De ZG516 Course Handout

Birla Institute of Technology & Science, Pilani
Work Integrated Learning Programmes Division

M.Tech. Design Engineering
Digital Learning Handout
Summary
Course Title Mechatronics
Course No(s) AE ZG511/ DE ZG516 / DM ZG511
Credit Units 5
Credit Model 1-1-2
(32 Hours of Class-room Instruction + 32 Hours of Case-
studies/Tutorials/Laboratories + 64 Hours of Student Preparation)
Content Authors Samatha Mujumdar
Instructor-In-Charge PRAKRUTHI HAREESH
Version No. 02
Date 20-7-2019
Course Objectives
No Objective
CO1 An introduction to the applications of mechatronics in various household and

industrial products like in washing machines, microwave ovens, computers, printers,
programmable logic controllers, CNC machines etc.
CO2 Introduction to the various mechatronics building blocks like the System modelling,
Signal sensing and conditioning, Control system engineering, Electrical and
mechanical actuation systems etc.
CO3 Learning about Sensors and Transducers, Operational Amplifiers, Hydraulic and
Pneumatics, Dynamic response of systems, System transfer function, Frequency
response, Closed loop controllers, Programmable logic controllers etc.
Text Book(s)
T1 Mechatronics by W. Bolton, 4th Edition, Pearson
T2 Introduction to Mechatronics and Measurement Systems by D.G. Alciatore and
M.B. Histand, 4th Edition, Tata McGraw Hill
Page 1 of 18
Reference Book(s) & other resources
R1 Mechatronics, HMT Limited, Tata McGraw Hill, 1998
R2 Pneumatics and Electro pneumatics: Basic Level by Festo Didactic
R3 Fluid Power with Applications by Anthony Esposito, Prentice Hall
R4 Control Systems by W. Bolton, Newnes
Page 2 of 18
Content Structure
1. Introduction to Mechatronics
1.1. Measurement systems
1.1.1. Sensors
1.1.2. Transducers
1.1.3. Need for signal conditioning
1.2. Control systems
1.2.1. Open and Closed loop controllers
1.2.2. Microprocessors and Microcontrollers
1.3. Actuators
1.3.1. Electric actuators
1.3.2. Mechanical actuators
1.4. Application examples
1.4.1. Mechatronics in Industry
1.4.2. Mechatronics in home appliances
2. Sensors and Transducers
2.1. Definition of sensors and transducers
2.2. Performance terminology
2.2.1. Range and Span
2.2.2. Errors: Hysteresis and Non-linearity errors
2.2.3. Accuracy, precision and sensitivity
2.2.4. Resolution
2.2.5. Repeatability and Stability
2.3. Static and Dynamic characteristics
2.3.1. Response, rise and settling times
2.3.2. Time constant
2.4. Sensing various physical quantities
2.4.1. Sensing displacement, position and proximity
2.4.2. Sensing force, velocity and motion
2.4.3. Sensing fluid flow rate, pressure and level
2.4.4. Sensing temperature with the following:
2.4.5. Thermocouples, Thermistors, RTDs, AD590, LM35
2.5. Sensor selection
3. Signal Conditioning
3.1. Need for signal conditioning
3.1.1. Signal protection
3.1.2. Noise elimination
3.1.3. Getting right type and level of signal
3.1.4. Signal manipulation
3.2. Signal conditioning with operational amplifiers
3.2.1. Inverting amplifier
3.2.2. Non-inverting amplifier
Page 3 of 18
3.2.3. Summing amplifier
3.2.4. Difference amplifier
3.2.5. Integrating amplifier
3.2.6. Differentiating amplifier
3.2.7. Logarithmic amplifier
3.2.8. Analog to Digital conversion and vice versa
3.3. Wheatstone bridge
3.3.1. Applications with strain gauges
3.3.2. Temperature compensation
3.3.3. Temperature compensation
4. System modelling and dynamic response
4.1. Basic system models
4.1.1. Mechanical, electrical, thermal and fluid systems
4.1.2. Rotational-translational systems
4.1.3. Electromechanical systems
4.1.4. Hydraulic-mechanical systems
4.2. Dynamic response of systems
4.2.1. 1 and 2nd order systems and their identification
st
4.2.2. Performance measures

4.3. System transfer functions
4.3.1. 1 and 2nd order systems
st
4.3.2. Systems in series

4.3.3. Systems with feedback loops
4.3.4. Effect of pole location on transient response
Page 4 of 18
4.4. Frequency response of systems
4.4.1. Frequency response with a sinusoidal input
4.4.2. Bode plots
4.4.3. Performance specifications
5. Controllers
5.1. Controller types
5.1.1. Open loop controllers
5.1.2. Closed loop controllers
5.2. Various control modes
5.2.1. Two step control mode
5.2.2. Proportional control mode
5.2.3. Derivative control mode
5.2.4. Integral control mode
5.2.5. PID controllers
5.3. Control system performance
5.3.1. Controller tuning
6. Actuators
6.1. Electrical actuators
6.1.1. Relays, contactors and solenoids
6.1.2. Electric motors: AC, DC, stepper
6.2. Mechanical actuators
6.2.1. Gears, belt and chain drives
6.2.2. Linkage mechanisms, Ratchet and pawl
7. Hydraulics and Pneumatics
Page 5 of 18
7.1. Hydraulics
7.1.1. Hydraulic power pack
7.1.2. Various types of pumps, valves, cylinders, motors
7.1.3. Hydraulic component symbols and drawings
7.2. Pneumatics
7.2.1. Various types of compressors
7.2.2. Compressed air distribution
7.2.3. Various types of valves, cylinders, pneumatic motors
7.3. Hydraulic and pneumatic circuits
7.3.1. Circuit for single and double acting cylinders
7.3.2. Circuits for counter-balancers
7.3.3. Expand here
8. Microprocessors and Microcontrollers
8.1. Microprocessor systems
8.1.1. Buses
8.1.2. Microprocessor components
8.1.3. Memory and input / output
8.2. Microcontrollers
8.2.1. Difference with microprocessor
8.2.2. Motorola M68HC11
8.2.3. Intel 8051
8.2.4. Programming
9. Programming Logic Controllers
9.1. Basic structure of a PLC
9.1.1. Input and output modules
9.1.2. Power supply and CPU
9.1.3. Sinking and sourcing inputs and outputs
9.2. PLC programming
9.2.1. Ladder logic programming
9.3. Timers, Counters, Internal relays, Registers
Learning Outcomes: Students will be able to
LO1 Apply mechatronics in the design of products
LO2 Acquire concepts of signal sensing and conditioning, control and decision making
and output actuation.
LO3 Illustrate working of various sensors and transducers, system modelling and
dynamic response, open and closed loop controllers, electrical and mechanical
actuators.
LO4 Develop hydraulic and pneumatic drawings for industry automation
LO5 Put to use PLC programming using ladder logic.
Page 6 of 18
Experiential Learning Components:
1. Lab: Onramp, Virtual lab (Automation Studio), Remote Lab (NI Elvis III)
2. Case study: None
3. Work integrated Learning Exercise: None
4. Design work/Field work: None
Part B: Learning Plan
Contact Hour 1
Type Content Ref. Topic Title Study/HW Resource Reference
Pre CH
During T1, T2 Introducing Mechatronics, T1: Chapter 1, T2: Chapter 1

CH Concepts of signal
measurement, control and
output actuation
Post CH
Contact Hour 2
Pre CH
During T2 Mechatronics application T2: Page no. 84, 98, 101, 108,
CH examples 146, 188, 245, 247, 290, 312,
405, 449
Post CH
Contact Hour 3
Pre CH
During T1, T2 Sensor and Transducers: T1: Chapter 2, T2: Chapter 9

CH Definition and performance
terminology, Static and
dynamic characteristics
Post CH Chapter end problems
Page 7 of 18
Contact Hour 4
Pre CH
During T1, T2 Sensing physical quantities: T1: Chapter 2, T2: Chapter 9

CH Displacement, position and
proximity
Contact Hour 5
Pre CH

CH Force, strain, velocity and
motion
Contact Hour 6
Pre CH

CH Fluid flow rate, pressure and
liquid level
Contact Hour 7
Pre CH

CH Temperature measurement
with Thermocouples,
Thermistors, RTDs, AD590,
LM35
Post CH
Page 8 of 18
Contact Hour 8
Pre CH
During T1, T2 Signal conditioning: Need for T1: Chapter 3, T2: Chapter 5
CH condioning, protection, noise
elimination
Post CH
Contact Hour 9
Pre CH
During T1, T2 T1: Chapter 3, T2: Chapter 5

CH Signal conditioning with
operational amplifiers:
Inverting, non-inverting
amplifiers
Contact Hour 10
Pre CH
During T1, T2 Signal conditioning with T1: Chapter 3, T2: Chapter 5

CH operational amplifiers:
Summing and difference
amplifiers
Contact Hour 11
Pre CH
During T1, T2 Signal conditioning with T1: Chapter 3, T2: Chapter 5

CH operational amplifiers:
Integrating, Differentiating and
lograthimic amplifiers
Page 9 of 18
Contact Hour 12
Pre CH
During T1, T2 Signal conditioning: T1: Chapter 3, T2: Chapter 9

CH Wheatstone bridge, application
examples and temperature
compensation
Post CH
Contact Hour 13
Pre CH
During T1 Signal conditioning: Analog to T1: Chapter 4

CH digital conversion and vice
versa
Post CH
Contact Hour 14
Pre CH
During T1 System modelling: Modelling T1: Chapter 10

CH of mechanical and electrical
systems, Modelling of thermal
and fluid systems
Contact Hour 15
Pre CH

CH of rotational and translational
systems, Modelling of
electromechanical systems
Page 10 of 18
Contact Hour 16
Pre CH

CH of hydraulic-mechanical
systems
Post CH
Contact Hour 17
Pre CH
During T1 Dynamic response of systems: T1: Chapter 12

CH 1st and 2nd order systems and
their performance measures
Contact Hour 18
Pre CH
During T1 System transfer functions: 1st T1: Chapter 13

CH nd 2nd order systems, systems
in series and with feedback,
effect of pole location
Contact Hour 19
Pre CH
During T1 Frequency response of T1: Chapter 13

CH systems: Response with a
sinusoidal input, Bode plots,
Performance specifications
Post CH
Page 11 of 18
Contact Hour 20
Pre CH
During T1, R4 Control systems: Open and T1: Chapter 15, R4

CH closed loop controllers, On-off
and proportional control
modes
Contact Hour 21
Pre CH
During T1, R4 Control systems: Derivative, T1: Chapter 15, R4

CH Integral and PID controllers
Contact Hour 22
Pre CH
During T1, T2 Actuators: Electric actuators T1: Chapter 9, T2: Chapter 10

CH like relay, contactor, solenoid,
AC, DC, Stepper motors
Post CH
Contact Hour 23
Pre CH
During T1 Actuators: Mechanical T1: Chapter 8

CH actuators like belt and chain
drives, linkage mechanisms
Post CH
Page 12 of 18
Contact Hour 24
Pre CH
During T1, R3 Hydraulics and pneumatics: T1: Chapter 7, R3: Chapter 6, 8

CH Hydraulic pumps and valves
Post CH
Contact Hour 25
Pre CH
During T1, R3 Hydraulics and pneumatics: T1: Chapter 7, R3: Chapter 7

CH Hydraulic cylinders and
motors
Post CH
Contact Hour 26
Pre CH
During T1, R2,R3 Hydraulics and pneumatics: T1: Chapter7, R2, R3: Chapter
CH Compressed air generation and 11, 12
distribution system,
compressors, valves and
cylinders
Post CH
Contact Hour 27
Pre CH
During T1, R2,R3 Hydraulics and Pneumatics: R2, R3

CH Drawing symbols and basic
circuits
Post CH
Page 13 of 18
Contact Hour 28
Pre CH
During T1, T2 Digital logic: Logic gates, T1: Chapter 5, T2: Chapter 6
CH boolean algebra, applications
Post CH
Contact Hour 29
Pre CH
During T1, T2 Microprocessors and micro- T1: Chapter 17, T2: Chapter 7
CH controllers: Components and
programming
Post CH
Contact Hour 30
Pre CH
During T1 Programmable logic T1: Chapter 21

CH controllers: Components,
programming using ladder
logic
Contact Hour 31
Pre CH
During T1 Programmable logic T1: Chapter 21

CH controllers: Use of relays,
timers, counters, registers in
ladder logic, application
examples etc.
Post CH
Page 14 of 18
Assignments
 Each student is given an individual assignment on any of the topics discussed in the
class
 Assignments are take-home and deadline-driven (typically of 2 weeks duration)
announced post Mid-semester examination
 Students to spend at least 16 hours of work in study, research, discussion and
preparation of the report and presentation.
 As part of deliverables, the student is expected to prepare a report and make a short-
presentation in the class
Evaluation Scheme
Evaluation Name Type Weight Duration Schedule

Component
EC - 1 Assignments Individual and 7.5% 2 Weeks Throughout

Take-home
Virtual Lab Exam Online 06% 2 Hrs. Throughout
Virtual Lab Quiz Online 04% 8 Weeks Throughout
Remote Lab Exam Online 12.5% 4 Hrs. Throughout
EC - 2 Mid-Semester Open Book 30% 2 Hrs. Sunday,

Examination 12/03/2023 (AN)
EC - 3 End-Semester Open Book 40% 2 ½ Hrs. Sunday,

Examination 21/05/2023 (AN)
Page 15 of 18
Closed Book: No reference material of any kind will be permitted inside the exam hall.
Open Book: Use of any printed / written reference material (books and notebooks) will be permitted
inside the exam hall. Loose sheets Photocopies and Laser printouts of any material will not be
permitted. Computers of any kind will not be allowed inside the exam hall. Use of calculators will be
allowed in all exams. No exchange of any material will be allowed.
Note:
It shall be the responsibility of the individual student to be regular in maintaining the self-study
schedule as given in the course handout attend the online/on demand lectures as per details that would
be put up in the BITS eLearn (Taxila) website elearn.bits-pilani.ac.in and take all the prescribed
components of the evaluation such as Assignments/Quizzes Mid Semester and End Semester
Examination according to the Evaluation Scheme given in the respective Course Handout. If the
student is unable to appear for the Regular Examination due to genuine exigencies the student must
refer to the procedure for applying for Make-up Examination which will be available through the
Important Information link on the eLearn website on the date of the Regular Examination. The Make-
up Tests/Exams will be conducted only at selected exam centres on the dates to be announced later.
Instructor-in-Charge
(P.T.O)
Page 16 of 18
Mechatronics: Simulation Lab
1. Scope of the lab
Mechatronics lab enables the students to understand and implement various electrical,
mechanical components to achieve automation in the industry.
2. Objectives of Lab
To simulate various mechatronics automation circuits with electrical, mechanical and
electronic components.
3. List of simulation experiments

Software Tool used for Virtual Lab (VL): Automation Studio.
Remote Lab (RL): NI_Elvis III with Controls Board and NI_Elvis III with Actuators
Board
Tutorials and manuals will be uploaded once the lab starts
# Tutorial Name Solving Lab Marks

Time Quiz
1. Basic pneumatic circuits -1 (VL) 2 hours
2. Advanced pneumatic circuits -2 (VL) 2 hours
4 6
3. Hydraulic circuits -1 (VL) 2 hours
4. PLC -2 (VL) 2 hours
5. E1:NI – ElvisIII with Controls Board (RL) 2 hours
No quiz
for Re-
mote 12.5
Lab
9. E1: NI-Elvis III with Actuators Board (RL) 2 hours
Total Marks
4. Learning Outcome of the lab
 Electric drive selection

 Simulate concepts of signal sensing and conditioning, control and decision making
and output actuation.
 Implement working of various sensors and transducers, system modeling and
dynamic response, open and closed loop controllers, electrical and mechanical
actuators.
 Put to use PLC programming using ladder logic
Note: After completion of every practice tutorial problem, take a snapshot and
include the same in the final assignment PPT lastly. Quiz questions will be based on
the practice tutorial problems and results
Page 17 of 18
(P.T.O)
Instruction Schedule
Lab Class work Instructions Online TBA 2 Hrs

Delivery
Evaluation Scheme
Evaluation Name Type Marks Lab Exam Date Duration
Component
Quiz based on Online 04

virtual lab
Assignment Online 06 Regular TBA

based on virtual TBA
lab
EC - I Makeup TBA
TBA
Assignment Online 12.5 No separate lab exam for Throughout

based on Remote Lab, assignment
Remote Lab question needs to be
performed and submitted in
E-Learning portal.
Note: After completion of every practice tutorial problem, take a snapshot and include the same in the
final assignment PPT lastly. Quiz questions will be based on the practice tutorial problems and
results.
Link for lab dates and other details (copy the link and paste it in your browser).
Instructor-in-Charge
Page 18 of 18

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Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

CO1 An introduction to the applications of mechatronics in various household and

4.2.2. Performance measures

4.3.2. Systems in series

Learning Outcomes: Students will be able to

LO1 Apply mechatronics in the design of products

LO4 Develop hydraulic and pneumatic drawings for industry automation

LO5 Put to use PLC programming using ladder logic.

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Introducing Mechatronics, T1: Chapter 1, T2: Chapter 1

Type Content Ref. Topic Title Study/HW Resource Reference

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Sensor and Transducers: T1: Chapter 2, T2: Chapter 9

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Sensing physical quantities: T1: Chapter 2, T2: Chapter 9

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Sensing physical quantities: T1: Chapter 2, T2: Chapter 9

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Sensing physical quantities: T1: Chapter 2, T2: Chapter 9

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Sensing physical quantities: T1: Chapter 2, T2: Chapter 9

Type Content Ref. Topic Title Study/HW Resource Reference

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 T1: Chapter 3, T2: Chapter 5

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Signal conditioning with T1: Chapter 3, T2: Chapter 5

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Signal conditioning with T1: Chapter 3, T2: Chapter 5

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, T2 Signal conditioning: T1: Chapter 3, T2: Chapter 9

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 Signal conditioning: Analog to T1: Chapter 4

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 System modelling: Modelling T1: Chapter 10

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 System modelling: Modelling T1: Chapter 11

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 System modelling: Modelling T1: Chapter 11

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 Dynamic response of systems: T1: Chapter 12

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 System transfer functions: 1st T1: Chapter 13

Post CH Chapter end problems

Type Content Ref. Topic Title Study/HW Resource Reference

During T1 Frequency response of T1: Chapter 13

Type Content Ref. Topic Title Study/HW Resource Reference

During T1, R4 Control systems: Open and T1: Chapter 15, R4