Two marks Questions Mechatronics [MH1031] Unit 1

1. What is Mechatronics? Give examples. Mechatronics is the synergistic integration of mechanical engineering with electronics & Intelligent control algorithms in the design & manufacture of products process. Examples : washing machine, Robot, automobile electronic fuel injection & antilock brake systems, digital camera etc. 2. Describe various elements of measurement system with help of a block diagram.

Sensor : It responds to the quantity being measured by giving as its output a signal which is related to the quantity. Signal conditioner : It takes the signal from the sensor & manipulates it into a condition which is suitable for either display (or) for use to exercise control. Display : The output from the signal conditioner is displayed. 3. Identify the sensor, signal conditioner & display elements in the measurement systems of a) mercury in glass thermometer b) a Bourdon pressure gauge. a) Sensor mercury b) Sensor curved tube signalconditionerfineborestem signal conditioner gears display marks on the stem. display pointer moving across a scale. 4. Identify the various elements that might be present in a control system involving a thermostatically controlled electric heater. Process heater Controlled variable temperature Measurement device bimetallic strip Comparison element thermostat Correction element relay. 5. What is meant by sequential control & illustrate with an example. The control system in which the actions are strictly ordered in a time or event driven sequence is known as sequential control. Example : domestic washing machine. The operations to be carried out in the correct sequence are, pre wash cycle, main wash cycle & rinse cycle.

6. State steps that might be present in the sequential control of a dish washer. Water in, rinse, water out Water in, heat water, rinse, water out Water in, rinse, water out 7. Compare & contrast the traditional design of a watch with that of a Mechatronics designed product. Traditional design i. Bulky ii. Limited functions iii. Requires rewinding iv. Costlier Mechatronics design i. Compact ii. More functions iii. Does not require rewinding iv. Cheaper.

8. Compare and contrast the control system for the domestic central heating system involving a bimetallic thermostat and that involving microprocessor. Bimetallic element i. Slow ii. Limited accuracy iii. Simple functions iv. Cheap Mechatronics design i. Fast ii. More accurate iii. Many functions iv. More Cheap.

9. List the advantages of Mechatronics system. 1. Increased functionality and letter design 2. More use of electronics & software instead of mechanical function 3. Assumes responsibility for process & operation with little interference of operators. 4. High levels of integration 5. Uses AI and intelligent process control 6. High reliability & safety. 10. Describe briefly the evolution of Mechatronics system. Modern Mechatronics systems evolved through several stages and categorized as : 1. Stand alone systems : Ex : washing machine, compact disk player, auto focus, camera, boat auto pilot etc. 2. System with high level of distributed sensor, micro controller, actuator Ex : wire aircraft. 3. Large factory system. 4. System that incorporates intelligent control Ex : humanoid robot. 11. What are the disadvantages of Mechatronics design. 1. Initial cost is very high 2. Complicated design 3. Repair & maintenance is complex

4. Its replacement is difficult.

12. What are the key elements of Mechatronics system. 1. Information system 2. Mechanical system 3. Electrical system 4. Computer system 5. Sensor & actuators 6. Real time interfacing. Unit 2 1. Define sensor & transducer Sensor is an element in a measurement system that acquires a physical parameter and changes it into a signal. Transducer is a device that converts the energy from one form to another. 2. Define range & span. The range of a transducer defines the limits between which the input can vary. The span is the maximum value of the input menus the minimum value. 3. Define accuracy & precision Accuracy : It is defined as the ability of an instrument to respond to a true value of a measured variable under the reference conditions. Precision : It is defined as the degree of exactness for which an instrument is designed to perform. 4. Define sensitivity. It is the relationship indicating how much output may be obtained per unit input. 5. Define Hysteresis. It is defined as the difference in the output for a given input when this value is approached from the opposite directions. 6. Define repeatability & reproducibility. Repeatability : It is defined as the ability of an instrument to produce the same output for repeated applications of the same input value. Reproducibility : It is defined as the closeness of agreement among the repeated measurements of the output for the same value of the input under the same operating conditions over a period of time. 7. Define stability : It is the ability of the transducer to give the same output when used to measure a constant input over a period of time. 8. Define dead band and dead time Dead band : It is the range of input values for which there is no output. Dead time : It is the length of time from the application of an input until the output begins to respond & change. 9. Define Resolution : It is the smallest change in the input value that will produce an observable change in the output. 10. Explain the significance of the following information given in the specification of a strain gauge transducers :

Range : 70 to 1000 K Pa Full range output : 40 mV Non linearity & hysteresis : 0.5% full range output.

The range indicates that the transducer can be used to measure pressures between 70 & 1000 KPa It gives an output of 40 mV when the pressure is 1000 KPa Non linearity & hysteresis will lead to erros of 0.5% of 1000, (ie) 5 KPa.

11. What is the non-linearity error, as a percentage of full range, produced when a 1K potentiometer has a load of 10K & is at onethird of its maximum displacement. R P =1K, R L =10K, x=0.33

RP 2 3 ( x -x ) RL non-linearity error= 100% RP x ( 1-x ) +1 RL = 0.10.33 ( 1-0.33) +1 0.1( 0.332 -0.333 ) = 0.7%

12. What is displacement & position sensor. Displacement sensors are concerned with the measurement of the amount by which some object has been moved. Position sensors are concerned with the determination of the position of some object with reference to some reference point. 13. Name some sensors which are used for displacement measurement. 1. potentiometer sensor 2. resistance strain gauge element 3. push pull displacement sensor 4. LVDT 14. Name some sensors which are used for position measurement. 1. photo electric sensors 2. Hall effect sensors 3. optical encoders.

15. Define proximity sensor. Proximity sensors are a form of position sensor and are used to determine when an object has moved to within some particular critical distance of the sensor. 16. Define optical encoder. What are its type. An encoder is a device that provides a digital output as a result of a linear (or) angular displacement. Incremental encoder : It detect changes in rotation from some datum position. Absolute encoder : It gives the actual angular position.

17. What is hall effect? When a beam of charged particles passes through a magnetic field, the beam is deflected from it straight line path due to the forces acting on the particles. This is known as Hall effect. 18. What is the working principle of eddy current proximity sensor? If a coil is supplied with an alternating current, an alternating magnetic field is produced. If there is a metal object in close proximity to this alternating magnetic field, then eddy currents are induced in it. The eddy currents themselves produce a magnetic field. As a result, the impedance of the coil changes & so the amplitude of the alternating current. 19. Name some sensors used for measurement of velocity 1. Tachogenerator 2. incremental encoder3. pyro electric sensor 20. Name some signal conditioning operations. Amplification, linearization, comparision, protection, filtering, compensation, Analog to Digital conversion, Digital to Analog conversion. temperature

21. What is the resolution of an AD converter with a word length of 12 bits & an analogue signal input range of 100v? 100 Resolution = =24.4mV 212 22. What is the conversion time for a 12 bit ADC with a clock frequency of 1 MHz? 1 Conversion time = =0.5 sec 2 106 23. State shannons sampling theorem. When the signal is sampled at a rate fs 2fm, the signal can be reconstructed from its samples without distortion. Unit 3 1. Draw the symbols for a) a pressure relief valve b) a 2/2 valve c) a 4/2 valve

2. A pneumatic system is operated at a pressure of 1000 k Pa. What diameter cylinder will be required to move a load requiring a force of 12 KN? Force Pressure = Area 12 A= =1210-3 1000 2 D =1210-3 4 D 2 = 0.015 D = 124mm. 3. If a stepper motor has a step angle of 7.5, what digital input rate is required to produce a rotation of 10 rev/sec?

No.of pulses per step =

360o =48 pulses/sec. 7.5o Digital input =4810 = 480 pulses/rev.

4. State the number of degrees of freedom each of the following mechanism has: Your knee degrees of freedom 1 Your ankle degrees of freedom 3 Wind screen wiper mechanism DOF 1 5. A hydraulic cylinder is to be used to more a work piece through a distance of 60 mm in 20 secs. A force of 15KN is required to move the work piece. Determine the required working pressure & hydraulic flow rate if a cylinder with a piston diameter of 75mm is available. 2 ( 0.075 ) Area = = m2 4 0.06 flowrate = = m 3 /sec. 20 F 15103 pressure = = = KPa A 6. Suggest suitable actuator for robot arm joint & justify.

7. An actuator has a stem movement which at full travel is 40mm. It is mounted with a linear plug process control valve which has a minimum flow rate of 0.4 a maximum flow rate of 0.2 m3/s. What will be the flow rate when the stem movement is a) 10 mm b) 20 mm? For a linear valve the percentage flow rate is the same as the percentage stem displacement. a) a percentage stem displacement of 25% gives a percentage flow rate of 25% (ie) 0.05 m3/s. b) a percentage stem displacement of 50% gives a percentage flow rate of 50% (ie) 0.1 m3/s. 8. An actuator has a stem movement which at full travel is 40 mm. It is mounted on a process control valve with an equal percentage plug & which has a minimum flow rate of 0.2 m3/s & a maximum flow rate of 4 m3/s. what will be the flow rate when the stem movement is a) 10mm b) 20mm. Q min = 0.2m3 / sec Q max = 4m 3 / sec S max = 40mm

Q Q max a) = Q min Q min 4 Q = 0.2 0.2

10 40

S max

= 0.42m3 /sec.
40

4 b) Q = 0.2 0.2

20

= 0.89m3 /sec.

9. What is mechanism & Kinematics. Mechanism are motion converters in that they transform motion from one form to some other required form. Kinematics is the study of motion without regard to forces. 10. What is kinematics chain & four bar chain. A sequence of joints & links is known as kinematics chain.The connection of four links to give four joints about which turning can occur is known as four bar chain. 11. What is cam? What are its types. A cam is a body which rotates or oscillates and in doing so imparts a reciprocating or oscillatory motion to a second body called the follower. Types : eccentric, heart shaped & pear shaped. 12. A compound gear train consists of the final driven wheel with 15 teeth which meshes with a second wheel with 90 teeth. On the same shaft as the second wheel is a wheel with 15 teeth. This meshes with a fourth wheel, the first driver, with 60 teeth. What is the overall gear ratio? overall gear ratio = = = w A w A wB w C = = = w D w B w C wD NB ND N A NC 15 15 1 = . 60 90 24

13. Identify the motions involved in the following mechanism. 1. The keys on a computer keyboard translational motion 2. The pen in an XY plotter translational motion 3. The hour hand of a clock rotational motion 4. the pointer on a moving coil ammeter rotational motion 5. An automatic screw driver translational plus rotational motion. 14. A d.c moter is required to have a) a high torque at low speeds for the movement of large loads b) a torque which is almost constant regardless of speed. Suggest suitable forms of motor. a) Series wound d.c. motor b) Shunt wound d.c. motor. 15. Suggest possible motors d.c (or) a.c, which can be considered for applications where a) cheap, constant torque operation is required b) high controlled speeds are required c) low speeds are required d) maintenance requirements have to be minimized. a) D.C. shunt wound b) induction motor

c) d.c. motor

d) a.c. motor. Unit 4

1. Define programmable logic controller PLC is defined as a digital electronic device that uses a programmable memory to store instructions and to implement functions such as logic, sequencing, timing, counting & arithmetic in order to control machines & processes. 2. Sketch the timing diagram for ON delay & OFF delay timer. ON delay timer : This type of timer waits for a fixed delay period before turning ON.

OFF delay timer : This type of timer switches off an output after a time delay from being energized.

3. Draw the relay programming & PLC Programming equivalents for two input AND & NOT gate. Relay programming PLC programming AND gate

A coil is not energized unless two, normally open switches are both closed. NOT gate A coil is energized, when there is no input to the switch. 4. What is latching in PLCs? In some situations, it is necessary to hold a coil energized, even when the input which energized it ceases. The latch circuit is used to carry out such an operation. It is a self maintaining circuit, in that after being energized, it maintains that state until another input is received. It remembers its last state. 5. Device a PLC timing circuit that will switch an output ON for 10 secs & then switch it off.

6. What are the criteria that need to be considered for selecting a PLC? 1. input / output capacity is required 2. type of input / output is required 3. size of memory is required 4. speed & power required for CPU is needed. 7. Mention specific features of PLCs 1. PLCs are rugged & designed to withstand vibrations temperature, humidity & noise. 2. The interfacing for inputs & outputs is inside the controller. 3. They are easily programmed. 8. State the programming methods of PLC. 1. Ladder programming 3. Function block diagram 5. Instruction list 2. Structured text programming 4. Sequential function charts

9. What are the three major types of PLC application? 10. Name the two ways in which input / output is incorporated into the PLC. 11. Draw the ladder logic diagram to represent a) two switches that are normally open & both have to be closed for a motor to operate b) Either of two, normally open, switches have to be closed for a coil to be energized & operate an actuator.

12. What is ladder programming? The ladder programming involves each program task being specified as though a rung of a ladder. Thus such a rung could specify that the state of switches A & B are both closed then a solenoid, the output is energized. 13. Write about internal relays? The internal relays behave like relays with their associated contacts, but in reality are not actual relay but associated by the software of the PLC. Internal relays are used when there are programs with multiple input conditions. 14. What is an up counter & down counter?

An up counter could count up to the preset value (ie) events are added until the number reaches the set values, when the set value is reached the counters contact changes state. A down counter could count down from the preset value to zero (ie) events are subtracted from the set value. When zero is reached the counters contact changes state. 15. What are operations that are carried out with a PLC on data words? 1. moving data 2. comparison of magnitudes of data 3. Arithmetic operations such as additons & subtraction 4. Conversions between BCD, binary & octal.

Unit 5 1. What are the various stages in designing Mechatronics system? The various stages in Mechatronics design are a) The need b) Analysis of the problem c) Preparation of the specification d) Generation of the possible solutions. e) Selection of the suitable solutions f) production of a detailed design g) Production of working drawings 2. What are the advantages of the micro processor controlled system? The microprocessor controlled system can cope easily with given precision & programmed control. The System is much more flexible. This improvement in flexibility is a common characteristic of Mechatronics systems when compared with traditional systems. 3. List down the various Mechatronics elements in an automatic camera. The basic elements of the control system used in an automatic camera is body, lenses & flash. The other elements are 1. sensors Light sensor, range sensor, lens sensor metering sensor. 2. solenoid valve 3. flash setting unit 4. motor drives, zoom & exposure unit. 4. What are the axes of a pick & place robot? The robot has three axes about which motion can occur a) Rotation in a clockwise (or) counter clockwise direction of the unit on its base. b) Arm extension or contraction & arm up or down c) Gripper open (or) close. 5. How do the movement of robot take place? Clockwise rotation of the unit might result from the piston in a cylinder being extended & the counter clockwise direction by its retraction. The upward movement of the arm might result from the piston in a linear cylinder being extended and the downward motion from it retracting. 6. List the actuators used in automatic camera & its function.

ACTUATOR Motor I Motor II Motor III Motor IV Motor V Shutter magnet

FUNCTION Film transport Shutter & mirror action, film rewind Focusing drive Lens aperture drive Flash zoom drive Exposure time control

7. List the difference between traditional design & Mechatronics design. TRADITIONAL DESIGN Bulky system Complex mechanisms Non adjustable movement cycle Constant speed drives Mechanical synchronization Rigid heavy structures Accuracy determined mechanism Manual controls by tolerance MECHATRONIC DESIGN Compact Simplified mechanisms Programmable movements Variable speed drives Electronic synchronization Lighter structures of Accuracy achieved by feedback Automatic and programmable controls