adjustable to handle components of varying weights and fragility

Sub-Function 2: Process and Manipulate Components

 Specifications:
o Integration with specific processing units (e.g., press, rotary table) as required by the product
assembly process
o Precise control over processing parameters (e.g., pressure, speed) based on component
specifications
o Ability to handle delicate components without damage

Sub-Function 3: Product Inspection and Quality Control

 Specifications:
o Vision system for inspection of assembled product (verify presence and correct placement of
components)
o Sensor integration for dimensional and quality control checks (e.g., ensure proper connection,
absence of defects)
o Automatic rejection system for faulty products
 ROBOTIC

1. For stationary robots (robotic arms), define the following elements: link, joint,
degree of freedom, orientation, position, workspace, and payload.

Elements of Stationary Robots (Robotic Arms):

1. Link: A rigid segment that connects two joints in a robotic arm. Links can come in various shapes

and sizes depending on the robot's function and payload capacity.

2. Joint: The connection point between two links. Joints allow for controlled movement between the

connected links, providing the robot with its flexibility. There are different types of joints, such as

rotary (rotational movement) and prismatic (linear movement).

3. Degree of Freedom (DOF): The number of independent movements a robotic arm can perform at

each joint. Each joint typically contributes one DOF, although some can be more complex. The total

DOF of the robot determines the range and complexity of its motion.

4. Orientation: The direction or posture of the robotic arm's end effector (the gripper or tool attached to

the final link). Orientation is typically described by angles or rotations around the robot's coordinate

system.

5. Position: The location of the end effector in space, defined by its coordinates (e.g., X, Y, Z) relative

to a fixed reference point.

6. Workspace: The three-dimensional volume that the end effector of the robotic arm can reach and

manipulate objects within. The workspace is determined by the robot's arm length, joint types, and

DOF.

7. Payload: The maximum weight or force the robotic arm can carry and manipulate with its end

effector. The payload capacity is crucial for selecting the right robot for specific tasks.

2. State the difference between linear and joint interpolation.

Here's the breakdown of the difference between linear and joint interpolation for robotic arm
movement:

Linear Interpolation:

 Focus: Straight-line path in Cartesian space (X, Y, Z coordinates).

 Calculation: Calculates the joint angles needed for the robot to follow this straight line at
intermediate points.
 Efficiency: May not be the most efficient path for the robot's physical structure, potentially straining
certain joints.
 Application: Useful for simple pick-and-place tasks where a straight-line motion is desired.

Joint Interpolation:
 Focus: Independently interpolates the angles of each joint between the start and end poses.
 Path: The resulting path in Cartesian space may not be a straight line. The robot prioritizes natural
joint movements.
 Efficiency: More efficient for the robot's mechanics as it considers joint limitations and avoids
unnecessary strain.
 Drawback: Can result in jerky or non-optimal end effector movement if not planned carefully,
especially for complex motions.

Analogy:

 Linear: Imagine moving a straight line on a map between two points. You force your arm (the robot)
to follow that line, even if it's awkward.
 Joint: Imagine the robot bending its joints naturally to reach the target point. The path might not be
perfectly straight, but it uses its joints more comfortably and efficiently.
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3. For the following stationary robot configurations, give an

application for which they are the most suitable choice: gantry,
SCARA, and articulated.

1. Gantry Robot:

 Application: Pick-and-place over a large, flat workspace

 Reasoning: Gantry robots excel in Cartesian movement (X, Y, Z) due to their three linear axes. This
precise, straight-line motion is ideal for tasks like:
o Material handling and palletizing in warehouses.
o Assembly line applications involving moving parts across a large area.
o CNC machining and 3D printing operations requiring precise positioning.

2. SCARA Robot (Selective Compliance Articulated Robot Arm):

 Application: High-speed assembly and pick-and-place in a confined space

 Reasoning: SCARA robots offer a good balance between speed, precision, and compact size. They
typically have two or three rotational axes for fast in-plane movement (X, Y) and a vertical Z-axis for
picking and placing objects. This makes them suitable for:
o High-speed assembly lines in electronics or food processing.
o Packaging and sorting applications requiring fast and precise handling.
o Small workspaces where a bulky articulated robot wouldn't fit.

3. Articulated Robot:

 Application: Tasks requiring high dexterity and flexibility in a large workspace

 Reasoning: Articulated robots mimic the human arm with multiple rotary joints, offering a wide range
of motion and the ability to reach around obstacles. This versatility makes them ideal for:
o Welding and painting applications requiring complex maneuvers.
o Machine tending and material handling in dynamic environments.
o Applications needing a robot to reach into confined spaces or perform tasks from various angles.
MACHINE VISION

1. Mention what the steps in the machine vision process are.

2. What is an image processing operation? Mention three examples.
3. What is image segmentation? In addition, describe how this technique/process
is useful in industrial automation applications.
4. Explain the differences between backlighting and top lighting and mention two
examples where each could be used

INDUSTRIAL NETWORKS

Define network topology and give two examples of standard topologies.

2. For each layer of the ’five-layer internet protocol’ architecture, describe the main
characteristics of the layer and state at least an example of their responsibilities/activities
3. What is multiplexing and demultiplexing?
4. Mention and describe three industrial network protocols, and mention three industrial network
applications.
5. Discuss the motivations and challenges for industrial wireless networks implementation.
6. What are the main challenges regarding industrial networks security system