Course Title: Introduction to Mechanical Engineering

Course Code: BESCK104D/204D

Course In charge: Ashoka

Module-5
Introduction to Mechatronics and Robotics: Open-loop and closed-loop mechatronic systems.
Classification based on robotics configuration: polar cylindrical, Cartesian coordinate and spherical.
Application, Advantages and disadvantages. Automation in industry: Definition, types – Fixed,
programmable and flexible automation, basic elements with block diagrams, advantages. Introduction to
IOT: Definition and Characteristics, Physical design, protocols, Logical design of IOT, Functional blocks,
and communication models.

Control system
A control system is defined as the mechanism or a system that provides the desired response or
output by controlling the input and processing system. These days, control systems are being implementing
in every smart devices and systems such as traffic lights system, washing machine, rocket launching
systems, electrical power system, etc.

Depending on the feedback path present in the system, the control systems can be classified into
following two types

 Open Loop Control System

 Closed Loop Control System

Open Loop Control System

An open loop control system is the one in which the output signal is not fed back to the input of the
system. Therefore, an open loop control system is also referred to as a non-feedback control system.

In case of open loop control system, the output has no control on the control action of the system.
Thus, the open loop control system follows its input signals regardless of the final results. The input is
supplied to the controller which produces an actuating signal (or control signal). This actuating single is
supplied to the plant or processing system which is to be controlled.
Closed Loop Control System
A closed loop control system is the one in which the output signal is fed-back to the input of the
system. Therefore, in a closed loop control system, the control action is a function of desired output signal.

The error detector accepts input signal and feedback signal to produce an error signal which is the
difference of input and feedback signals. The feedback signal is the sample of output of the overall system.

Now, the error signal is supplied to the controller to produce an actuating signal which controls the plant or
processing system to produce desired results. Therefore, in the closed loop control system, the input of the
system is automatically adjusted to produce a desired response from the system.
Difference between Open-Loop Control System and Closed-Loop Control System

Basis of Open Loop Control System Closed Loop Control System

Difference
Definition A control system in which there is no The control system in which there is a
feedback path is provided is called feedback path present is called a closed
an open loop control system. loop control system.
feedback control Open loop control system is also called Closed loop control system is also called a
system non-feedback control system feedback control system
Control action In open loop control system, the control In closed loop control system, the control
action is independent of the output of action is dependent on the output of the
the overall system. system.
Design complexity The design and construction of an open Closed loop control system has
loop control system is quite simple. comparatively complex design and
construction.
Main The major components of an open loop The main components of a closed loop
Components control system are − controller and control system are − Controller, plant or
plant. process, feedback element and error
detector (comparator).
Response Open loop control system has fast The response of the closed loop control
response because there is no system is slow due to presence of feedback.
measurement and feedback of output.
Reliability The reliability of open loop control The closed loop control system is more
system is less. reliable.
Accuracy The accuracy of open loop control Closed loop control system is
system depends upon the system comparatively accurate because the
calibration and therefore, may be less. feedback maintains its accuracy.

Maintenance Open loop control system requires less Comparatively more maintenance is needed
maintenance. in closed loop control system.
Implementation Open loop control system is easy to The implementation of a closed loop
implement. control system is relatively difficult.
Cost Open loop control system is less The cost of the closed loop control system
expensive. is relatively high.
Noise Open loop control system has more In closed loop system, the internal noise in
internal noise. the system is less.
Examples Electric Hand Drier, Washing Machine, Air Conditioner, Water Level controller,
Bread Toaster, Light switch etc. Automatic Electric Iron, Voltage stabilizer,
etc.

INDUSTRIAL ROBOTICS
Robot Anatomy ( Optional)
Robot Configuration
Industrial robots are available in a wide variety of sizes, shapes, and physical configurations. These
configurations are mainly depending on the movement of joints.
Classification based on robotics configuration:

1. Cartesian Robot Configuration (3P)

2. Polar Configuration (P2R) or Spherical configuration
3. Cylindrical robot configuration
4. Jointed-arm configuration

1. Cartesian Robot Configuration (3P)

These robots are made of three linear joints that position the end effector, which is usually followed by
additional revolute joints that orientate the end effector. 3P represents three Prismatic or Linear joints used
in the robots. By moving the three slides relative to one another, the robot is capable of operating within a
rectangular work envelope.

Advantages
• Highly accurate & speed,
• Fewer costs,
• Simple operating procedures, and
• High payloads.

Disadvantages
• Less work envelope, reduced flexibility.
• Low dexterity (not able to move quickly and easily)
• Limited manipulability
2. (i) Polar Configuration (P2R)
The polar configuration uses a telescopic arm that can be moved up or down about a horizontal pivot. The
pivot is mounted on a rotating base. A rotating base supports the two links. These various joints can move
the arm endpoint within a partial spherical space. It is also called a spherical co-ordinate‖ configuration,
which allows manipulation of objects on the floor. This system has one Prismatic and two revolute joints
that denote the P2R.

Advantages
• Long reach capability in the horizontal position.

Disadvantages
• Vertical reach is low
• Low mechanical stiffness
• Complex construction
• Accuracy decreases with the increasing radial stroke.

ii) Spherical configuration

A spherical robot is a robot with two rotary joints and one prismatic joint; in other words, two rotary axes
and one linear axis. Spherical robots have an arm which forms a spherical coordinate system.
3. Cylindrical Robot Configuration (PRP)

The cylindrical configuration uses a vertical column and a slide that can be moved up or down along the
column. The robot arm is attached to the slide so that it can be moved radially with respect to the column.
By rotating the column, the robot is capable of achieving a workspace that approximates a cylinder. This
cylindrical configuration has two Prismatic or Linear joints and one revolute joint, (PRP) denotes this only.

Advantages
• Increased rigidity, and
• Capacity to carry high payloads

Disadvantages
• Floor space required is more, and
• Less work volume.
• Accuracy decreases as the horizontal stroke increases.
4. Jointed Arm Configuration
The jointed Arm configuration is made up of rotating joints. This robot configuration is also sometimes
called anthropomorphic as its anatomy is similar to the Human arm. These configuration joints are all
revolute (3R). They are the most common configuration for industrial robots.

Advantages
• Increased flexibility,
• Huge work volume, and
• Quick operation.

Disadvantages
• Very expensive,
• Difficult operating procedures, and
• Plenty of components.
Advantages and Disadvantages of Robots
Applications of Robots
 Automation
Automation could be defined as the technology dealing with design of machine tools and systems
utilising electronics and computer systems to produce the final product at minimum cost, involving
minimum labour intervention, producing components of high accuracy repeatedly without causing
rejections.

The Advantages of automation are:

 Reduced human labour required
 Consistency in quality
 Fewer risks of human error
 Improved health & safety
 Improved efficiency

The Disadvantages of automation are:

 Initial investment is high
 Require some manual labour: observation and programming
 Failures could lead to temporary downtime in production

Types of Manufacturing Automation

1) Fixed Automation
2) Programmable Automation
3) Flexible Automation
 1) Fixed Automation
In fixed automation, the sequence of processing is fixed for one particular product. Such a system can
be used for mass production of a product. Its initial cost is high and any changes in product design can
be incorporated with difficulty.
If product has to be changed, then lot of modifications, new additions, etc. may be required and to
accommodate same would be very costly and time consuming. But it provides high production rates.
This type of automation is best suited for: High demand and general products that require no change.
This is relatively useful for many companies who use automation to create food products of one type
and variant. It allows them to effectively produce that item and package it in bulk.

Advantages of fixed automation include:

 High levels of production
 Consistent quality in production
 Low cost per unit produced
Disadvantages of fixed automation include:
 High initial cost
 Difficult to accommodate change

2. Programmable Automation
In programmable automation (as with numerically controlled machines and robots), it is
possible to accommodate the change in sequence of operations for new product by changing the program
(set of instructions). Such a system is thus suited for batch production. For new product, not only
programs have to be changed, but new tools and fixtures may have to be loaded, and machine settings
changed.
Programmable automation will often be used by factories who make different variants of
foods. This allows them to make batches, from a few dozen to potentially thousands at a time, of one
product. If the product needs changing, it simply needs to be reprogrammed.
This type of automation is well suited for: Low/Medium demand and occasional changes in products.

Advantages of Programmable automation:

 Flexibility to change products if needed
 Suitable if batch production is required

Disadvantages of Programmable automation:

 Expensive for equipment
 Lower production levels
 Often time-consuming to change products
 3. Flexible Automation
Flexible automation, also known as “soft automation”, is similar to programmable
automation, although a little more complicated. Essentially, flexible automation enables the
production of different types of products without losing time when reprogramming.
A flexible automation system can produce various combinations of products efficiently without
having to separate them into different batches, as required in batch production. No time is lost for
production of one product and changing over to new product. Complete information and programs
for the products desired to be produced are available in computer system
Altering the part programme is usually done by coding the program offline on a computer
and then transferring it to the automated system. Such systems are best suited for production of large
variety of spare parts for large industrial plant/process/complex.

Advantages of automation:
 Flexibility of products
 No time lost with new changes to production

Disadvantages include:
 High custom machinery/automation cost
 Higher cost per unit
Basic Element of an Automated System
 The Internet of Things (IOT)
The Internet of Things (IoT) describes the network of physical objects—“things”—that are embedded with
sensors, software, and other technologies for the purpose of connecting and exchanging data with other
devices and systems over the internet.

With more than 10 billion connected IoT devices today, experts are expecting this number to grow to 22
billion by 2025

The things receive inputs (using sensors) and transform them into data that is transmitted through Internet.
The things also can produce output or take action using actuators.

Some of the examples of IoT devices are:

 Home appliances: smart TV, smart refrigerator, smart AC, etc.

  Smart phones and computers
 Wearable’s: smart watch, smart sensors, etc.
 Automobiles like self-driving cars
 Energy systems
 Retail : smart payment
 Printers
 Industrial machines
 Healthcare: smart watch, smart healthcare, etc.
 Surveillance: smart cameras, smart trackers, etc.

Advantages and Disadvantages of Internet of Things

Advantages Disadvantages

Can lead to network attacks as multiple devices are

It minimizes the human efforts interconnected

As personal data are shared so it has privacy

It saves the time concerns

As most of the work is performed by machine so it

It enhances the data collection can lead to unemployment

The security is improved with the help of IoT The complexity of the system is high

There are high chances of the entire system to get

It is very efficient in resource utilization corrupted easily

It reduces the usage of multiple electronic

equipment. There is a lack of international standardizations

As most of the work is performed using the data in

It uses in traffic system very efficiently cloud so it has high dependency on internet

We can also use IoT in healthcare Industry It reduces mental and physical activity

Usage of sensors and other smart electronics

devices save electricity consumption. Lack of Security

High dependency on internet so risk of malware

attack

Advantages and Disadvantages of Internet of Things (Optional)

Advantages of IoT

Internet of things facilitates several advantages in our daily lives. Some of its advantages are given below:

1. Minimize human effort: As IoT devices interact and communicate with each other, they can automate
the tasks helping to improve the quality of a business’s services and reducing the need for human
intervention.
2. Save time: By reducing the human effort, it saves a lot of our time. Saving time is one of the primary
advantages of using the IoT platform.
3. Enhanced data collection: Information is easily accessible, even if we are far away from our actual
location, and it is updated frequently in real-time. Hence these devices can access information from
anywhere at any time on any device.
4. Improved security: If we have an interconnected system, it can assist in the smarter control of homes
and cities through mobile phones. It enhances security and offers personal protection.
5. Efficient resource utilization: We can increase resource utilization and monitor natural resources
by knowing the functionality and how each device works.
6. Useful for safety concerns: It is helpful for safety because it senses any potential danger and warns
users
7. Useful in the healthcare industry: Patient care can be performed more effectively in real-time
without needing a doctor’s visit. It gives them the ability to make choices as well as provide
evidence-based care.

Disadvantages of IoT

As the Internet of things facilitates advantages, it also creates a significant set of drawbacks. Some of
the IoT disadvantages are given below:

1. Security issues: IoT systems are interconnected and communicate over networks. So, the system
offers little control despite any security measures, and it can lead to various kinds of network attacks.
2. Privacy concern: The IoT system provides critical personal data in full detail without the user’s
active participation.
3. Increased unemployment: Unskilled workers or even the skilled ones are at a high risk of losing
their jobs, leading to high unemployment rates.
4. The complexity of the system: The designing, developing, maintaining, and enabling the extensive
technology to IoT system is quite complicated.
5. High chances of the entire system getting corrupted: If there is a bug in the system, it is possible
that every connected device will become corrupted.
6. Lack of international standardizations: As there is no international standard of compatibility for
IoT, it is problematic for devices from different manufacturers to communicate with each other.
7. High dependency on the internet: They rely heavily on the internet and cannot function effectively
without it.
8. Reduced mental and physical activity: Overuse of the internet and technology makes people
ignorant because they rely on smart devices instead of doing physical work, causing them to become
lethargic and inactive.
 Characteristics of the Internet of Things(IoT)

IoT has various characteristics but most common are explained under,
1. Identity
Each IoT device has its unique identity. If it needs to access the data from specific device then its
identification element is very helpful. The collaboration of name and number gives an identity to an internet
device. Giving an identity to the device is an essential aspect of loT. Identity helps to differentiate between
various internet devices and select the device we want to send the command.
For Example, An IP address of a device is a unique identifier that represents a device in a network.

2. Dynamic and Self-Adapting

IOT devices should dynamically adapt themselves according to situations Assume a camera meant for the
surveillance. It should be adaptable to work in different conditions and different light situations (morning,
afternoon, night).
3. Self-Configuring – This is one of the most important characteristics of IoT.IoT devices are able to
upgrade their software in accordance with requirements with a minimum of user participation.
Additionally, they can set up the network, allowing for the addition of new devices to an already-existing
network.
4. Connectivity
As the name suggests, it’s all about the connectivity of 2 or more devices. This characteristics of IoT help to
communicate with and share information between two or more devices. The IoT has created a world where
everything is connected to communicate well and share user data. This connectivity also enables objects to
be controlled remotely
5. Scalability –
The number of elements connected to the IoT zone is increasing day by day. Hence, an IoT setup should
be capable of handling the massive expansion. The data generated as an outcome is enormous, and it
should be handled appropriately
6. Safety
The basic idea of IoT is to connect everything to the internet and make the system easier for the users.
However, when things are connected to the internet in such a way there is always a danger of the sensitive
personal details of the users getting compromised. So safety is undoubtedly a crucial characteristic of IoT.
7. Architecture/Heterogeneity
The architecture of IoT is designed in a way that it is capable of supporting various devices, technologies,
and protocols. Its main work is to confirm whether each connected device does not interfere with the other.
This way, the safety and security of each device's data are maintained.
 Physical Design of Internet of Things (IoT)
The physical design of an IoT system is referred to as the Things/Devices and protocols that are used to build
an IoT system. All these things/Devices are called Node Devices and every device has a unique identity that performs
remote sensing, actuating and monitoring work and the protocols that are used to establish communication between
the Node devices and servers over the internet.

Generic block diagram of an IoT Device

Connectivity
Devices like USB hosts and ETHERNET are used for connectivity between the devices and the server.
Processor
A processor like a CPU and other units are used to process the data. These data are further used to improve the
decision quality of an IoT system.
Audio/Video Interfaces
An interface like HDMI and RCA devices is used to record audio and videos in a system. It shows all the information
that the processor sends to the screen
Input/output interface
To give input and output signals to sensors, and actuators we use things like UART, SPI, CAN, etc.
Storage Interfaces
Things like SD, MMC, and SDIO are used to store the data generated from an IoT device.
 IoT Protocols
The set of rules governing all direct or indirect exchange of data between computers on a network. These
rules are formulated at the application level and are used collectively to define how devices communicate
irrespective of differences in their internal designs and operations.
IoT protocols help send commands and data between a network of devices controlled by sensors or
other physical attributes like motion, temperature, or vibration. Network protocols help achieve reliable data
transfer across all layers like the application, transport, network, and link layer.

Application Layer Protocols

On this layer, protocols use an application interface to define how the data can be sent over the network.
These protocols include HTTP, XMPP, Web Socket, DDS, MQTT, and AMQP.
Transport Layer Protocols
This layer is responsible for data flow control and error handling, ensuring that there are rules in place to
deal with errors. This layer also provides end-to-end message transfer capability, independent of the
underlying network infrastructure. It provides essential connectivity between the two nodes on either end of
the point-to-send-point-receive model used by key protocols such as TCP/IP.
Network Layer
This layer is used to send data from a source network to a destination network. For this, IPv4 and IPv6
protocols are used for host identification, which transfers data in packets.
Link Layer
Link-layer protocols are the type of data transmission protocol used to help send data over the physical
layer. They also determine how devices signal and code packets on the network.

Logical Design of Internet of Things (IoT)

IoT Functional blocks

An IoT system comprises of a number of functional blocks that provide the system the capabilities for identification,
sensing, actuation, communication and management functional blocks are:
Application
It is an interface that provides a control system that use by users to view the status and analyze of system.
Management
This functional block provides various functions that are used to manage an IoT system.
Services
This functional block provides some services like monitoring and controlling a device and publishing and deleting the
data and restoring the system.
Communication
This block handles the communication between the client and the cloud-based server and sends/receives the data using
protocols.
Security
This block is used to secure an IoT system using some functions like authorization, data security, authentication, 2-
step verification, etc.
Device
These devices are used to provide sensing and monitoring control functions that collect data from the outer
environment.

IoT Communication Models

There are several different types of models available in an IoT system that is used to communicate between
the system and server like the request-response model, publish-subscribe model, push-pull model, exclusive
pair model, etc.
Request-Response Communication Model
This model is a communication model in which a client sends the request for data to the server and the
server responds according to the request. When a server receives a request it fetches the data, retrieves the
resources and prepares the response, and then sends the data back to the client.
In simple terms, we can say that in the request-response model server send the response of equivalent to the
request of the client. In this model, HTTP works as a request-response protocol between a client and server.

Example

When we search a query on a browser then the browser submits an HTTP request to the server and then the
server returns a response to the browser (client).

Publish-Subscribe Communication Model

In this communication model, we have a broker between publisher and consumer. here publishers are the
source of data but they are not aware of consumers. they send the data managed by the brokers and when a
consumer subscribes to a topic that is managed by the broker and when the broker receives data from the
publisher it sends the data to all the subscribed consumers.

Example

On the website many times we subscribed to their newsletters using our email address. these email addresses
are managed by some third-party services and when a new article is published on the website it is directly
sent to the broker and then the broker sends these new data or posts to all the subscribers.

Push-Pull Communication Model

It is a communication model in which the data push by the producers in a queue and the consumers pull the
data from the queues. here also producers are not aware of the consumers.
Example

When we visit a website we saw a number of posts that are published in a queue and according to our
requirements, we click on a post and start reading it.

Exclusive Pair Communication Model

It is a bidirectional fully duplex communication model that uses a persistent connection between the client
and server. Here first set up a connection between the client and the server and remain open until the client
sends a close connection request to the server.

Course In charge: Ashoka