September 2021

Uninterrupted machining is one of the challenges in front manufacturers to meet the production goals and customer satisfaction in terms of product quality. Tool wear is a critical factor which affects the productivity of a machining operation. Complete automation of a machining processrealizes when there is a successful prediction of tool  (wear)  state  during  the  course  of  machining  operation.  Mechatronics  based cutting tool-wear condition monitoring system is an integral part of automated tool rooms and unmanned factories. These systems predict the tool wearand give alarms to the system operator to prevent any damage to the machine tool and workpiece. Therefore it is essential to know how the mechatronics is helping in monitoring the tool wear.  Tool wear can be observed in a variety of ways. These can be classified in two groups (Table1.2.1). Table 1.2.1 Tool monitoring systems [2] Direct methods Indirect methods Electrical resistance Torque and power Optical measurements Temperature Machining hours Vibration & acoustic emission Contact sensing Cutting forces & strain measurements Direct methods deal with the application of various sensing and measurement instruments such as micro-scope, machine/camera vision; radioactive techniques to measure the tool  wear.  The used  or  worn-out  cutting tools  will  be taken  to  the metrology or inspection section of the toolroom or shop floor where they will be examined by using one of direct methods. However, these methods can easily be applied  in  practice when  the cutting tool  is  not  in  contact  with  the work  piece. Therefore they are called as offline tool monitoring system. Figure 1.2.2 shows a schematic of tool edge grinding or replacement scheme based on the measurement carried out using offline tool monitoring system. Offline methods are time consuming and difficult to employ during the course of an actual machining operation at the shop floor.            Figure 1.2.2 Off-line and on-line tool monitoring system for tool edge grinding Indirect methods predict the condition of the cutting tool by analyzing the relationship between cutting conditions and response of machining process as a measurable quantity through sensor signals output such as force, acoustic emission, vibration, or current. Figure 1.2.2…

CNC machine is the best and basic example of application of Mechatronics in manufacturing automation. Efficient operation of conventional machine tools such as Lathes, milling machines, drilling machine is dependent on operator skill and training. Also a lot of time is consumed inwork part setting, tool setting and controlling the process parameters viz. feed, speed, depth of cut. Thus conventional machining is slow and expensive to meet the challenges of frequently changing product/part shape and size. Figure 1.2.1 Comparison between a conventional machine tool and a CNC machine tool Computer numerical control (CNC) machines are now widely used in small to large scale industries. CNC machine tools are integral part of Computer Aided Manufacturing (CAM) or Computer Integrated Manufacturing (CIM) system. CNC means operating a machine tool by a series of…

Mechatronics has a variety of applications as products and systems in the area of ‘Manufacturing automation’. Some of these applications are as follows: 1.   Computer numerical control (CNC) machines 2.   Tool monitoring systems 3.   Advanced manufacturing systems a.   Flexible manufacturing system (FMS) b.   Computer integrated manufacturing (CIM) 4.   Industrial robots 5.   Automatic inspection systems: machine vision systems 6.   Automatic packaging systems Now, let us know in brief about these applications one by one.

Figure 1.1.3 Operations involved in design and manufacturing of a product Today’s customers are demanding more variety and higher levels of flexibility in the products. Due to these demands and competition in the market, manufacturers are thriving to launch new/modified products to survive. It is reducing the product life as well as lead-time tomanufacture a product.  It is therefore essential to automate the manufacturing and assembly operations of a product. There are various activities involved in the product manufacturing process.  These are shown in figure 1.1.3. These activities can be classified into two groupsviz. design and manufacturing activities. Mechatronics concurrently employs the disciplines of mechanical, electrical, control and computer engineering at the stage of design itself. Mechanical discipline is employed in terms of various machines and mechanisms, whereas electrical engineering as various electric primemovers viz. AC/DC, servo motors and other systems is used. Control engineering helps in the development of various electronics- based control systems to enhance or replace the mechanics of the mechanical systems. Computers are widely used to write various software’s to controlthe control systems; product design and development activities; materials and manufacturing resource planning, record keeping, market survey, and other sales related activities. Using computer aided design (CAD) / computer aided analysis (CAE) tools, three- dimensional models of products can easily be developed. These models can then be analyzed and can be simulated to study their performances using numerical tools. These numerical tools are beingcontinuously updated or enriched with the real-life performances of the similar kind of products. These exercises provide an approximate idea about performance of the product/system to the design team at the early stage of the  product  development.  Based  on  the  simulation  studies,  the  designs  can  be modified to achieve better performances. During the conventional design- manufacturing process, the design assessment is generally carried out after the production of first lot of the products. This consumes a…

Graduates with a Mechatronics degree can take up careers in a wide spectrum of industries including robotics, aerospace, chemical, defence and automotive and manufacturing where complex software plays a major role, as well as in businesses that require extensive computer support, such as banking and commerce. Contributions can be made to these industries in a…

Mechatronics combines mechanical, electrical and software engineering in the design, development and control of diverse systems used in a range of industries including manufacturing, medicine and the service industries. Examples of mechatronic systems include aircraft, dishwashers, motor vehicles, automated manufacturing plants, medical and surgical devices and systems, robots of all types, many toys, artificial organs…

The evolution of modern mechatronics can be illustrated with the example of the automobile. Until the 1960s, the radio was the only significant electronics in an automobile. All other functions were entirely mechanical or electrical, such as the starter motor and the battery charging systems. There were no “intelligent safety systems,” except augmenting the bumper…

The study of mechatronic systems can be divided into the following areas of specialty: 1. Physical Systems Modeling 2. Sensors and Actuators 3. Signals and Systems 4. Computers and Logic Systems 5. Software and Data Acquisition As the field of mechatronics continues to mature, the list of relevant topics associated with the area will most certainly expand and evolve.

Mechatronics is a concept of Japanese origin (1970’s) and can be defined as the application of electronics and computer technology to control the motions of mechanical systems (figure 1.1.1). Figure 1.1.1 Definition of Mechatronics It is a multidisciplinary approach to product and manufacturing system design (Figure 1.1.2). It involves application of electrical, mechanical, control and computer engineering to develop products, processes and systems with greater flexibility, ease in  redesign  and  ability  of  reprogramming.  It concurrently includes all these disciplines.            Figure 1.1.2 Mechatronics: a multi-disciplinary approach Mechatronics can also be termed as replacement of mechanics with electronics or enhance   mechanics   with   electronics.   For   example,   in   modern   automobiles, mechanical fuel injection systems are now replaced with electronic fuel injection systems. This replacement made theautomobiles more efficient and less pollutant. With the help of microelectronics and sensor technology, mechatronics systems are providing high levels of precision and reliability. It is now possible to move (in x – y plane) the work table of a modern production machine tool in a step of 0.0001 mm. By 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 suchas air-bags, parking (proximity) sensors, anti- theft electronic keys etc.