AKTU SYLLABUS Unit-5: Introduction to Measurement and Mechatronics

Introduction to Measurement: Concept of Measurement, Error in measurements,

Calibration, measurements of pressure(Bourdon Tube Pressure and U-Tube
Manometer), temperature(Thermocouple and Optical Pyrometer), mass flow
rate(Venturi Meter and Orifice Meter), strain(Bonded and Unbonded Strain Gauge),
force (Proving Ring) and torques(Prony Brake Dynamometer); Concepts of accuracy,
precision and resolution.
Introduction to Mechatronic Systems: Evolution, Scope, Advantages and
Disadvantages of Mechatronics, Industrial applications of Mechatronics, Introduction
to autotronics, bionics, and avionics and their applications. Sensors and Transducers:
Types of sensors, types of transducers, and their characteristics.
……………
Overview of Mechanical Actuation System – Kinematic Chains, Cam, Ratchet
Mechanism, Gears and its type, Belt, Bearing.
Hydraulic and Pneumatic Actuation Systems: Overview: Pressure Control Valves,
Direction Control Valves, Rotary Actuators, Accumulators and Pneumatic
Sequencing Problems.
Q.1 Define mechatronics. Also write down the advantages, disadvantages,
and applications of mechatronics. AKTU-2020-21, 2021-22, 2022-23 7Marks

Mechanics + electronics = Mechatronics

 The term "mechatronics" itself is a blend of "mechanics" and
"electronics.
 Mechatronics is a multidisciplinary field
that combines mechanical engineering,
electronics, computer science, and
control engineering to design and
create intelligent systems and products.
 Concurrently it includes all these
disciplines.
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Example of mechatronics
 For example, in modern automobiles, mechanical fuel injection systems
are now replaced with electronic fuel injection systems.
 This replacement made the automobiles more efficient and less pollutant.

 With the employment of reprogrammable microcontrollers/microcomputers, it

is now easy to add new functions and capabilities to a product or a system.

 Today’s domestic washing machines are “intelligent” and four-wheel

passenger automobiles are equipped with safety installations such as airbags,
parking (proximity) sensors, antitheft electronic keys, etc.

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Advantages of Mechatronics
1.Integrated Design: Mechatronic systems integrate mechanical, electrical, and
computing components, leading to more efficient and compact designs.

2.Enhanced Functionality: Mechatronic systems can perform complex tasks with

greater precision and flexibility compared to purely mechanical systems.

3.Automation: Mechatronic systems are often used in automation processes,

leading to increased productivity, reduced labor costs, and improved safety.

4.Improved Performance: The integration of sensors and control systems in

mechatronic designs allows for real-time monitoring and adjustment, leading to
improved performance and reliability.

5.Adaptability: Mechatronic systems can be easily reprogrammed or reconfigured to

adapt to changing requirements.
6. It is also more user-friendly and safer to use.
Disadvantages of Mechatronics

1.Complexity: Designing and integrating multiple disciplines can increase the

complexity of mechatronic systems, leading to challenges in development,
maintenance, and troubleshooting.

2.Cost: High initial cost -Mechatronic systems can be more expensive to develop
and manufacture compared to purely mechanical systems due to the need for
additional components such as sensors, actuators, and control systems.

3.Skills Requirement: Developing mechatronic systems requires expertise in

multiple disciplines, which may be challenging to find in one individual or team.

4. It is expensive to incorporate a mechatronic approach into an existing/old

system.
5. Specific problems for various systems would have to be addressed separately
and properly.
Industrial Applications of Mechatronics
1.Manufacturing Automation: Mechatronic systems are widely used in
manufacturing processes for automation, precision control, and quality assurance.
Industrial robots equipped with mechatronic systems perform tasks such as welding,
assembly, painting, and material handling in factories, leading to increased
productivity and reduced labor costs.

2.CNC Machines: Computer Numerical Control (CNC) machines, including CNC

milling machines, lathes, and machining centers, utilize mechatronic systems for
precise control of cutting tools and work pieces. Mechatronics enables CNC machines
to execute complex machining operations with high accuracy and repeatability.

3.Process Control: Mechatronics plays a crucial role in industrial process control

systems, including chemical plants, refineries, and power plants. Mechatronic sensors,
actuators, and control algorithms monitor and regulate parameters such as
temperature, pressure, flow rate, and chemical composition to optimize production
processes and ensure safety and efficiency.
4. Packaging Machinery: Mechatronic systems are integrated into packaging
machinery to automate packaging processes in industries such as food and beverage,
pharmaceuticals, and consumer goods.

5. Material Handling Systems: Mechatronics is used in material handling systems

such as conveyor belts, and automated guided vehicles (AGVs in warehouses,
distribution centers, and production facilities. Mechatronic material handling systems
enhance efficiency, reduce errors, and optimize logistics operations.

6. 3D Printing/Additive Manufacturing: Mechatronic systems are utilized in 3D

printing and additive manufacturing technologies to control the deposition of materials
layer by layer, Mechatronics plays a vital role in ensuring the accuracy, speed, and
reliability of 3D printing processes across various industries.

7. Automated Inspection and Quality Control: Mechatronic systems are integrated

into inspection and quality control systems to detect defects, measure dimensions,
and ensure product conformity in manufacturing processes.
Autotronics

Avionics

Bionics
Q.2 Write short notes on (i) Autotronics (ii) Bionics (iii)Avionics along
with their applications. AKTU-2020-21, 2021-22, 2022-23 7Marks

(i) Autotronics
Autotronics is the integration of automotive technology with electronics. It
involves the use of electronic systems in vehicles for various functions such as
engine management, transmission control, and safety features like airbags and
ABS.

Applications: Enhancing vehicle performance, improving fuel efficiency,

increasing safety features, and enabling advanced functions like autonomous
driving.
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(ii) Bionics
Bionics is a field that merges biology with engineering and technology to
create systems, devices, and materials that interface with biological
systems.
Applications: Bionics aids in addressing body damage by developing
highly functional prosthetic limbs, and restoring mobility and quality of life
for individuals with limb loss. Additionally, bionics contributes to tissue
regeneration through the development of bio-inspired materials and
technologies, offering promising solutions for repairing damaged tissues
and organs.
(iii) Avionics
Avionics refers to the electronic systems used in aircraft for
communication, navigation, monitoring, and control.

Applications: Essential for safe air travel. Used in commercial planes,

military aircraft, drones, and even space exploration for navigation,
communication, and flight control.
Q.3 What are Sensors and Transducers and their types? Also, explain the
characteristics of sensors and transducers. AKTU-2022-23 Odd

Sensor: A sensor is a device that provides usable output in response to change in a

specified physical quantity which is measured. A device that receives and responds to a
signal.
 The physical quantity may be temperature, force, pressure, displacement, flow, etc.
 For example, the bulb of a thermometer senses the temperature of the body
in contact.

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 The transducer is a device that changes the physical attributes of the non-
electrical signal into an electrical signal which is easily measurable. The
process of energy conversion in the transducer is known as the
transduction(figure). It consists of two parts:
Transducers convert one form of energy into another
1. Sensing element/detector
For example : Thermometer
2. Transduction element

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Types of Sensors
1.Temperature Sensors: Measure temperature changes.
2.Pressure Sensors: Measure pressure variations.
3.Proximity Sensors: Detect the presence or absence of an object without
physical contact.
4.Motion Sensors: Detect motion or movement.
5.Light Sensors: Measure light intensity or detect the presence of light.
6.Humidity Sensors: Measure relative humidity in the air.
Types of Sensors
1.Temperature Sensors: Measure temperature changes. Types include thermocouples,
resistance temperature detectors (RTDs), and thermistors.
2.Pressure Sensors: Measure pressure variations. Types include piezoelectric,
capacitive, and strain gauge pressure sensors.
3.Proximity Sensors: Detect the presence or absence of an object without physical
contact. Types include inductive, capacitive, and photoelectric sensors.
4.Motion Sensors: Detect motion or movement. Types include accelerometers,
gyroscopes, and proximity sensors.
5.Light Sensors: Measure light intensity or detect the presence of light. Types include
photodiodes, phototransistors, and light-dependent resistors (LDRs).
6.Humidity Sensors: Measure relative humidity in the air. Types include capacitive,
resistive, and thermal conductivity sensors.
Types of Transducers
1.Piezoelectric Transducers: Convert mechanical stress or pressure into
electrical energy and vice versa.
2.Thermoelectric Transducers: Convert temperature differences into electrical
voltage.
3.Strain Gauge Transducers: Measure strain or deformation in an object.
4.Optical Transducers: Convert light energy into electrical signals and vice versa.
Capacitive Transducers: Measure changes in capacitance due to variations in
physical quantities like displacement, pressure, or humidity.
5.Inductive Transducers: Measure changes in inductance due to variations in
physical quantities like position or displacement.
Types of Transducers
1.Piezoelectric Transducers: Convert mechanical stress or pressure into
electrical energy and vice versa. Used in sensors for measuring pressure, force,
and acceleration.
2.Thermoelectric Transducers: Convert temperature differences into electrical
voltage. Used in thermocouples for temperature measurement.
3.Strain Gauge Transducers: Measure strain or deformation in an object. Used in
load cells for measuring force, pressure, and weight.
4.Optical Transducers: Convert light energy into electrical signals and vice versa.
Used in photodiodes, phototransistors, and fiber optic sensors.
5.Capacitive Transducers: Measure changes in capacitance due to variations in
physical quantities like displacement, pressure, or humidity. Used in capacitive
proximity sensors and pressure sensors.
6.Inductive Transducers: Measure changes in inductance due to variations in
physical quantities like position or displacement. Used in inductive proximity
sensors and position sensors.
Transducer based on need of an External Power Source

Active Transducer: Active transducers are those which do not require any power
source for their operation. For example, a thermocouple, thermometer etc.

Passive Transducer: Transducers which require an external power source for their
operation is called as a passive transducer. For example, a strain gauge,
thermistor etc.

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Characteristics of sensors and transducers
Characteristics are mainly divided into two categories:
i) Static characteristics ii) Dynamic characteristics

i. Static characteristics:
Static characteristics refer to the characteristics of the system when the input is either held
constant or varying very slowly. For example Range, sensitivity, linearity, etc.

ii. Dynamic characteristics:

Dynamic characteristics describe the behavior of sensors and transducers in response to
changes or variations in the input quantity over time. These characteristics are important for
applications involving dynamic or time-varying signals.
For example Response Time, Bandwidth, Frequency Response, etc.
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Q.4 Write short notes on (i) Kinematic Chains (ii) Cam (iii) Ratchet Mechanism
(iv )Gears and their type, (v)Belt (vi) Bearing.
(i) Kinematic Chains
Kinematic Link or Element:
Every part of a machine which is having some relative
motion with respect to some other parts will be known as
a kinematic link or element.

Examples: Piston, Connecting rod, crank, lever, etc.

Kinematic Chain:
“If all the links are connected in such a way that first link
is connected to last link in order to get the close chain
and if all the relative motion in this close chain are
constrained then such a chain is known as kinematic
chain”.
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(ii) Cam
(ii) Cam
A cam is a mechanical device used to convert rotary motion into reciprocating motion or
vice versa. It typically consists of a cylindrical or irregularly shaped component (the cam)
mounted on a shaft, along with a follower that moves in contact with the surface of the
cam. As the cam rotates, the shape of its surface causes the follower to move in a specific
pattern, producing linear motion.

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(iii) Ratchet Mechanism
 A ratchet mechanism is a mechanical device that allows motion in one direction while
preventing motion in the opposite direction.
 It typically consists of a toothed wheel (the ratchet) and a pawl that engages with the
teeth of the wheel.
 When the pawl engages with the teeth, it allows the wheel to rotate in one direction,
but it prevents it from rotating in the opposite direction.

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(iv ) Gears and their type AKTU-2022-23(E) 2Marks

Gears are mechanical components used to

 Transmit power
 Change the velocity
 Change the direction

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Types of Gears

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Types of Gears
Spur gear : This is Cylindrical gear. Teeth are parallel to axis. This is a highly
demanded gear, which is easy to manufacture and to assemble.

Helical gear : This is a Cylindrical gear. Teeth have helix curve. Helical gear
provides more strength, less oscillation and lower noise level compared with
Spur gears.
Internal gear : This is a cylindrical gear ring with teeth formed at the inner
diameter.
Straight bevel (Miter) gear: Miter gear has shaft angle of 90° and
gear ratio of 1:1.
Rack and pinion : „A rack is a gear whose pitch diameter is infinite, resulting in
a straight line pitch circle. Used to convert rotary
motion to straight line.
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(v) Belt Drive
(v) Belt
 Belt drives use the friction that develops between the pulleys attached to
the shafts and the belt around the arc of contact in order to transmit a
torque.
 The torque is due to the differences in tension that occur in the belt during
operation.
 Let T1 is the tension in the tight side and T2 is the tension in slack side.

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Types of Belt
 Flat: The belt has a rectangular cross-section and produces less noise.
They can transmit power over a long distance between pulley centers
 Round: The belt has a circular cross-section and is used with
grooved pulleys.
 V: V-belts are used with grooved pulleys and are less efficient than flat
belts.

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(vi) Bearing
A bearing is a mechanical component that supports and reduces friction between
moving parts, allowing for smooth and efficient motion within a machine or
mechanical system.

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Q.5 Explain Hydraulic and Pneumatic Actuation Systems.

 The controlled movement of parts or a controlled application of force is a

common requirement in industries.
 These operations are performed mainly by using electrical machines or
diesel, petrol, and steam engines as a prime mover.
 These prime movers can provide various movements to the objects by using
mechanical attachments like screw jacks, levers, racks, pinions, etc.
 However, these are not the only prime movers. The enclosed fluids (liquids
and gases) can also be used as prime movers to provide controlled motion
and force to the objects.
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Hydraulic Actuation Systems

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Basic Components of Hydraulic System………..
The hydraulic system consists a number of parts for its
proper functioning. It consists of:
 a movable piston connected to the output shaft in an
enclosed cylinder
 storage tank
 filter
 electric pump
 pressure regulator
 control valve
 leakproof closed loop piping. 62
Applications of hydraulic systems
 Construction Equipment
 Manufacturing machinery
 Aerospace systems
 Automotive systems
 Marine applications
 Agricultural machinery
 Material handling equipment
 Power generation
 Civil engineering structures
 Oil and gas industry.
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Pneumatic Actuation System.

 Pneumatic technology deals with the study of behavior and

applications of compressed air in our daily life in general
and manufacturing automation in particular.
 Pneumatic systems use air as the medium which is
abundantly available and can be exhausted into the
atmosphere after completion of the assigned task.

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Basic Components of Pneumatic System?

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Important components of a pneumatic system are shown in fig.

a) Air filters: These are used to filter out the contaminants from the air.

b)Compressor: Compressed air is generated by using air compressors. Air

compressors are either diesel or electrically operated. Based on the
requirement of compressed air, suitable capacity compressors may be used.

c)Air cooler: During compression operation, air temperature increases.

Therefore coolers are used to reduce the temperature of the compressed air.

d) Dryer: The water vapor or moisture in the air is separated from the air by
using a dryer.

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e)Control Valves: Control valves are used to regulate, control, and
monitor for control of direction flow, pressure, etc.

f)Air Actuator: Air cylinders and motors are used to obtain the required
movements of mechanical elements of a pneumatic system.

g)Electric Motor: Transforms electrical energy into mechanical energy. It

is used to drive the compressor.

h)Receiver tank: The compressed air coming from the compressor is

stored in the air receiver

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Q.6 What do you mean by Valves in hydraulic and
pneumatic systems? AKTU-2022-23(E) 7 Marks

 In hydraulic and pneumatic systems, valves are mechanical devices that control
fluid flow (liquid or gas) within the system.
 Valves are crucial components because they regulate the direction, pressure,
and quantity of fluid flow, allowing for precise control and operation of various
hydraulic and pneumatic equipment.

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Functions and types of valves commonly used in hydraulic and pneumatic
systems:
1.Directional Control: Valves determine the direction of fluid flow within the system.
 Pneumatic and hydraulic systems use
directional control Valves to direct the flow of
fluid through a system.

 They do not vary the rate of fluid flow

but are either completely open or completely closed
i.e. ON/OFF devices.

 They might be activated to switch the

fluid flow direction by means of mechanical,
electrical, or fluid pressure signals.

 A common type of directional control valve is the

spool valve.
2. Pressure Control: These are used to control the pressure in hydraulic and
pneumatic systems.

Pressure – limiting/relief valves

Pressure sequence valves : Sequence valves control the sequence of

operations in hydraulic systems, ensuring that certain actions occur in a
specific order.
Pressure-Limiting/Relief Valves:
Function: Pressure-limiting valves, also known as relief valves,
are designed to limit the maximum pressure in a hydraulic
system by diverting excess fluid flow back to the reservoir when
the pressure exceeds a predetermined threshold.
Operation: When the pressure in the system exceeds the set
limit, the relief valve opens, allowing fluid to bypass the primary
circuit and return to the reservoir, thus preventing overpressure
and potential damage to the system components.

Applications: They are commonly used in hydraulic systems to protect

pumps, actuators, and other components from damage due to overpressure
conditions.
3. Flow Control Valve: Valves regulate the flow rate of fluid passing
through the system, controlling the speed of actuators or cylinders.

4. Check Valves: These valves allow fluid to flow in one direction only,
preventing backflow and maintaining system integrity.

5. Sequence Valves: Sequence valves control the sequence of

operations in hydraulic systems, ensuring that certain actions occur in a
specific order.
Q.7 What do you mean by Actuators? Explain Linear and Rotary
actuators. AKTU-2022-23(E) 2Marks

 Actuators are output devices which convert energy from pressurized hydraulic oil
or compressed air into the required type of action or motion.

 In general, hydraulic or pneumatic systems are used for gripping and/or moving
operations in industry. These operations are carried out by using actuators.

 In general actuators can be classified into two types.

1. Linear actuators: These devices convert hydraulic/pneumatic energy

into linear motion.(Ex-cylinder)

2. Rotary actuators: These devices convert hydraulic/pneumatic energy

into rotary motion. (Ex-Gear motor)
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The construction of hydraulic and pneumatic linear actuators is similar.

However, they differ in their operating pressure ranges.

The typical pressure of hydraulic cylinders is about 100 bar and of

pneumatic system is around 10 bar.
Linear Actuator : Single-acting cylinder.
 These cylinders produce work in one direction of motion hence they are named as
single-acting cylinders.
 The figure shows the construction of a Single-acting cylinder.
 The compressed air pushes the piston located in the cylindrical barrel
causing the desired motion.

 The return stroke takes place by the action of a spring.

 Generally, the spring is provided on the rod side of the cylinder.
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Linear Actuator: Double-acting cylinder.
 The main parts of a hydraulic double-acting cylinder are the piston, piston rod,
cylinder tube, and end caps.
 As shown in the fig. the piston rod is connected to the piston head and the other
end extends out of the cylinder.
 The piston divides the cylinder into two chambers.
 The seals prevent the leakage of oil between these two chambers.
 The cylindrical tube is fitted with end caps.

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 The pressurized oil, air enters the
cylinder chamber through the ports
provided.
 In the rod end cover plate, a wiper
seal is provided to prevent the leakage
of oil and entry of the contaminants
into the cylinder.
 The piston seal prevents metal to
metal contact and wear of piston head
and the tube. These seals are
replaceable.
 End cushioning is also provided to
prevent the impact with end caps.

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Rotary Rotary Actuators.
 Rotary actuators convert the energy of pressurized
fluid into rotary motion. Rotary actuators are similar
to electric motors but are run on hydraulic or
pneumatic power.
 It consists of two intermeshing gears inside a
housing with one gear attached to the drive shaft.
 Figure shows a schematic diagram of Gear
motor.
 The air enters from the inlet, causes the rotation of
the meshing gear due to the difference in the
pressure, and produces the torque.
 The air exits from the exhaust port.
 Gear motors tend to leak at low speeds and, hence
are generally used for medium speed applications.

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Thank You