MT19601- Design of Mechatronics System

Class/Sem: IIIMTS/VI Sem

Unit I - Fundamentals
Part-A (2 Mark Questions and Answers)

1. Define Mechatronic Systems.

The system changed from electro – mechanical systems with discrete electrical and
mechanical parts to integrated electronic – mechanical systems with sensors, actuators and
digital micro electronics. These integrated systems are called mechatronic systems.

2. Write the important life cycle factors in mechatronic systems.

Delivery, Reliability, Maintainability, Serviceability, Upgradeability and Disposability.

3. Define Modeling.
Modeling is the process of representing the behavior of a real system by a collection of
mathematical equations and logic.

4. What are the properties should be considered for the design process?
Design for strength or stiffness, Design for reliability, Design for maintainability and
Design for manufacture.

5. Write its applications of Mechatronics Systems.

Fuzzy based washing machine, Autofocus Camera, Engine management system and
Autonomous Robots.

6. Write the main area of operator risks.

Trapping, Entanglement, Impact and Ejection.

7. Define the term ergonomics.

Ergonomics or human factors engineering is concerned with the application of the
knowledge about the physical skills and limitations of a human being to provide a safe and
effective working environment.

8. Define Simulation.
Simulation is the process of solving the model and is performed on a computer.
Although simulations can be performed on analog computers, it is far more common to
perform them on digital computers. The process of simulation can be divided into three
sections: initialization, iteration and termination.

9. What are the key elements of a Mechatronics system?

Physical System Modeling, Sensors and Actuators, Signals and Systems, Computers
and Logic Systems and Software and Data Acquisition
10. Write any two differences between Tradition versus Mechatronics.
Tradition: Bulky Systems, and Complex Mechanisms
Mechatronics: Compact Systems, and Simplified Mechanisms.

11. What is Mechatronics?

It is multidisciplinary embodying four fundamental disciplines : Electrical,
Mechanical, Computer Science and Information technology.

12. Define Mechatronic design methodology.

The mechatronic design methodology is based on a concurrent (instead of sequential)
approach to discipline design, resulting in products with more synergy.

13. Draw the block diagram of Key elements of Mechatronics.

14. Define the term Automatic control.

The term automatic control describes the situation in which a machine is controlled
by another machine.

15. Write the characteristics of concurrent engineering.

The characteristics of concurrent engineering are: Better definition of the product
without late changes, design of manufacturing and assembly undertaken in the early design
stage, process on how the product development is well defined, better cost estimation and
decrease in the barriers between design and manufacturing.

16. Write the important life cycle factors.

The important life cycle factors are: Delivery, Reliability, Maintainability,
Serviceability, upgradeability and Disposability.

17. Define optimization.

Optimization solves the problem of distributing limited resources throughout a system
so that pre-specified aspects of its behavior are statisfied.
18. Define Models.
Models are cause and effect structures; they accept external information and process
it with their logic and equations to produce one or more outputs.

19. Write the types of condition monitoring systems.

1. Monitoring systems that display the machine conditions to enable the operator to
make decisions.
2. Automated monitoring of conditions with adaptive control features.

20. What is model based manufacturing?

Model based monitoring systems generally use a set of modeling equations and an
estimation algorithm to estimate the signal important to the machine performance.

Part - B (16 Mark Questions)

21. i) Compare hardware in loop simulation and control prototyping processes in the design
of Mechatronics system.
ii) Discuss with flow diagram the stages of Mechatronics design process.
22. i) What are the steps involved in the design of Mechatronics system? Explain.
ii) Why a system should be designed ergonomically? Explain with an example.
23. i) Discuss in detail the advanced approaches in Mechatronics such as intelligent supervisory
control structure and model based monitoring system.
ii) With the help of a block diagram, explain the key elements of a Mechatronics system
24. What are the applications of a Mechatronics system? What are its merits and demerits?
25. Explain the role of modeling and simulation in the analysis of Mechatronics systems.
26. With the neat diagram explain the historical development of Mechanical, Electrical and
Electronic Systems.
27. Explain the functions of Mechatronic Systems briefly.
28. Explain the concurrent design procedure for Mechatronic System in detail.
29. Explain the Industrial design and Safety in Mechatronic System Design in detail.
30. Explain the Traditional and Mechatronic designs briefly.

Unit II - System Modeling

Part-A (2 Mark Questions and Answers)

1. What are various risks involved in designing safety Mechatronics systems?

Operator safety and Machine safety are the two safety systems involved in
Mechatronics system.

2. Mention the fields of application of two model categories.

Bottom up design, Top-down design, Relationship of design strategies to modeling,
modeling for the specification, Modeling for the design are the fields of application.
3. What is transfer function?
It is defined as the relationship between the input parameter and output parameter.

4. Define mathematical model.

Model is defined as the group of objects that represent the entire system. It is a prototype
that represents collection of entities like mathematical expressions such as state graphs,
multi body diagrams.

5. What is modified analog approach?

Analog approach includes the state graphs, multi body diagrams, circuit diagrams to
represent a model. The implementation of the digital control systems replaces the electric
circuits and prototype for the mechanics system. This technique is called modified analog
approach.

6. Define viscous friction.

Viscous friction is a measure of the resistance of the fluid which is being deformed by
either shear stress or tensile stress.

7. State Faraday’s law.

The induced electromotive force in any closed circuit is equal to the negative of the
time rate of change of the magnetic flux through the circuit.

8. What is simulation?
Simulation is the imitation of the real world process. It is the creation of the model
using the mathematical calculations by software. Ex: ARENA.

9. How over framing problem can be solved in a real time data acquisition and control
system?
It refers to the process of collecting the input data in digital form as rapidly accurately
completely and economically. The basic instrumentation used may be a digital panel meter.

10. List the components required for real time interfacing.

It is the process of interfacing the completed model with software equipment to view
the internal operation of the model. The operation of the mechanical and electrical system
is viewed.

11. Write the benefits of simulation.

1. Simulated models are generally completely controllable.
2. Simulated models are generally fully monitorable.

12. Write the disadvantages of Simulation.

1. Each virtual experiment requires a complete, validated and verified modeling of the
system.
 2. The accuracy with which details are reproduced and the simulation speed of the
models is limited by the power of the computer used for the simulation.

13. What is Replicative Validity?

A model is replicatively valid of it moves along tracks that have already been marked
out by measurements upon the real system.

14. What is Predictive validity?

A model is predictively valid if it predicts data that are not extracted from the system
until later.

15. What is Structural validity?

A model is structurally valid if it not only describes the outward behavior of a real
system accurately enough, but also imitates the internal processes for the generation of
the behavior at the pins.

16. Write the merits of top down design sequence.

1. Errors and weaknesses in the design are noticed early.
2. The implementable part of the specification can be validated by simulations.

17. Write the different types of model validation.

Empirical validity, Theoretical Validity, Pragmatic validity and heuristic validity.

18. What do you mean by Analogy?

Analogies on the level of electronic components and mechanical bodies represent the
predominant theme running through the joint consideration of electronics and mechanics.

19. Write the approaches in multibody simulation.

1. Electronic modeling using the lagrange approach.
2. Object oriented approach.

20. Write the domine independent description forms.

1. Bond graphs.
2. Block diagrams.
3. Modelling languages for physical systems.

Part - B (16 Mark Questions)

21. i) Explain with block diagram the principle of simulator plane used to couple simulators.
ii) Discuss methods adopted to carry out the following process.
a) Model validation.
b) Model verification.
22. i) Explain the process of building up of models for the following system with an Example.
a) Mechanical system, b) Pneumatic system, and c) Hydraulic system.
ii) Explain a sequential control system with an example.
23. Discuss in detail the major components of a data acquisition and control system and their
interconnections for a system with four sensors and two actuators.
24. Explain the fields of applications in model development.
25. Explain the various modeling techniques.
26. Briefly explain the various merits and demerits of the simulation that often also used as a
substitute for experiments on an existing system.
27. Explain the various degree of validity for a model in detail.
28. Explain the model verification and validation in detail.
29. With the neat example explain analogies and its limits.
30. Elaborate on the necessary ingredients for the general I/O process required as part of a
Mechatronics system.

UNIT III - System Interfacing

Part - A (2 Mark Questions and Answers)

1. Define RS 485 communication standard.

RS 485 is an Electronics Industry Association (EIA) standard for multipoint
communications. It supports several types of connectors, including DB-9 and DB-37. It can
support more nodes per time.

2. What are the features of GPIO card used for data acquisition and control?
GPIB (General purpose interface bus)is a standard for instrumentation communication
and control for instruments from manufacturers. It is designed to connect the programmable
instruments to their computers.

3. What is the function of a peripheral interface adopter?

It is a peripheral integrated circuit providing parallel I/O interfacing capability for
microprocessor systems. Some of the PIAs are Motorola MC6820 and MC6821. It is a 40
pin package.

4. What is the use of GUI card?

It is a type of user interface item that allows people to interact with programs in more
ways than typing such as computers, hand held devices such as MP3 players’ household
appliances. It offers graphical icons and visual indicators to text based interfaces, typed
command labels to provide information to the user.
5. Define data acquisition.
The data acquisition system refers to the process of collecting the input data in digital
form as rapidly, accurately, completely and economically. It is based on the properties of
analog data and on the processing to be carried out.

6. Write the significance of DAQ.

1. Resolution and accuracy.
2. The number of channels to be monitored.
3. Sampling rate per channel.
4. Signal conditioning requirement of each channel.
5. Cost.

7. What are the major components present in DAQ system.

1. Sensors,
2. Actuators,
3. Screw terminal panel(s),
4. General – purpose input/output card and
5. Application software.

8. List the electrical characteristics of RS 232 interface.

The RS 232 specifies the signaling rate between the DTE and DCE and a digital signal
is used on all interchange circuits. The RS 232 standard specifies that logic “1” is to be sent
as a voltage range -15v to -5v and that logic “0” is to be sent as a voltage in the range +5v
to +15v.

9. Write down the significance of IEEE 488 standard interface.

1. Token passing: The controller addresses the next controller SRQ Service request when
the controller assigns modes.
2. The IEEE488 is most commonly used for data acquisition of HP peripherals.
Programmable interfaces and drivers exist and simplify the development of
microprocessor interfaces.

10. What is meant by Ethernet switch?

It is used to build network connection between the attached computers. Hub will send
incoming data packets to all ports. It operates on the data link layer of the OSI model.

11. Define real time interfacing.

Real time interfacing is a general term used to describe the aspects of connecting a
computer with a real world process and communicating data between the two.

12. Define DMA.

Direct Memory Access with this mechanism data is transferred between the DAQ
device and computer memory without the involvement of the CPU.
13. Define Interrupt Request.
IRQ transfers rely on the CPU to service data transfer requests. The device notifies the
CPU when it is ready to transfer data.

14. What is Programmed I/O?

This is a data transfer mechanism in which a buffer is not used instead the computer
reads and writes directly to the device.

15. What is memory mapping?

It is a technique for reading and writing to a device directly from the program, which
avoids the overhead of delegating the reads and writes to kernel level software.

16. What do you mean by multiplexing?

A common technique for measuring several signals with a single measuring device is
multiplexing.

17. Define Quantization.

Quantization is a process of taking continuous analog signals and breaking it into a
number of discrete steps.

18. What is Resolution?

The number of bits that the ADC uses to represent the analog signal is the resolution.

19. Write some application softwares.

LabView, VimSim, and Matlab.

20. Write the LabView applications.

Temperature measurement and the Weigh measurement systems.

Part - B (16 Mark Questions)

21. i) What are the features of a data acquisition system?
ii) Describe the procedure including both hardware and software adopted to interface
computer to real world process using general purpose input output cards.
22. i) Describe the functions that are required for an interface.
ii) Explain about system interfacing using RS 232 interface.
23. What are the primary differences between RS 232, RS 422 and RS 485 serial interfaces?
Explain.
24. Explain the modes of operation of GUI card.
25. Explain Ethernet switch in detail.
26. Explain the balanced and unbalanced data transmission system in detail.
27. Explain the Universal Asynchronous Receiver Transmitter in detail.
28. With the example explain the addressing of GPIB devices.
29. With the neat diagram explain the point to point and multi point communication system.
30. Explain the various IEEE 488 standard interface.

UNIT IV - Micro Mechatronic System

Part - A (2 Mark Questions and Answers)

1. Define the principle of micro Mechatronics system.

Micro systems technology enables the realization of very small systems by the use of
technologies originally developed for the manufacturing of ICs. This technology push
matches very well the continuous demand to further miniature a broad category of system.

2. What are the scaling laws used in Mechatronics system design.

1. Scaling in rigid body dynamics
2. Scaling in electrostatic forces
3. Scaling in electricity
4. Scaling in fluid mechanics and
5. Scaling in heat transfer.

3. Write any two differences between Microsystems and microelectronics.

Microelectronics:
1. Stationary structures and
2. Primarily 2-D structures.
Microsystems:
1. May involve moving components and
2. Complex 3-D structures.

4. Define the term MEMS.

MEMS stand for Micro Electro Mechanical systems. It is separate and distinct from the
hypothetical vision of molecular electronics. It is made of components of 1 to 100
micrometers.

5. List out the applications of MEMS.

1. Health care industry
2. Consumer products
3. Aerospace industry and
4. Telecommunication.

6. What is LIGA and SLIGA process?

It requires a special synchrotron radiation facility for deep X- ray lithography. This is
not readily accessibility to most of the MEMS industry. These processes also require
development of microinjection molding technology and facilities.
7. Write the materials that used in MEMS.
Many Microsystems uses microelectronic materials such as silicon, and gallium
arsenide [GaAs] for the sensing or actuating elements. Other elements such as quartz,
Pyrex, polymers, plastics and ceramics are commonly used in microelectronics.

8. Write the different types of micro sensors.

1. Acoustic wave sensors.
2. Biomedical Sensors.
3. Bio-Sensors.
4. Chemical Sensors and
5. Optical Sensors.

9. Write the different types of actuation motions in micro devices.

1. Actuation using thermal forces.
2. Actuation using shape-memory alloys.
3. Actuation using piezoelectric crystals and
4. Actuation using electrostatic forces.

10. Define system design.

It involves following steps:
1. Design considerations
2. Selection of manufacturing processes
3. Selection of materials and
4. Selection of signal transduction.

11. Write the materials that used in MEMS.

1. Active substrate material.
2. Passive substrate material.

12. What are the different process designs?

1. Photolithography.
2. Thin film fabrications.
3. Geometry shaping.

13. Write the types of scaling in heat transfer.

1. Scaling in Heat conduction.
2. Scaling in Heat convection.

14. Define Actuators.

A mechanical device for moving or controlling something is called actuators.
15. Write the different types of actuation motions in micro devices.
1. Actuation using thermal forces.
2. Actuation using shape memory alloys.

16. What are the applications of micro-valves?

Microvalves are primarily used in industrial systems that require precision control of
gas, or in biomedical applications.

17. Write the merits of LIGA and SLIGA process.

Great flexibility and these are the best of the manufacturing process for mass
production.

18. What are the mechanical problems associated with surface micromachining?
1. Requires the building layers of materials over the substrate.
2. Complex Mask.

19. Write the four typical constraints for Microsystems.

1. Customer demands.
2. Time to marker.
3. Environmental conditions.
4. Applications.

20. Write the major factors that affect the packaging of Microsystems.
1. Die passivation.
2. Media protection.
3. System Proctection.
4. Electric interconnect.
Part - B (16 Mark Questions)
21. i) Describe the design construction and working of micro motors with an application.
ii) Discuss the design and working of micro robot.
22. i) With suitable example, discuss the working of a micro actuator.
ii) Describe the construction and working of micro pump with its applications.
23. i) Explain surface micro machining in detail.
ii) Explain the scaling laws used for micro elements.
24. Explain the bulk micro-manufacturing in detail.
25. Explain the principle science and engineering disciplines involved in Microsystem design
and manufacture with the neat diagram.
26. i) Explain the scaling in geometry with an example.
ii) Explain the scaling in rigid body dynamics with an example.
27. Explain the scaling law in electrostatic forces with neat diagram.
28. Explain the types of scaling law in heat transfer.
29. Explain the Microsystems scaling law in electromagnetic forces.
30. Explain the applications of Microsystems in the health care industry and aerospace
industry.

UNIT V - Case Studies on Mechatronic System

Part - A (2 Mark Questions and Answers)

1. List the sensors used in engine management system.

1. Oxygen sensor
2. Mass air flow sensor
3. Temperature sensor
4. Pressure sensor and
5. Speed sensor.

2. What are the steps followed to process image of a surface to find its quality?
1. Image grabber
2. Calculation circuit for extraction of characteristics
3. 2 D image memory for maximum brightness and
4. 3 D shape of the object.

3. Define embedded system.

An embedded system is a computer system with a larger mechanical system or electrical
system, often with real time computing constraints. Modern embedded systems are based
on the microcontrollers (i.e CPUs with integrated memory).

4. What is PID?
A proportional integral derivative is a generic control loop feedback mechanism widely
used in industrial control systems. A PID controller calculates an “error” value as the
difference between a measured process variable and desired set point.

5. What is the function of oxygen sensor in engine management system?

An oxygen sensor is an electronic device that measures the proportion of oxygen in the
gas or liquid being analyzed. It is frequently used to measure exhaust gas concentration of
oxygen in internal combustion engines.

6. List out the hardware components required for the pick and place robot.
1. Base
2. Arm
3. Shoulder
4. Elbow
 5. Pitch
6. Roll and
7. Wrist.

7. What is fuzzy logic system and write its components?

Fuzzy logic is a form of many valued logic; it deals with reasoning that is approximate
rather than fixed and exact. It may have the truth value ranges between 0 and 1.

8. List out the parts used in pH control system.

The pH control system requires one sensor for measuring pH and one actuator to control
a metering device that adds a neutralizing agent to the solution.

9. Mention the uses of RFID.

It is Radio Frequency Identification is wireless non-contact use of radio frequency
electromagnetic fields to transfer data for the purpose of automatically stored information.

10. Give two applications of fuzzy logic in Mechatronics.

Washing machine and Micro electro mechanical system.

11. Write the applications of Mechatronic systems.

Automotive Industry, Healthcare Industry, Consumer industry, and Aerospace
industry.

12. Write the general components of data acquisition system.

Transducers, Signal Conditioning, Computer and software.

13. Write the wide variety of applications of position control of D.C. motor.
Transport system, Machine control, Material Handling and Packaging.

14. What are all the components required for the implementation of real system.
Sensors, GPIO card, PC and Application software.

15. What is the purpose of PH control system.

To monitor the pH level of a solution and makes adjustments as needed to maintain
the pH level at a specified set point.

16. Write the components used for pH control using mechatronic system.
pH meter, Solution, Tank, Digital pump control, Pulsing pump and circulating pump.

17. What are all the main components used for skip control in the CD player.
Power supply, Pinball machine tilt sensor, induction magnet actuator and GPIO card.

18. What is the purpose of testing rocket thrust control.

 Controlling the nozzle pressure to within a set tolerance of a given set point by
modulating the water flow into the nozzle using a valve controlled by a rotary motor.

19. What is the purpose of testing of transportation bridge surface materials?

To measure the strength of materials used for beams in transportation bridges.

20. What is the purpose of transducer calibration system in automotive application?

To investigate a method for automatic calibration of the motion transducers used to
sense exhaust value motion on diesel engines in test cells.

Part - B (16 Mark Questions)

21 i) Discuss in detail the data acquisition application of controlling the temperature of a
hot/cold reservoir system.
ii) Explain the design of fuzzy based Washing machine system with suitable diagram.
22. In a conveyor system a robot is used to pick the object and place it on a drilling machine,
with a block diagram explain the working of robot.
23. Explain the Mechatronics system for Engine management system.
24. What is image processing? How will you measure the surface using image processing?
25. What is RFID? Explain the part identification and tracking technique using RFID.
26. With the neat diagram explain the Position Control of a Permanent Magnet DC Gear
Motor.
27. Explain the auto control system for green house temperature with the neat diagrams.
28. Explain the skip control system for CD player with the neat diagram.
29. Discuss the working of Autofocus camera with exposure control.
30. How will you control the motion of DC motor and solenoids?