Chapter 1

DESIGN OF
ELECTROMECHANICAL SYSTEMS
II
UNIT 1
Fundamentals
CHAPTER-1
• INTRODUCTION TO
MECHATRONIC SYSTEMS-
 Mechatronics is a
methodology used for the
optimal design of
electromechanical products
 Mechatronic system is
multidisciplinary, embodying
four fundamental disciplines:
electrical, mechanical,
computer science, and
information technology
KEY ELEMENTS:
Mechatronics is the result of applying information systems to physical

systems.
The physical system consists of mechanical, electrical, and computer

systems as well as actuators, sensors, and real-time interfacing.
STAGES IN DESIGNING MECHATRONIC SYSTEMS:
 The mechatronic design process consists of three
phases: modelling and simulation, prototyping, and
deployment.
 Important Features:
 • Modeling: Block diagram or visual interface
 • Simulation: Numerical methods for solving models
containing differential, discrete, hybrid, partial, and implicit
nonlinear (as well as linear) equations
 Project Management: Database for maintaining project
information and subsystem models for eventual reuse.
 • Design: Numerical methods for constrained optimization of
performance functions based on model parameters and
signals.
 • Analysis: Numerical methods for frequency-domain, time-
domain, and complex-domain design.
 • Real-Time Interface: A plug-in card is used to
replace part of the model with actual hardware by
interfacing to it with actuators and sensors. This is
called hardware in the loop simulation or rapid
prototyping and must be executed in real time.
 • Code Generator: Produces efficient high-level
source code from the block diagram or visual
modeling interface. The control code will be
compiled and used on the embedded processor. The
language is usually C.
 • Embedded Processor Interface: The embedded
processor resides in the final product. This feature
provides communication between the process and
the computer-aided prototyping environment. This is
called a full system prototype.
• Hardware-in-the-Loop Simulation:
• The process of fusing and synchronizing model, sensor, and
actuator information is called real-time interfacing or
hardware-in-the-loop simulation
• The mechatronic design methodology has Several important
life cycle factors are indicated.
• Delivery: Time and cost.
• Reliability: Failure rate, materials, and tolerances.
• Maintainability: Modular design.
• Serviceability: On board diagnostics, prognostics, and modular
design.
• Upgradeability: Future compatibility with current designs.
• Disposability: Recycling and disposal of hazardous materials.
Hardware in the loop model
There are different ways in which hardware-in-the-loop could be

simulated, such as electronics simulation, simulation of actuators and
sensors, or simulation of mechanical systems alone.
DIFFERENCE BETWEEN TRADITIONAL AND MECHATRONIC
APPORACH
Data Acquisition and Control
system
ADVANCED APPROACHES IN
MECHATRONICS DESIGN PROCESS
• Monitoring On-Line
• Model-Based Monitoring System
• Mechatronics Systems with Open
Architecture
• Supervisory Control Structure
Monitoring On-Line
• The importance of lean production systems has
created an opportunity for intelligent autonomous
inspection, manufacturing, and decision-making
systems that perform tasks without human
intervention
• Currently, quality is ensured in the product
engineering cycle at two distinct levels.
• At the product design stage: To ensure that quality is
designed into the product. Using the robust design
method.
• At the final inspection stage: Using statistical process
control methods
Model-Based Monitoring System
• Model-based monitoring systems generally use
a set of modelling equations and an estimation
algorithm (such as a state observer) to estimate
the signal important to the machine
performance
Mechatronics Systems with Open
Architecture
Supervisory Control Structure
• hierarchical control structure where the
controller elects position and velocity at the
machine level, force and wear at the process
level, and quality control issues (like dimension
and roughness) at the product level.

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DESIGN OF

Mechatronics is the result of applying information systems to physical

The physical system consists of mechanical, electrical, and computer

There are different ways in which hardware-in-the-loop could be

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