Unit-2

Basic Mechatronics Systems

Introduction

 System model mainly concern to determine how systems are behave with
Time when subject to some disturbance.
 A systems can be made up from a range of building blocks from a number
of basic building blocks.
Mechanical System building Blocks:-

 The basic building blocks of models used to represent mechanical systems

are (Translational)

1) Springs
2) Dashpots
3) Masses
 Mechanical System building Blocks:-
1) Spring :-

 The spring represent the stiffness of a system.

 Fig. shows the spring subjected to the force “F”
 Mechanical System building Blocks:-

 In the case of a linear spring

F= k x
Where,

F= Applied force
k= Constant
x=Extension or Compression.

Equation indicates that, as per the Newton's third law, the force F is equal in size and in
the opposite direction to the force exerted by the stretched spring (i.e. kx)
Mechanical System building Blocks:-

 The spring when stretched stores the energy.

 The energy released when spring springs back to its original length.

 Energy Stored when there is an extension x,

 Mechanical System building Blocks:-
2) Dashpots :-
 The dashpot represent the forces opposing motion.
Mechanical System building Blocks:-

 Here faster the object is pushed greater becomes the opposing forces.
 In ideal case,

Damping or resisting force “F” is proportional to the velocity “v” of the piston.
Thus,

Where “c” is constant.

 In a Dashpot no energy is stored. It does not return to is original position when

there is no force input.
 The Dashpot dissipates energy rather storing it.
 Power dissipated is
 Mechanical System building Blocks:-
3) Mass :-

The Masses represent the inertia or resistance to acceleration.

Mechanical System building Blocks:-

 The mass building block exhibits the property that the bigger the mass the
greater the force required to a specific acceleration.
Mechanical System building Blocks:-

The Energy (Kinetic energy) stored in mass when it is moving with Velocity
“v” and released when it stop moving
 Mechanical System building Blocks:-

Rotational System –

In mechanical system, when Rotation is involved then three building blocks are…

1) A torsional Spring
2) Rotary Damper
3) Moment of Inertia
 Mechanical System building Blocks:-

1) A torsional Spring :-

 In torsional spring the angle rotated (θ) is proportional to the torque “T”.
i.e
T=K θ
Where , K is constant.

 Energy stored in torsional spring , when twisted through an angle θ.

 Mechanical System building Blocks:-

2) Rotary Damper :-

 In rotary damper , a disc is rotated in a fluid and resistive torque (T) is proportional to
the angular velocity
i.e

Where , C is constant & is rate of change of Angular Displacement.

 Power Dissipated by the rotary damper when rotating with a angular velocity
 Mechanical System building Blocks:-

3) Movement of Inertia (I) :-

 The movement of inertia of a building block exhibits the property that , the greater
the movement of inertia I, greater the torque needed to produce the an angular
acceleration

or

Here, angular acceleration is rate of change of angular velocity and angular velocity is
rate of change of angular displacement.
 “Energy stored” by the mass rotating with an angular velocity
 Electrical System building Blocks:-

The Electrical System building Blocks are

1) Resistors
2) Inductors
3) Capacitors.
 Electrical System building Blocks:-

1) Resistors:-

 The potential difference across the resistor at any instant depends on the Current “I”
through it.

Where R is the resistance

 Power dissipated by resistance :-

 Electrical System building Blocks:-

2) Inductor :-

 The potential difference across the inductor at any instant depends on the rate of
change of Current through it.

Where L is the inductance.

 Energy stored by inductor :-

 Electrical System building Blocks:-

3) Capacitors :-

 The potential difference across the capacitor depends on the charge “Q” on the
capacitor plates at any concerned

Where C is the Capacitance .

 Energy stored in Capacitance :-

 Building up a Model for an Electrical System

The various electrical building blocks can be combined by using “Kirchhoff's Law”

 Kirchhoff's Current Law (KCL):-

“The sum of currents entering a junction is equal to the sum of the currents leaving the
junction”

 Kirchhoff's Voltage Law (KVL):-

“The sum of e.m.fs (rise of potential) around any closed loop of a circuit equals the sum
of the potential drops in that loop”
Building up a Model for an Electrical System

Let us consider Principal Node A with VA

Node analysis
 Building up a Model for an Electrical System

According to Kirchhoff's KCL,

But

Therefore
 Building up a Model for an Electrical System

In Mesh Analysis, by using KVL,

Mesh analysis
 Building up a Model for an Electrical System

In Mesh Analysis, by using KVL to each mesh,

For the mesh with Current I1 and source of e.m.f V

Now, the mesh with Current I2

So, the mesh with Current I1 and I2 are calculated from these equations.
 System Models

Rotational Translation System:-

 System Models

Rotational Translation System:-

 System Models

Rotational Translation System:-

 There are many mechanisms which involve the conversion of rotational motion to
translational motion or vice-versa.
 For example:- there are rack-and- pinion, shaft with lead screws, pulley and cable
systems, etc.
 System Models

Electromechanical System:-

Electromechanical devices such as Potentiometers, motors and generators transform the

electrical signals to rotational motion or vice versa.
 System Models

Electromechanical System:-
 System Models

Electromechanical System:-

 A Rotary Potentiometer gets an input of rotation and supplies an output of

an potential difference
 System Models

Electromechanical System:-
 System Models

Electromechanical System:-
 System Models

Electromechanical System:-

The electrical DC motor is used to convert an electrical input signal into a

mechanical output signal.
 CNC Machine- (Computer Numerical Control )
  CNC Machine- (Computer Numerical Control )

 For Flexible automation on shop floor, CNC machines plays a major role.
 This technology is applied for large scale industries.
 For manufacturing a component, CAD/CAM process generates an NC (Numerical
Control) program, which can run on the CNC machine.
 Above fig. shows the General Configuration of CNC system.
 Tape reader:- Tape reader are used to store the Part Program.
 Mini Computer/Microcomputer:- (Soft- wired) Used to run the stored programs ,
controls the machine tools, actuators and other peripheral devices.
 Servos and interface logic (Hard-wired):- The decoded position and velocity control
signals, generated by the CPU for the axis movement forms the input to the servo control
unit. This unit in turn generates suitable signals as command values. The command
values are converted by the servo drive units which are interfaced with the axes and the
spindle motors. The servo control unit receives the position feedback signals for the
actual movement of the machine tool axes from the feedback devices (like linear scales,
rotary encoders, revolvers, etc.)
  CNC Machine- (Computer Numerical Control )

 Major Elements of CNC Systems:-

1. Hardware:- It includes a microprocessor, machine tools, actuators and other

peripheral devices.

2. Software:- CNC software includes various instructions, programming languages , I/O

control and graphics.

3. Information :- Information is nothing but the data required for cutter location,
programming, machining process.
  CNC Machine- (Computer Numerical Control )

 Types of CNC Machines:-

1. CNC machining Center

2. CNC turning Center
3. CNC lathes
4. CNC milling/drilling machines
5. CNC special- Purpose machines.
  CNC Machine- (Computer Numerical Control )

 Applications of CNC Machines:-

1. Used in the metal- cutting industry for processes such as milling, drilling, boring,
turning, grinding, sawing etc. and for production jobs where:
 Part are processed frequently and in small in lot size.
 Design changes are likely.
 Close tolerance are necessary.

2. It is also used in

 Welding Machines
 Press working machine tools
 Cloth cutting
 Laser beam process
 Assembly machines.
 G- Code
 Manufacturers all around the world use CNC programming to control a machine’s tools
to produce parts. Automated manufacturing process is a set of instructions that tells a
CNC machine where – and how – to move. These instructions are called G-Code.

G-code is a language in which people tell computerized machine tools (CNC) how to
make something. The "how" is defined by g-code instructions provided to a machine
controller (industrial computer) that tells the motors where to move, how fast to move,
and what path to follow.

 G-code was first established in the 1960s by the Electronics Industry Association (EIA).
While the official language was documented as RS-274D, everyone refer to it as G-code.

 While G-code is supposed to be a universal standard.

 G-Code Blocks
 The G-code standard was published ,when machines had small amounts of memory.
Because of this memory limitation.

 G-code is an extremely compact language .

 Example this line of code:

G01 X1 Y1 F20 T01 M03 S500

In this single line we’re giving the machine a series of instructions:

G01 – Perform a linear feed move

X1/Y1 – Move to these X and Y coordinates
F20 – Move at a feed rate of 20
T01 – Use Tool 1 to get the job done
M03 – Turn the spindle on
S500 – Set a spindle speed of 500
 Multiple lines of G-code like these combine to form a complete CNC program.
 CNC machine will then read the code one line at a time from left to right and top to
bottom, like reading a book. Each set of instructions is on a separate line, or a block.
G0 – Rapid Move
 This code tells a machine to move as fast as possible to a specified coordinate position.
G0 will move the machine axis by axis, meaning that it will first move along both axes
and finish the move on whichever axis is not in positions.

Example of this motion in the image below:

G1 – Linear Move
This code tells a machine to move in a straight line to a coordinate position with
a defined feed rate. For example, G1 X1 Y1 F32 will move the machine to
coordinates X1, Y1, at a feed rate of 32.

G2, G3 – Clockwise Arc, Counter-clockwise Arc

These codes tell the machine to move in an arc to a coordinate destination. Two
additional coordinates, I and J, define the arc’s center location as shown below:
G17, G18, G19 – Plane Designations
These codes define what plane an arc will be machined on. By default your CNC machine
will use G17, which is the XY plane. The other two planes are shown in the image below:
G40, G41, G42 – Cutter Diameter Compensation
These codes define the cutter diameter compensation, or CDC, which allows a CNC
machine to position its tool to the left or right of a defined path. A D-register stores
the offset for each tool.
G43 – Tool Length Compensation
This code defines the length of individual tools using a Z-axis height. This allows the
CNC machine to understand where the tip of a tool is in relation to the piece it is
working on. A register defines the tool length compensations, where H is the tool
length offset and Z is the length of the tool.
G54 – Work Offset
This code is used to define a fixture offset which determines the distance from
a machine’s internal coordinates to the datum on a workpiece. In the table
below only G54 has an offset definition. However, you can program multiple
offsets if a job requires machining multiple parts at once.
Some common drill cycles includes:

G81 – Simple Drill Cycle

This cycle will make a hole by plunging to a specific Z-axis coordinate and then
retracting. Programming this cycle requires a depth, feed rate, XY coordinates, and
plane to drill on.
G83 – Peck Drill
This cycle is used for quickly drilling deep holes. A tool will first drill a defined distance
and then retract, which clears any material out of the hole and allows coolant to flush
away chips. The simplest implementation of this cycle requires an initial height, feed
plane, peck increment, and depth.
 G98 – Return to Initial Rapid Height
This cycle will retract a tool to a clearance plane between holes which helps to avoid
clamps. Programming this cycle requires an initial height and feed plane to drill on.
 CNC Milling G Code List
G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G17 X Y plane selection
G18 Z X plane selection
G19 Y Z plane selection
G28 Return to reference position
G30 2nd, 3rd and 4th reference position return
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation + direction
G44 Tool length compensation – direction
G49 Tool length compensation cancel
G53 Machine coordinate system selection
G54 Workpiece coordinate system 1 selection
G55 Workpiece coordinate system 2 selection
CNC Milling G Code List…
G56 Workpiece coordinate system 3 selection
G57 Workpiece coordinate system 4 selection
G58 Workpiece coordinate system 5 selection
G59 Workpiece coordinate system 6 selection
G68 Coordinate rotation
G69 Coordinate rotation cancel
G73 Peck drilling cycle
G74 Left-spiral cutting circle
G76 Fine boring cycle
G80 Canned cycle cancel
G81 Drilling cycle, spot boring cycle
G82 Drilling cycle or counter boring cycle
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
G90 Absolute command
G91 Increment command
G92 Setting for work coordinate system or clamp at maximum spindle
speed
G98 Return to initial point in canned cycle
G99 Return to R point in canned cycle
 CNC Lathe G Code List
G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G09 Exact stop
G10 Programmable data input
G20 Input in inch
G21 Input in mm
G22 Stored stroke check function on
G23 Stored stroke check function off
G27 Reference position return check
G28 Return to reference position
G32 Thread cutting
G40 Tool nose radius compensation cancel
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
CNC Lathe G Code List…

G70 Finish machining cycle

G71 Turning cycle
G72 Facing cycle
G73 Pattern repeating cycle
G74 Peck drilling cycle
G75 Grooving cycle
G76 Threading cycle
G92 Coordinate system setting or max. spindle speed
setting
G94 Feed Per Minute
G95 Feed Per Revolution
G96 Constant surface speed control
G97 Constant surface speed control cancel
 M- Code
 M-code is the machine control language for CNC machining. It is used in
combination with G-code to switch various machine functions off and on.

 The M in M-code tells the machine that a miscellaneous command follows. For
instance, M03 starts the spindle and is generally preceded by an S code to set the
speed.
The following partial list of M-codes, shown below as examples, fanuc Codes…

M00 Program stop

M01 Program stop--optional
M02 End of program
M03 Spindle start--forward, of clockwise rotation
M04 Spindle start--reverse, or counterclockwise rotation
M05 Spindle stop
M06 Tool change

Codes continue on, up to M99, which ends a subprogram.

Other vendors provide more codes.
Many manufacturers also leave a number of M-codes unassigned for definition by the
user.
Table 1 below shows a more list of M-codes for lathe operations. Table 2 has a similar list
of M-codes for milling operations. Both of these tables are based on the Fanuc codes.
M-Codes Commands
M – Codes for Lathe Operations
M - Code Description
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M08 Coolant on
M09 Coolant off
M29 Rigid tap mode
M30 End of program reset
M40 Spindle gear at middle
M41 Low Gear Select
M42 High Gear Select
M68 Hydraulic chuck close
M69 Hydraulic chuck open
M78 Tailstock advancing
M79 Tailstock reversing
M94 Mirrorimage cancel
M95 Mirrorimage of X axis
M98 Subprogram call
M99 End of subprogram
 M-Codes Commands …
M – Codes for Milling Operations
M code Description
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M06 Tool change
M07 Coolant ON – Mist coolant/Coolant thru spindle
M08 Coolant ON – Flood coolant
M09 Coolant OFF
M19 Spindle orientation
M28 Return to origin
M29 Rigid tap
M30 End of program (Reset)
M41 Low gear select
M42 High gear select
M94 Cancel mirrorimage
M95 Mirrorimage of X axis
M96 Mirrorimage of Y axis
M98 Subprogram call
M99 End of subprogram
 G-Code Programs
 The goal of every G-code program is to produce parts in the safest and most efficient way possible.
To achieve this G-code blocks arranged in a very specific order like this:

1. Start the CNC program

2. Load the required tool
3. Turn the spindle on
4. Turn the coolant on
5. Move to position above a part
6. Start the machining process
7. Turn the coolant off
8. Turn the spindle off
9. Move away from the part to a safe location
10. End the CNC program

This flow is an extremely simple program using only one tool for one operation.
For example, the G-code program below encompasses all of the code blocks above with repeating
sections where needed:
 Modals and Address Codes
 Like other programming languages, G-code has the ability to repeat an action until
stopped. This looping process uses modal code, which performs an action until either
turn it off or modify it with another modal code.

 For example, M03 is a modal code that will run a spindle until you tell it to stop with
M05.

Words that start with an M are machine codes, and they turn machine functions like
coolant, spindle, and clamps on or off.

Address codes begin with the letter designation, like G, and then with a set of numbers.
For example, X2 defines an X-coordinate address code, where 2 is value on the X-axis to
move the machine to.
The complete list of address codes includes:
There are also several special character codes that can be added into a G-code program.
These are typically used to start a program, comment out text, or ignore characters and
include:

% Begins or ends a CNC program

() Defines a comment written by a CNC operator, occasionally these must be in all caps
/ Ignores all characters that come after the slash
; Determines when a block of code ends, not shown in a text editor