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The document introduces mechatronics and its key elements. It defines mechatronics as the synergistic integration of mechanical engineering, electronics, and computer control in system design. Mechatronics systems combine sensors, actuators, power electronics, microprocessors, and software. The evolution of mechatronics is traced from the industrial revolution through semiconductor and information revolutions. Core elements of mechatronics systems including mechanical, electromechanical, electrical/electronic, control interface, and computer components are described.
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0% found this document useful (0 votes)
61 views54 pages

TTTT

The document introduces mechatronics and its key elements. It defines mechatronics as the synergistic integration of mechanical engineering, electronics, and computer control in system design. Mechatronics systems combine sensors, actuators, power electronics, microprocessors, and software. The evolution of mechatronics is traced from the industrial revolution through semiconductor and information revolutions. Core elements of mechatronics systems including mechanical, electromechanical, electrical/electronic, control interface, and computer components are described.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Welcome!

Department of Electrical-Electronics
Technology
Introduction to Mechatronic

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Unit of Competence Install Mechatronics Device

• At the end of this module the trainer will be


able to
• LO1: Prepare and Plan to install mechatronics
device
• LO2: Install Mechatronics devices
• LO3: Configure and adjust mechatronics
devices

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LO1: Prepare and Plan to install mechatronics
device
Mechatronics Defined — I
• “The word, mechatronics is composed of mecha
from mechanics and tronics from electronics.
• In other words, technologies and developed
products will be incorporating electronics more
and more into mechanisms, intimately and
organically, and making it impossible to tell
where one ends and the other begins.”
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Mechanics mecha

Mechatronics

Eletronics tronics

Mechatronics Defined — II
“Synergistic use of precision engineering, control theory, computer science, and
sensor and actuator technology to design improved products and processes.”

“Synergistic integration of mechanical engineering with electronics and


intelligent computer control in the design and manufacturing of industrial
products and processes.”

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Mechatronics Defined — III

“Field of study involving the analysis, design,


synthesis, and selection of systems that combine
electronics and mechanical components with
modern controls and microprocessors.”
Mechatronics: Working Definition for us
Mechatronics is the synergistic integration of sensors,
actuators, signal conditioning, power electronics, decision
and control algorithms, and computer hardware and
software to manage complexity, uncertainty, and
communication in engineered systems”.
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What is the Mechatronics?

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Hardware, Software, and Firmware
• Hardware is the name given to the physical devices and
circuitry of the computer.
• Software refers to the programs written for the computer.
• Firmware is the term given to programs stored in ROMs or in
Programmable devices which permanently keep their stored
information

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Disciplinary Foundations of Mechatronics

• Mechanical Engineering
• Electrical Engineering
• Computer Engineering
• Computer/Information Systems

Information Mechanical
Systems Systems

Mechatrnoics

Computer
Electrical
Systems
Systems
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Evolution of Mechatronics as a Contemporary Design
Paradigm
• Technological advances in design, manufacturing, and operation of engineered
products/devices/processes can be traced through:
– Industrial revolution
– Semiconductor revolution
– Information revolution
Industrial Revolution
• Allowed design of products and processes for energy conversion and transmission thus
allowing the use of energy to do useful work.
• Engineering designs of this era were largely mechanical
– e.g., operations of motion transmission, sensing, actuation, and computation were
performed using mechanical components such as cams, gears, levers, and linkages).
• Purely mechanical systems suffer from
– Power amplification inability.
– Energy losses due to tolerances, inertia, and friction

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Semiconductor Revolution

• Led to the creation of integrated circuit (IC) technology.


• Effective, miniaturized, power electronics could amplify and
deliver needed amount of power to actuators.
• Signal conditioning electronics could filter and encode
sensory data in analog/digital format.
• Hard-wired, on-board, discrete analog/digital ICs provided
rudimentary computational and decision-making circuits for
control of mechanical devices.

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Information Revolution
• Development of VLSI technology led to the introduction of microprocessor,
microcomputer, and microcontroller.
• Now computing hardware is ubiquitous, cheap, and small.
• As computing hardware can be effortlessly interfaced with real world
electromechanical systems, it is now routinely embedded in engineered
products/processes for decision-making.
– Microcontrollers are replacing precision mechanical components, e.g., precision-
machined camshaft that in many applications functions as a timing device.
– Programmability of microcontrollers is providing a versatile and flexible alternative
to the hard-wired analog/digital computational hardware.
– Integrated computer-electrical-mechanical devices are now capable of converting,
transmitting, and processing both the physical energy and the virtual energy
(information).
• Result: Highly efficient products and processes are now being developed by judicious
selection and integration of sensors, actuators, signal conditioning, power electronics,
decision and control algorithms, and computer hardware and software.

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Mechatronics Revolution: Example

Mechatronics Revolution: Example

Masterless Cam Grinder


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Elements of Mechatronics—

• The followings are basic Elements of Mechatronics


 Mechanical
 Electromechanical
 Electrical/Electronic
 Control Interface/Computing Hardware
 Computer/Information System
• Mechanical elements refer to
– mechanical structure, mechanism, thermo-fluid, and hydraulic aspects of a
mechatronics system.
• Mechanical elements may include static/dynamic characteristics.
• A mechanical element interacts with its environment purposefully.
• Mechanical elements require physical power to produce motion, force, heat, etc.

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Machine Components: Basic Elements

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Elements of Mechatronics—Electromechanical

• Electromechanical elements refer to:


– Sensors
• A variety of physical variables can be measured using sensors, e.g., light using
photo-resistor, level and displacement using potentiometer, direction/tilt using
magnetic sensor, sound using microphone, stress and pressure using strain gauge,
touch using micro-switch, temperature using thermistor, and humidity using
conductivity sensor
– Actuators
• DC servomotor, stepper motor, relay, solenoid, speaker, light emitting diode (LED),
shape memory alloy, electromagnet, and pump apply commanded action on the
physical process
– IC-based sensors and actuators (digital-compass, -potentiometer, etc.).

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Elements of Mechatronics—Electrical/Electronic

• Electrical elements refer to:


– Electrical components (e.g., resistor (R), capacitor (C), inductor (L),
transformer, etc.), circuits, and analog signals
• Electronic elements refer to:
– analog/digital electronics, transistors, thyristors, opto-isolators, operational
amplifiers, power electronics, and signal conditioning
• The electrical/electronic elements are used to interface electro-
mechanical sensors and actuators to the control interface/computing
hardware elements

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Elements of Mechatronics— Control
Interface/Computing Hardware
• Control interface/computing hardware elements refer to:
– Analog-to-digital (A2D) converter, digital-to-analog (D2A) converter, digital
input/output (I/O), counters, timers, microprocessor, microcontroller, data
acquisition and control (DAC) board, and digital signal processing (DSP) board
• Control interface hardware allows analog/digital interfacing
– communication of sensor signal to the control computer and communication
of control signal from the control computer to the actuator
• Control computing hardware implements a control algorithm, which uses
sensor measurements, to compute control actions to be applied by the
actuator.

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Elements of Mechatronics—Computer/Information
System
• Computer elements refer to hardware/software utilized to perform:
– computer-aided dynamic system analysis, optimization, design, and simulation
– virtual instrumentation
– rapid control prototyping
– hardware-in-the-loop simulation
– PC-based data acquisition and control

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PNEUMATICS AND HYDRAULICS SYSTEM

FUNDAMENTALS OF PNEUMATICS
• Fluid power Source of energy for industrial
processes
– Electric energy- electric motor
– Fluid power – cylinder (piston)
• Fluid power- deals with ways of using pressurized
gas (usually air) or liquid (usually oil) for doing work.
• The two forms named as
– Pneumatic – pressurized air
– Hydraulic – pressurized oil
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Introduction to pneumatic control

The word ‘Pneuma’ means breath or air. Pneumatics is


application of compressed air in automation. In
Pneumatic control, compressed air is used as the working
medium, normally at a pressure from 6 bar to 8 bar. Using
Pneumatic Control, maximum force up to 50 k N can be
developed. Actuation of the controls can be manual,
Pneumatic or Electrical actuation. Signal medium such as
compressed air at pressure of 1-2 bar can be used [Pilot
operated Pneumatics] or Electrical signals [ D.C or A.C
source-24V–230V ] can be used [Electro pneumatics]

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Characteristics of compressed air

The following characteristics of Compressed air speak


for the application of Pneumatics
 Abundance of supply of air
 Transportation
 Storage
 Explosion Proof
 Cleanliness
 Speed
 Regulation
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Advantages

 Air is available everywhere in unlimited quantity


and free of cost. Air can be transported through
pipes.
 Air can be stored.
 Compressed air does not cause explosion hazards.
 Components are overload safe.
 Automation with pneumatics is the cheapest.

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Limitations

 Air is compressible, therefore precise speed


control is difficult
 To do some work pressurized air is must.
During compression heat generated
necessarily be dissipated, which is wastage
 Leakage causes high pitched noise . Can be
hazardous

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Applications

Push
Pull
Lift
Combination
Transfer
Hold
Tilt
Lock

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Industrial application

Chemicals Packaging

Textiles Machine Tools

Plastics Mining

Paints Construction

Pharmaceuticals Robots

Food Processing Health Care


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Automation techniques

• Technique applied to reduce human interference in


• a process cycle is known as AUTOMATION TECHNIQUE.
• e.g.
• Mechanical
• Electrical
• Pneumatic
• Hydraulic
• PLC

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Pressure measurement units

Quantity Symbol SI unit Name Remarks

Pressure p Pa Pascale 1Pa=1N.m2

Standard Vn m 3n Standard cubic


volume meter

Volume flow Q m3n . s-1 Standard cubic  


meter/sec

Temperature T 0
K Kelvin 0 0C =273.16 0K

Energy, work E, W J Joule 1J=1N.m=1Pa.m3

Power P W Watt W=N.m.s-1 , P = p.Q

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Practical values
 It should be noted that the SI unit of pressure is Pascal (Pa).
However, this unit is very small and so to avoid huge
numbers in practice, an agreement has been made to
define and use another large unit called bar. It is defined as
1bar = 100,000 Pa (100KPa)
 Its Imperial equivalents are
1 STD atm = 14.696 psi = 1.01325 bar
 A pressure in the context of pneumatics is assumed as
over-pressure i.e. above atmospheric pressure
– i.e. above 14.7 psi or 1 bar up to 10 bar or 145 psi
(commonly referred to as gauge pressure (psig)).

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Pneumatic system structure and signal flow

• A simple pneumatic system


• It consists of an interconnection of three
elements.

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• Depiction of the
general structure
and signal flow of
pneumatic system

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Energy Flow Diagram

Actuator

Control System

Source

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Components of pneumatic system

• Pneumatic components can be classified into three


general groups:
– Air generation and distribution components
(compressor-air cooling (drying)-reservoir-air
service units and other accessories)
– Actuators (pistons, air motors, rippers etc.)
– Valves (Input valves, processing valves and control
valves as we have seen in the structure of
pneumatic system)

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AIR GENERATION AND DISTRIBUTION

• Main function is to provide the system with


compressed air which is dry, clean, and at the
required pressure.
• Air is compressed by the air compressor and
delivered to an air distribution system in the factory.
• To ensure that the quality of the air is acceptable, air
service unit is utilized to prepare the air before
being supplied to the control system.
• Malfunctions can be considerably reduced in the
system if the compressed air is correctly prepared.

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Compressed Air Supply
Atmospheric Air

Energy Supply Compressor Vane, Screw, Piston

Storage Receiver

Electric Motor Absorption,


Diesel or Petrol Engine Drying Refrigeration,
Adsorption

Distribution Air Distribution System

Service unit Filter, Regulator,


Lubricator

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Plant 35
Air compressor
• Used to produce the compressed air for the
system by the required volume and pressure.
• As a rule, pneumatic components are designed
for a maximum operating pressure of 800-1000
kPa (8 - 10 bar) but in practice it is
recommended to operate at between 500-600
kPa (5 and 6 bar) for economic and safe use.
• Due to the pressure losses in the distribution
system, the compressor should be delivered
between 650-700 kPa (6.5 -7 bar).
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Air compressor symbol
• Figures below is an example of air compressor
and its ISO symbol.

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Types Of Compressors
The principal types of compressors

Displacement Type

Reciprocating type Rotary Type

Piston Diaphragm
Type Type

Vane Type Screw Type Roots


Type
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Air drying unit
• As the air from the compressor is very hot and humid, the cooling
and drying unit is used to reduce the compressed air temperature
and condensate the water vapor (humidity) and remove from the
compressed air.
• The accumulation of condensate depends largely on the relative air
humidity of the intake air that depend on the surrounding air
temperature and the weather situation.
• The most effective way to remove the major part of this condensate
is to use an after cooler immediately after air compression.
• After coolers are heat exchangers, being either-air cooled or water-
cooled and have an auto-drain to remove the accumulated
condensation.
• To remove the humidity, we may also use other many types of air
dryers.

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Air dryers
• In addition to aftercooler there are other types
of dryers that can condensate the water vapor
from the compressed air that pass through
them. They are
 Absorption dryers- Dehydrated chalk or
magnesium chloride or calcium chloride reacts
with the moisture to form a solution which
drained from the bottom of the vessel- (see
Fig)
 Adsorption dryers- silica gel or activated
alumina to physically absorb moisture from the
compressed air and retain it inside then
drained the water by pressurized gas.
 Refrigerator – It is a separate refrigerating unit
which not an integrated part with the
compressor.

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Air dryer symbol

• Figures below show some example of real after


cooler and air dryer and an ISO symbol of air dryer.

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Air Tank (reservoir)

• An air reservoir should be fitted


– To store and stabilizes the compressed air,
– To minimize the frequent run and stop of the
compressor or motor and
– To provide an additional cooling of the air.
• It is fitted with a pressure gauge, safety valve,
automatic drain, and inspection for checking and
cleaning inside.

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Air Tank symbol

• Figure below shows a real air tank and ISO symbol of


an air reservoir.

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Main piping materials

• The are different materials for the main piping in


different standard size.
– Standard Gas Pipe (SGP) – steel or malleable pipe
obtained either in black or galvanized
– Stain less steel pipe- when large diameter in long
straight main are required
– Copper tube – where corrosion, heat resistance
and high rigidity are required but costly for more
than 28mm diameter pipe
– Rubber tube (Air Hose/ reinforced plastic )- they
are most suitable for air actuated hand tools as it
offers flexibility for freedom of movement for
operator
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Plastic tubing and fittings

• Figures below show some types of tubes that are


commonly used in connecting pneumatic
components and associated fittings such as T
connections and cross connections.

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Shut-off valve

• It is used to open and close the compressed air supply


manually.
• Figures below show a sample of shut-off valve and the
ISO symbol of the shut-off valve.

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Pressure gauge
• It used to display the actual amount of the
pressure mostly in two main units Pascal and
bar (1 bar = 14.5 psi (pressure per square
inch)).
• Figures below show a real pressure gauge and
the ISO symbol of the pressure gauge.

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Air service units
• The air service unit is a combination
of the following:
– Compressed air filter
(with water separator),
– Compressed air regulator
– Compressed air lubricator.
• The main function of the service unit
is providing the pneumatic components
with a well cleaned, lubricated and regulated
compressed air. 06/01/2023

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Air service units symbol
Figures below show a real service unit (filter and
pressure regulator), its ISO symbol and also the
simplified symbol

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Air filter
• Compressed air filter has the job of
removing all contaminants from
the compressed air flowing through
it as well as water which has
already condensed.
• The compressed air enters the
filter bowl through guide slots.
Liquid particles and larger particles
of dirt are separated centrifugally collecting in
the lower part of the filter bowl. The
collected condensate must be drained
before the level exceeds the
maximum
condensate mark, as it will otherwise be
re-entrained in the air stream.
• Two types of drain – manual and auto drain

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Air filter symbols
• Figures below shows air filter and the ISO
symbol of an air filter.

Filter with water trap (manual drain)

Filter with water trap (auto-drain)

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Pressure regulator
• Its purpose is to keep the operating pressure
of the system (secondary pressure) virtually
constant regardless of fluctuations in the line
pressure (primary pressure) and the air
consumption.
• Figures below show a regulator and the ISO
symbol of the air regulator.

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Air lubricator

• Most moving parts require some type of lubrication.


• The efficiency of cylinders, valves and air motors can be
greatly improved if they are supplied with adequate
lubrication.
• Pneumatic components can be lubricated by using an
airline lubricator - a device for adding lubricating oil in
aerosol form into a compressed air line.
• The air passing through the lubricator transports the
lubricant to air tools, cylinders or other air operated
equipment.

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Manifold
• It is used to provide multi equal pressure
outlets. Each output port has check valve (Non
return valve).
• Figures below show a pneumatic manifold
(distributor) and its ISO symbol of the
pneumatic manifold.

• 5454

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