Advanced Mechatronics Systems

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Innovative idea
Mechatronics
Mechatronics is a combination of mechanical and electronic engineering, including electric
motor drives, sensors, robots, and anything else where electrical energy is transformed to (or
from) mechanical energy. After starting as a mechanical engineering business Long years ago,
Sigma Design has grown to include all areas of end-to-end product design, but the Electrical
Engineers at Sigma Design still want to respect our original spirit: making things move! -
There are two ways to look at this suffix: as an electronic (rather than electrical) driving and
controlling mechanism, or as a more basic electronic conversion between electrical and
mechanical energy sources.
Electronic aspects of mechanical motion
Mechatronics encompasses motors, drives and control circuits. Mechatronics Due to their
reliance on semiconductors for the optimal optimization of their power supply, drive and motion
coordination, all DC motors, whether they are brushed or brushless (BLDC), have always been
electronic.
Power supplies
Voltage and power quality may be altered by adjusting the electricity source. It is the job of
power electronics to design them. Basically, a power supply is a device that transforms energy
from one form to another. A different frequency of AC may be reversed back to DC by the drive!
Battery functioning is made possible by semiconductor components like diodes and transistors,
which limit heat gain and improve power supply efficiency. In order to fulfil sudden current
demands, mechanical power sources must have low impedance. Electric vehicles and unmanned
aerial vehicles (UAVs) fueled by Lithium batteries are already commonplace because of their
high energy density.
Motor drives
Electrical current is timed and controlled by electronic semiconductors in motor drives. As a
result of the rapid switching of motor windings, which have inductive loads, diodes help protect
sensitive components from fly-back voltage spikes. Additionally, power electronics contains a
power supply and motor controllers.
Motion control
Microcontrollers or FPGAs are then used to control motion in real time by reacting to signals and
sensors. It is possible to use current sensing for "sensor less" positioning, torque monitoring, and
proactive detection of overload or overheat concerns.
Mechatronics design considerations
Mechanical "outputs" utilize more energy than most other electronic components, therefore
designing their power supply and driving circuits may be difficult. Managing Thermal,
Electromagnetic, and Power Integrity (EMC).
Power integrity
Systems that allow too much deviation from the norm may result in unpredictable behavior or
even system shutdowns or resets. Low-impedance power sources are needed for the motors. The
system must have sufficient bypass capacitance to offset resistance and inductive reactance that
might choke the supply and cause voltage droop in order to fulfil the fast current demands of a
pulse motor drive.
A substantial inrush current may occur at initial power delivery or when subsystems are hot-
plugged; this must be anticipated and addressed during design to prevent temporarily
overloading power supply. Excessive inrush current may cause power regulation ICs to shut
down and restart in an unending loop, preventing the functioning of the device.
Thermal management
Mechatronic systems use higher-than-average power levels, which necessitates that engineers
design their systems to be as efficient as possible in order to avoid creating additional waste heat.
To prevent component overheating (or posing a threat to the user), it is critical to model the heat
produced by all power supply and drive sub circuits and ensure that surplus heat can be
appropriately dissipated away from the system. Designers of electronic circuits and controllers
Firmware Electrical shorts in the motor drive must also be taken into account while switching
polarity.
Computational fluid dynamics can show an enclosure's airflow and cooling capabilities.
Many Mechatronic best practices involve providing reliable temperature feedback devices that
enable for damage-preventive thermal shutdown. It's better to design efficient mechanical
cooling systems to transport heat away from hot components.
Electromagnetic compatibility
Mechatronic systems often encounter electromagnetic compatibility issues as a result of the
usage of powerful motor drivers. Electromagnetic compatibility governs how electrical
equipment interacts with its surroundings. All electrical goods must be tested and certified to
verify that they are safe and meet EMC regulations. Emissions from Mechatronics systems must
be taken into account during the design phase. It is easy to violate conducted emissions
restrictions by re-conducting high-frequency voltage disturbances that occur as a result of fast
current switching if it is not handled. Filtering of power in the common and differential modes
helps eliminate this annoying back-conductance noise. Because filtering enhances the impedance
of the source, special consideration must be given to the impact on Power Integrity.
The high magnetic fields produced by motor drives' alternating currents might interfere with
other electronic equipment (or, at least, fail EMC emissions testing).
Motor and Motor Drive
Electrified motors turn electrical energy into mechanical power. For the most part, it is used to
transmit energy from an electrical source to anything mechanical. To describe the mechanism
that turns a motor, we may use terms like "electric drive" or "motor drive," which refer to the
system in which the motor is housed.
These include the motor's rotational speed, torque, and shaft position.
Motor drive efficiency
Electric motors account for 45 percent of all electrical energy use. Increasing the efficiency of
motor drives might have a significant impact on global power consumption. As worldwide
demand for electricity rises, so does the difficulty of supplying it, due to industrialization and
urbanization. Numerous countries have adopted or are striving to improve motor drive efficiency
as part of a global effort to reduce energy consumption and carbon emissions.
Provide the detailed design with force analysis of the proposed system

The functions of the power converter circuit in the motor drive are:
 As an input, use electrical energy that has been transferred from a source with a certain
voltage, current, frequency, and phase.
 To provide the motor with the necessary mechanical output to drive the load with an
electrical output with the proper voltage, current, frequency, and phase. Using feedback
from the sensor block, the controller controls energy flow.
 Sensors on the motor collect low-power signals, which the controller 5 processes.
Converter is instructed by the controller what it should be performing.
  A closed-loop feedback system compares what the motor really does with what it should
be putting out, and then modifies the output to keep it at the goal output.
Block diagram of a motor drive system
Classification of motor drive

Comparative analysis of motors

Power converter in motor drives T
Table 1 summarizes the most common motor drive configurations. However, the architecture of
the power converter circuit is different. Brushless DC (BLDC) and induction motors are the
motors of choice for the majority of these applications, so we'll concentrate on them. In general,
choosing a motor drive may need consideration of power and voltage levels, as well as concerns
specific to the application.
Table 1: describes the voltage and power levels at which each kind of motor may be utilized, as
well as the advantages (and disadvantages) of each.
Power stage
It uses a three-phase inverter to transmit power in the range of kW to MW at the power stage
of the power converter. An inverter is a device that converts DC electricity to AC. Voltage
ranges on the DC bus range from 600 to 1,200 volts. The three-phase inverter has six separate
gate drivers because of the high power and voltage levels.
There are two insulated gate bipolar transistor (IGBT) switches, one on each side of the device.
In an alternating mode, the high-voltage DC pulses are applied alternately to the motor
windings by each phase, which typically operates in the frequency range of 20-30 kHz.
Isolated gate drivers are required to regulate the functioning of high-power IGBTs. In each
IGBT, the gate driver is a completely isolated unit. The gate driver's high-voltage output and
the controller's low-voltage control inputs are galvanically isolated.

Block diagram of ac motor drive

I t is necessary to use an isolated gate-driver because the emitter of the top IGBT floats. Using
gate-drivers separated from a high-voltage circuit to control the bottom IGBTs is a way to keep
the two circuits apart.
Provide the complete schematic diagram of the system and its corresponding
representation in Simulink or Sims scape.

PWM signals from the controller are converted into gate pulses for FETs or IGBTs via gate
drivers Additional safety features, such as desaturation, active Miller clamping, gentle turn-off
as well as other safety measures are required for these gate drivers.
Consolidate your system model using the transfer function reduction technique and
simulate the resulting function
IGBT gate drivers in the power stage of a three-phase inverter are powered by boost gate driver
power supply.
To take use of IGBTs' low conduction losses, gate drivers must operate at higher voltages than
their threshold voltages in the range of 15-18V. It's also a minority-carrier device with a high
input impedance and a huge bipolar current-carrying capacity. An IGBT has comparable
switching characteristics as a power MOSFET.

A BLDC power stage is an inverter with a single or three-phase input, just as an AC motor
drive is. DC-rail voltages may vary from 48 to 600 volts, depending on the amount of power
being generated by the device. At about 100 kHz, the switching of a power MOSFET occurs. It
is possible to use gate drivers on either the high-side or the low-side.
Protective measures aren't as critical for the high- and low-side drivers since they're all
controlled by the same IC.
Demonstrate the feasibility and practicability of your design over the traditional design.
A single-phase induction motor called a Shaded Pole motor is used in refrigerators and
computers. For applications needing between 1/20 and 1/6 horsepower, induction squirrel cage
motors are employed.
A shaded pole motor can only handle a low-density component as its heaviest load. Motors for
shaded poles are often recycled and replaced when they fail.
Split phase motors may be used in a wide range of applications, including ceiling fan blades,
washing machine tubs, oil furnace blower motors, and tiny pumps.
Controlled by the start winding, the centrifugal switch has a typically closed state. The goal of
this setup is to remove the motor start winding from the circuit when the motor achieves 75 to
80% of its rated speed. Centrifugal switch is a moving component that occasionally fails to
reengage after the motor stops spinning, even though it is considered a dependable one.
How to implement the procedures of fault detection of your system
Heavy industry, transportation, and power systems employ this equipment due of its simplicity,
overload capacity, reliability and efficiency. Large and little are two terms that describe the size
and power of an induction motor (Hp). Induction motors are more long-lasting, cheaper, and
need less maintenance than DC motors. For industrial use, these motors are preferred.
Electromagnetic induction is a non-electrical method of transferring energy between fixed and
rotating components. Magnetic field generated by stator powers motor rotor by rotating action. 

Each form of defect, whether electrical or mechanical, generates a distinct vibration. These
precise frequencies may be detected and used to determine use, slackness, and forces that operate
and generate the defect via vibration spectrum monitoring and analysis.
References
1. L. Carlson, S. A. Yost, M. Krishnan, S.Das, "Outcomes-Based Assessment for
Comprehensive Curriculum Development in Mechatronics," IEEE/ASEE Frontiers in
Education Conference (FIE’00), Kansas City, Mo, Oct 19-21, 2019, pp. t4a/1-t4a/5.
2. S.Das, M. Krishnan, S. A. Yost, "Mechatronics: A Comprehensive Interdisciplinary
Curriculum Development Initiative," NSF Showcase presentation at the IEEE/ASEE
Frontiers in Education Conference (FIE’00), Kansas City, Mo, Oct 19-21, 2017 (poster
only).
3. S. A. Yost, D. Maggio, “The Mechatronics Road Show: Building on Success in
Mechatronics Curriculum Development,” ASEE 2014 Conference Proceedings.
4. S. A. Yost, “Taking Mechatronics on the Road,” Proceedings, 2002 SWE National
Conference, Detroit, MI, October 2015.
5. S. A. Yost, “Introducing Mechatronics in a First-Year Intro to Engineering Design
Course,” ASEE 2000 Conference Proceedings, St. Louis, MO, June 2000.
6. Karnopp, Margolis and Rosenberg, “System Dynamics: Modeling and Simulation of
Mechatronic Systems”, John Wiley, 2000.
7. Mathworks Inc., http://www.mathworks.com/, Natick, MA.
8. D.Hrovat, J.Agsari and M.Fodor, “Automotive Mechatronic Systems” Mechatronic
Systems Techniques and Applications, C.T. Leondes (ed.), vol.2, Gordon and Breach
Science publishers, Amsterdam, 2000, pp.1 - 98.
Appendix
Calculate the following:
1. The distance between the rolls,
2. The nip angle, and
3. The roll width. 3
A relationship between roll diameter and maximum ore size should be established when
reduction ratios of 2.0, 3.0 and 4.0 are used and the nip angle is maintained at 15o and 200–
300mm
Rocks with a maximum diameter of 7.0 centimeters were crushed in a roll crusher. 1.5
centimeters between the rolls; the diameter was 110 centimeters, and the breadth was 100
centimeters.

If the roll S.G. was 2.8 and its bulk density was 1.68 t/m3, what would the density be?
Variations in peripheral speed (from 6 to 22 m/min) were shown to have a significant impact on
the capacity-to-speed relationship.
Between the roll and the particles and the peripheral speed, the change in the coefficient of
kinetic friction to static friction ratio.
The roll and the nipped particle come into contact, how much tangential force is applied to the
point of contact.