The article provides an overview of mechatronic system, their components, and functions, highlighting the integration of mechanical, electronic, and software elements for intelligent control. It discusses key components such as controllers, microcontrollers, sensors, actuators, and control systems, emphasizing their roles in automated and feedback-based operations.
Mechatronics is the field of study concerned with the design, selection, analysis, and control of systems that combine mechanical elements with electronic components, including computers and/or microcontrollers. Mechatronics topics involve elements from mechanical engineering, electrical engineering, and computer science, and the subject matter is directly related to advancements in computer technology. Yasakawa Electric Company coined the term ‘mechatronics’ to refer to the use of electronics in mechanical control (i.e., ‘mecha’ from mechanical engineering and ‘tronics’ from electrical or electronic engineering). Auslander et al. defined mechatronics as the application of complex decision-making to the operation of physical systems. This definition eliminates the reference to the particular technology used when performing the operation.
Mechatronic System Components
A block diagram of a typical mechatronic system is shown in Figure 1. A mechatronic system has at its core a mechanical system that needs to be commanded or controlled. Such a system could be a vehicle braking system, a positioning table, an oven, or an assembly machine. The controller needs information about the state of the system. This information is obtained from a variety of sensors, such as those that give proximity, velocity, temperature, or displacement information. In many cases, the signals produced by the sensors are not in a form readable by the controller and need some signal conditioning operations performed on them. The conditioned, sensed signals are then converted to a digital form (if not already in that form) and presented to the controller.
Figure 1. Typical components of a mechatronic system
Mechatronic System Controller
The controller is the ‘mind’ of the mechatronic system. It processes user commands and sensed signals to generate command signals to be sent to the actuators in the system. The user commands are obtained from a variety of devices, including command buttons, graphical user interfaces (GUIs), touch screens, or pads. In some cases, the command signals are sent to the actuators without utilizing any feedback information from the sensors. This is called open-loop operation, and for it to work, it requires a good calibration between the input and output of the system with minimal disturbances. The more common mode of operation is the closed-loop mode in which the command signals sent to the actuators utilize the feedback information from the sensors. This mode of operation does not require calibration information, and it is much better suited for handling disturbances and noise.
Microcontroller Unit
In many cases, the command signals to the actuators are first converted from a digital to an analog form. Amplifiers implemented in the form of drive circuits also can amplify the command signals sent to the actuators. The actuator is the mechanism that converts electrical signals into useful mechanical motion or action. The choice of the controller for the mechatronic system depends on many factors, including cost, size, ease of development, and transportability. Many mechatronic systems use personal computers (PCs) with data acquisition capabilities for implementation. Examples include control of manufacturing processes such as welding, cutting, and assembly. A significant number of controllers for a mechatronic system are implemented using a microcontroller unit (MCU), which is a single-chip device that includes a processor, memory, and input-output devices on the same chip. Microcontrollers often control many consumer devices, including toys, hand-held electronic devices, and vehicle safety systems. Control systems that use MCUs often are referred to as embedded control systems.
Control System
The control system for a mechatronic system can be classified as either a discrete-event control system or a feedback control system. In a discrete-event system, the controller controls the execution of a sequence of events, while in a feedback control system, the controller controls one or more variables using feedback sensors and feedback control laws. Almost all realistic systems involve a combination of the two. This textbook will discuss these two classes in detail.
A mechatronic system integrates mechanical components, electronic components, and software implemented either on a PC or MCU to produce a flexible and intelligent system that performs the complex processing of signals and data. In many cases, a mechatronic system improves the performance of a system beyond what can be achieved using manual means. An example is the speed control of rotating equipment. In some cases, a mechatronic system is the only means by which that system can operate (such as the control of magnetic bearings and in nano-positioning control applications).
Mechatronic System Components and Functions Key Takeaways
Mechatronic system play a crucial role in modern applications by enhancing automation, precision, and efficiency across various industries. Their integration of mechanical, electronic, and software components enables advancements in robotics, manufacturing, automotive systems, and consumer electronics. By improving control, reducing human intervention, and optimizing performance, mechatronics has become essential for developing intelligent and adaptive technologies that drive innovation in industrial and everyday applications.