Unit 1: - Introduction to Mechatronics and its Systems

Introduction to Mechatronics:
 Mechatronics is an interdisciplinary field of engineering that synergistically
integrates principles from mechanical engineering, electrical engineering,
electronic engineering, computer science engineering, control engineering,
thinking to design and create intelligent, automated systems and products.
 The term "Mechatronics" was coined in 1969 by Tetsuro Mori, an engineer at
Yaskawa Electric Corporation in Japan. Initially, it combined "mechanics" and
"electronics," but as technology evolved, the scope expanded to include
computer science, control systems, and systems engineering.
Evolution of Mechatronics:
 Stage 1: Primary Level Mechatronics (1969 – Early 1970s)
 Integration of basic mechanical systems with electrical I/O devices such as
sensors and actuators.
 Simple control logic, limited or no feedback.
 Examples: Electrically controlled fluid valves, relays.
 Stage 2: Secondary Level Mechatronics (Late 1970s – 1980s)
 Integration of microelectronics into electrically controlled devices.
 Improved precision and device functionality.
 Examples: Cassette players, VCRs.
 Stage 3: Tertiary Level Mechatronics (1980s – 1990s)
 Incorporation of advanced feedback functions into control systems.
 Use of microprocessors and ASICs (Application-Specific Integrated Circuit) for
enhanced quality.
 Examples: Industrial robot motors, hard disks, CD drives, automatic washing
machines.
 Stage 4: Quaternary Level Mechatronics (2000s – 2020s)
 Introduction of intelligent control and Fault Detection and Isolation (FDI)
capabilities.
 Systems become autonomous, adaptive, and AI-enabled.
 Integration of Artificial Intelligence (AI), Machine Learning (ML), and Internet of
Things (IoT) into mechatronic systems.

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Scope of Mechatronics:
 Manufacturing and Industrial Automation: Mechatronics plays a central role in
modern manufacturing and industrial automation. It is the foundation of smart
factories, also known as Industry 4.0. In these factories, robotics, automated
guided vehicles, and computerized production systems work together to improve
efficiency, precision, and product quality on assembly lines.
 Automotive Engineering: Modern vehicles are highly complex mechatronic
systems. Mechatronics engineers design and develop engine control units, anti-
lock braking systems, advanced driver-assistance systems, and autonomous
vehicle technologies. These systems enhance vehicle performance, safety, and
driver convenience.
 Aerospace and Defense: Mechatronics is widely used in aerospace and defense
applications. It helps in designing precise control systems for aircraft, satellites,
and drones. Applications include flight control systems, navigation systems, and
automated surveillance systems to ensure safety and reliability in aerospace
operations.
 Medical and Biomedical Engineering: Mechatronics has revolutionized
healthcare by enabling advanced medical devices. Examples include robotic
surgical systems such as the da Vinci Surgical System, advanced prosthetic
devices, and medical imaging technologies. Mechatronics is also essential for
developing wearable health monitors and automated drug delivery systems,
improving patient care and treatment efficiency.
 Consumer Electronics: Many everyday consumer devices rely on mechatronics.
Products such as autofocus cameras, printers, dishwashers, and hard disk drives
integrate mechanical movements with electronic control systems. These systems
improve the functionality, precision, and convenience of consumer electronics.
 Robotics: Robotics is a core discipline of mechatronics. It involves the design,
control, and programming of intelligent machines that can interact with their
environment. Applications include industrial robots for manufacturing, humanoid
service robots for assistance, and drones for surveillance or delivery.

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Key Elements of Mechatronics System:

 Mechanical System: This encompasses the physical parts and structures of a

system designed to perform a specific function, considering its physical model
and dynamic behavior.
 Actuators: Devices that convert energy (electrical, hydraulic, pneumatic) into
mechanical motion or force to control the mechanical system, acting as its
"muscles". e.g. Solenoids, voice coils; D.C. motors; Stepper motors; Servomotor;
hydraulics; pneumatics
 Sensors: Components that detect and measure physical quantities (like
temperature, position, pressure) and convert them into usable signals, typically
electrical, providing feedback to the system. e.g. Switches; Potentiometer;
Photoelectric; Digital encoder; Strain gauge; Thermocouple; accelerometer
 Input Signal Conditioning and Interfacing: This stage processes raw sensor
signals through amplification, filtering, and A/D conversion to prepare them for
the digital controller. e.g. Discrete circuits; Amplifiers, Filters; A/D, D/D.
 Digital Control Architectures: The "brain" of the system, involving
microcontrollers or PLCs and software, that processes information and executes
control algorithms based on sensor input and desired outputs.
e.g. Logic circuits; Microcontroller; SBC; PLC; Sequencing and timing; Logic and
arithmetic; Control algorithms; Communication.
 Output Signal Conditioning and Interfacing: This prepares the control signals
from the digital controller for the actuators, potentially involving D/A conversion

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 and power amplification (e.g., using power transistors or PWM). e.g. D/A, D/D;
Amplifiers; PWM; Power transistors; Power Op-amps.
 User Interface: The point of interaction between humans and the machine,
allowing users to input commands (buttons, screens) and receive feedback
(displays, indicators). e.g. LEDs; Digital displays; LCD; CRT.
In a mechatronic system, actuators produce motion or perform specific
actions, while sensors detect the state of system parameters, including inputs and
outputs. Digital devices control the system by processing the information from
sensors. Conditioning and interfacing circuits provide connections between the
control circuits and the input/output devices, ensuring proper communication.
Finally, graphical displays give visual feedback to users, helping them monitor and
understand the system’s operation.
Advantages and disadvantages of Mechatronics System:
Advantages:
 Cost-Effective & High Quality: Mechatronics enables the production of products
that are both economical and of superior quality.
 Superior Performance: They achieve performance characteristics and
functionalities that are difficult to realize without the synergistic integration of
multiple engineering disciplines.
 High Flexibility: Mechatronic systems offer a high degree of adaptability and ease
of modification.
 Synergistic Benefits: The integrated whole performs better than the sum of its
individual parts.
 Enhanced Machine Utilization: They lead to a greater extent of machine utilization,
improving operational efficiency.
 Reduced Capital Expenses: The integration of sensors and control systems within a
complex system can help reduce overall capital expenses.
 Increased Productivity & Reliability: Intelligent, self-correcting sensory and
feedback systems lead to higher productivity, quantity, and production reliability.
Disadvantages:
 High Initial System Cost: The upfront investment for designing and implementing
mechatronic systems can be significant.
 Multidisciplinary Expertise Required: Designing and implementing these systems
necessitates comprehensive knowledge across various engineering fields.
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 Specific Problem Addressing: Unique problems inherent to different mechatronic
systems often require tailored solutions.
 Expensive Integration into Old Systems: Incorporating mechatronic approaches
into pre-existing or older systems can be a costly endeavor.
Measurement Systems:
A measurement system is a combination of instruments and devices used to
observe, measure, and quantify physical quantities, converting them into signals that
can be interpreted or used for control, monitoring, or analysis.
Below diagram shows basic elements of generalized measurement system.

 Input quantity to be measured: This represents the physical variable or

phenomenon that needs to be measured E.g. temperature, pressure, flow,
length).
 Primary Sensing Element: This is the first element that comes into contact with
the input quantity. It senses or detects the physical quantity and converts it into
a related, more usable form of energy, often an electrical signal, a mechanical
displacement, or another physical variable, suitable for further processing.
E.g. thermocouple (converts temperature into a small voltage), a strain
gauge (converts mechanical strain into a change in electrical resistance).
 Variable Conversion Element: This element converts the output from the
primary sensing element into a more suitable or standardized form for
manipulation or transmission, while preserving the information content. For
example, it might convert a resistance change into a voltage change.

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 E.g. A Wheatstone bridge circuit used with a strain gauge (converts resistance
change into a voltage change), an analog-to-digital converter (ADC) converting
an analog voltage into a digital signal.
 Variable Manipulation Element: This element manipulates the signal received
from the variable conversion element (or directly from the primary sensing
element). This manipulation might involve amplification (increasing signal
magnitude), attenuation (decreasing magnitude), filtering (removing noise), or
other operations, without changing the fundamental physical nature of the
variable being represented. e.g. An amplifier (increases the amplitude of a small
voltage signal from a thermocouple), a filter (removes unwanted noise from the
signal).
 Data Transmission Element: This element Transfers the processed signal to
another location within the system or to a control/display unit. E.g. Coaxial
cables carrying electrical signals, fiber optic cables for optical signals, wireless
communication modules (e.g., Bluetooth, Wi-Fi) transmitting data.
 Data Storage & Playback Element: It stores the measured data for later retrieval,
analysis, or replay.
 Data Presentation Element: This element displays or outputs the final measured
information in a human-readable or machine-interpretable format. E.g. A digital
multimeter display showing a voltage reading, an analog pressure gauge with a
needle indicating pressure, a computer monitor displaying a graph of
temperature trends, a printer generating a report.
Control Systems:
 A control system is an arrangement of physical components that are connected
or related in such a way as to command, direct, or regulate itself or another
system.
 A control system is a system that uses feedback from sensors to continuously
adjust its inputs or actions, ensuring the output meets the desired performance
or follows a reference signal.
 A system that manages, commands, or regulates the operation of a device or
process to achieve a desired output, often by comparing actual performance with
a reference or set point.

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 Elements of Control Systems:

Element Definition Example

The quantity or condition of the In a room heater, the controlled

Controlled Variable system that can be directly variable is the room
measured and controlled. temperature.

A variable related to the In a boiler, water temperature

Indirectly Controlled
controlled variable, but cannot is measured instead of steam
Variable
be directly measured. pressure.

The input that can be

Setting the desired speed on a
Command independently varied in the
cruise control system in a car.
system.

A standard signal used for

The set temperature given to an
Reference Input comparison in a closed-loop
air conditioner.
system.

In a fan regulator, the difference

The difference between the
between desired speed and
Actuating Signal feedback signal and the
actual speed generates the
reference signal.
actuating signal.

Any external signal, other than Open windows affecting the

Disturbance the reference, that affects the room temperature while the AC
system’s performance. is running.

The difference between the

If AC is set to 24°C but room is
System Error actual value and the ideal
26°C, the error is 2°C.
(desired) value of the output.

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 Examples of Control System Applications:
 Steering control of an automobile – Used to maintain the desired direction of
the vehicle.
 Print wheel control system – Ensures accurate positioning of the print wheel in
printers.
 Industrial sewing machine – Controls the needle movement and fabric feed for
precision stitching.
 Sun-tracking control of solar collectors – Keeps solar panels aligned with the sun
for maximum energy absorption.
 Speed control system – Regulates the speed of motors or vehicles to maintain
desired performance.
 Temperature control of an electric furnace – Maintains the furnace temperature
at a specified set point for consistent heating.
Open Loop and Closed Loop Control Systems:
OPEN LOOP CONTROL SYSTEM:
 An open-loop control system is a system in which the control action is
independent of the desired output. In this type of system, the actuating signal
depends only on the input command, and the output has no influence or
feedback to control the process.
 An open-loop system is a type of control system that operates without feedback,
meaning the output has no influence on the control action.

This block diagram illustrates a fundamental open-loop control system, which

operates without a feedback mechanism from the output to influence the control
action. The key components and their roles are:

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  Reference Input: This is the desired value or setpoint for the controlled variable.
It represents what the system is intended to achieve, for example, a desired
temperature or speed.
 Controller: This element receives the reference input and processes it to
generate an appropriate actuating signal. In an open-loop system, the controller's
output is not adjusted based on the actual output of the process. Examples
include a timer in a washing machine or the on/off switch of a light.

 Actuating Signal: This is the output signal from the controller that is sent to the
controlled process. It is designed to directly influence the process based on the
reference input, without correction from the output.

 Controlled Process (or Plant): This represents the system or mechanism whose
output needs to be controlled. It receives the actuating signal and produces the
controlled variable as its output. Examples include a heating element in an oven
or the engine of a car.

 Controlled Variable (or Output): This is the actual output or the measured
physical variable of the controlled process that is being regulated. In an open-
loop system, this output is not fed back to the controller for comparison or
adjustment.
Examples of Open Loop Control System:
1.Print wheel control System:

 In the print wheel system: A reference command input is sent to the motor to
move the print wheel. The motor moves the wheel based on this input, but
there is no sensor or feedback to check the actual wheel position.
 The system assumes the wheel will reach the desired position correctly after
some time.
 Because the printing starts based on timing, not actual wheel position, the
system does not automatically correct errors if the wheel lags or overshoots.
 The print wheel control system is open-loop because the output (wheel
position) does not influence the control action, and there is no feedback used to
adjust the motor automatically

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2. Simple Automatic Electric Toaster

 In this system, the heating element turns on for a fixed time when the user
presses the lever.
 The toaster does not measure the actual browning of the bread; it only follows
the preset timer.
 The output (toast color or crispness) has no feedback to adjust the heating
automatically.
 The toaster operates based on time alone, not on the result, which makes it an
open-loop system.
 Advantages and disadvantages of Open Loop Control System:
Advantages:
 The system is easy to design and build.
 Fewer components make it easier to maintain.
 Cheaper than a closed-loop system.
 The system is inherently stable because there is no feedback.
 Open-loop systems are useful when it is difficult or expensive to measure the
output precisely.”
Disadvantages:
 Internal or external disturbances can make the output differ from the desired
value.
 Accurate results need careful and regular adjustments
 Any change in system components cannot be corrected automatically.
 Presence of non-linear elements can lead to errors or improper functioning.
CLOSED LOOP CONTROL SYSTEM:
 A closed-loop system is one in which control action is somehow dependent on
the output.

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 In this case the controlled output is fed back through a feedback element and
compared with the reference input. Thus, the actuating signal is the difference of
desired output and reference input.

The above diagram shows a closed-loop speed control system.

r(t) → Reference Input e(t) → Error Signal
m(t) = Manipulated Signal u(t) →Control effort
b(t) → Feedback Signal c(t) → Controlled Output
 Reference Transducer: The Reference Transducer converts the user's desired goal
(Command Input) into a standardized, scaled, and measurable electrical signal
r(t) suitable for the electronic control circuit. E.g., A circuit converts the 250C
temperature setting into a 2.5 V reference voltage.
 Comparator (Summing Point): The Comparator calculates the difference by
subtracting the Feedback Signal b(t) from the Reference Input r(t) to
instantaneously produce the Error Signal e(t), quantifying the system's deviation
from the goal. E.g., It calculates: 2.5 V(desired)−2.3 V(actual)=0.2 V error signal.
 Controller: The Controller analyzes the Error Signal e(t) using a control algorithm
and determines the precise strength and timing of the necessary corrective
action, resulting in the Manipulated Signal m(t) output. E.g., The PID loop sees
the error and outputs a 70% Pulse Width Modulation (PWM) signal to the heater.
 Correction Element/Actuator: The Correction Element is the Actuator and Power
Stage that takes the low-power m(t) signal from the Controller and amplifies it
into a high-power physical effort, the Control Effort (u(t)), which is immediately
applied to the system. E.g., The Relay or Contactor receives the 70% PWM signal
m(t) and switches high current u(t) (Control Effort) to the heating element.
 Process to be controlled: The Process (or Plant) is the physical system whose
output variable is being regulated. It receives the high-power Control Effort u(t)
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 and responds, resulting in the desired Controlled Output c(t). E.g., The Heating
Element and the Room Air (the Process) receive the heat and respond by
increasing the room temperature c(t).
 Feedback Element: The Feedback Element (which includes the sensor and signal
conditioner) measures the physical Controlled Output (c(t)), converts it into a
scaled electrical signal, the Feedback Signal (b(t)), and sends it back to the
Comparator. E.g., A Thermistor or RTD (temperature sensor) measures the room
temperature (≈23∘C) and outputs a proportional 2.3 V signal b(t) back to the
summing point.
Examples of Closed Loop Control System:
1. Automatic Water Temperature Control System

 The aim of the system is to maintain the hot water temperature constant.
 Water enters the system through the water inlet at a constant flow rate.
 Steam enters the system through a valve, which controls the heating of the water.
 A pressure thermometer (P) measures the water temperature and sends a signal
to the comparator.
 The comparator compares the actual temperature with the set point and
generates an error signal.
 This error signal adjusts the valve to control the steam flow.
 By controlling the steam flow, the system ensures that hot water leaves the
system at the desired temperature.

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2. Automatic Water Level Control System

 The system keeps the water level in a tank constant.

 The lever and float are initially set to cut off the water at the desired level.
 When water is used, the float drops, moving the lever and opening the water
supply.
 Water enters until the float rises enough to move the lever and stop the flow.
 The error is the difference between the actual water level and the set level.
 The pivoted lever and flap act to correct the water level automatically.
 This is a closed-loop system, which can also be implemented electronically using
sensors, a computer, and a valve.

 Advantages and disadvantages of Closed Loop Control System:

Advantages:
 Closed-loop systems are highly accurate and reliable because they constantly
measure the output and correct any errors automatically.
 They are insensitive to disturbances, meaning they can handle internal changes
or external factors like load or temperature variations.
 These systems adapt automatically to changes in component characteristics
without needing frequent manual adjustments.
 They have an improved dynamic response, reaching the desired output faster
than open-loop systems.

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 Feedback helps reduce the effect of non-linearities, minimizing errors caused by
non-linear system components.
Disadvantages
 Closed-loop systems have a complex design because they require more
components like sensors, comparators, and controllers.
 They are more expensive due to additional sensors, signal processing, and
controllers
 If not designed properly, they can become unstable, causing oscillations or
runaway behavior.
 They require more maintenance because of the higher number of components.

 Difference between Open Loop & Closed Loop Control System:

Open-Loop Control System Closed-Loop Control System

Has no feedback. Output is not Has feedback. Output is continuously
compared with input. compared with input to adjust control
action.
Control action is independent of the Control action is dependent on the
output. output.
Has simple design. Has complex design.
Accuracy is less. Accuracy is more.
Generally, it is a stable system. Systems may become unstable if the
feedback loop is not properly designed
and tuned.
Cost is low. Cost is high.
Maintenance is less. Maintenance is high.
Bandwidth is small. Bandwidth is large.
Highly affected by non-linearities. Reduced effect of non-linearities.
Reliability is less. Reliability is high.

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Sequential Controllers:
 A Sequential Controller is a system that governs a process by following a fixed,
predetermined series of steps in order.
 The system logic is based on state transitions: Step 2 only starts after Step 1 is
completed (or a condition is met).
 Control can be time driven (based on a timer) or event driven (based on a sensor
signal).
Examples: -
1. Washing Machine Cycle – Sequence: Fill →Pre Wash →Main wash → Drain →
Rinse → Spin (moves step by step with time and sensor conditions).
2. Traffic Light Control – Sequence: Green → Yellow → Red (changes step by step
with timer condition).
 In the old electromechanical method, sequential controllers used mechanical
cams or relay logic to physically establish the sequence of operations.
 In modern sequential controllers, a microprocessor or microcontroller acts as the
central control unit, executing a software program that defines the entire
sequence of operations.
Example: -
Microprocessor Based Domestic Washing Machine

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Pre-Wash Cycle:
 The microprocessor supplies current to open the valve, allowing cold water to fill
the drum.
 The microprocessor operates the switch to open and close the valve.
 The valve closes automatically once the water level sensor signals that the
required level is reached.
 The microprocessor stops the water flow by switching off the current.
 The drum motor is switched on to rotate the drum for a stipulated time.
 The pump is activated to empty the drum.
 Clothes are swashed with cold water during this cycle.
Main Wash Cycle:
 Cold water is supplied after the Pre-Wash cycle is completed.
 The microprocessor or cam switches on the heater to heat the water.
 The temperature sensor switches off the heater when the water reaches the
required temperature.
 The microprocessor or cam switches on the drum motor to rotate the clothes for
washing.
 The microprocessor or cam operates the discharge pump to empty the drum.
Rinse Cycle:
 The microprocessor opens the valve to allow cold water into the drum.
 The microprocessor switches off the water supply once the required level is
reached.
 The drum motor rotates the clothes.
 The pump empties the water from the drum.
 This sequence is repeated several times to properly rinse the clothes.
Spinning Cycle:
 The drum motor is switched on to rotate at a higher speed than during the rinse
cycle.
 Water is removed from the clothes through high-speed spinning.

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Microprocessor based Engine Management System:

 The above diagram, illustrates the "Elements of an engine management system,"

showcasing how a microprocessor system interacts with an engine through a
network of sensors and actuators.
Key Components and Interactions:
1. Microprocessor System: This acts as the brain of the engine management
system, receiving input from various sensors, processing the data according to
pre-programmed algorithms, and then sending control signals to actuators.
2. Sensors (Inputs to Microprocessor): The diagram labels several sensors that
provide critical real-time information about engine operating conditions to the
microprocessor system:
 Engine Speed Sensor: Measures the rotational speed of the crankshaft,
essential for timing calculations.
 Crankshaft Position Sensor: Detects the precise position and speed of the
crankshaft, crucial for fuel injection and ignition timing.
 Spark Timing Feedback Sensor: Provides feedback on the actual spark
timing, allowing for closed-loop control and adjustments.
 Engine Temperature Sensor: Monitors engine coolant temperature,
influencing fuel enrichment, idle speed, and cooling fan operation.
 Throttle Position Sensor: Measures the throttle valve's opening, indicating
driver's demand for power and affecting fuel delivery and ignition timing.
 Mass Air Flow Sensor: Measures the volume and density of air entering the
engine, directly impacting fuel injection calculations.

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 3. Actuators (Outputs from Microprocessor to Engine): The microprocessor system
sends signals to these components to control engine operation:
 Spark timing: The microprocessor precisely controls the timing of the spark
plugs to ignite the air-fuel mixture for optimal combustion, performance, and
emissions.
 Air-fuel mixture solenoid: This, or a similar component like an idle air control
valve, regulates the air supplied to the engine to maintain the correct air-fuel
ratio, especially during idle conditions.
 Fuel injection valve: The microprocessor controls the fuel injectors to
precisely meter the amount of fuel delivered to the engine cylinders, ensuring
the ideal air-fuel ratio for various operating conditions.
In essence, the system works in a closed-loop manner: sensors gather data, the
microprocessor analyzes it and makes decisions, and actuators execute commands to
manage fuel delivery, ignition timing, and other engine functions for optimal
performance, fuel economy, and emission control
Microprocessor based Digital Camera:

Modern digital cameras use microprocessors to automate functions like focusing,

exposure, and image storage.
Fig. (a) shows a basic microprocessor-based camera system commonly found in
simpler cameras.
 When the shutter button is pressed, the range sensor sends information to the
microprocessor.
 The microprocessor calculates the lens position and drives a motor to move the
lens.
 Lens position is fed back to the microprocessor for fine adjustment.

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  Light sensor measures ambient light; the microprocessor controls shutter
duration or aperture opening.
 After the photo is captured, the microprocessor advances the film or stores the
image in memory.
 Effective for short to medium distances; less accurate for distant objects.

Fig. (b) shows a more advanced autofocus system used in modern or expensive
cameras.
 In this system, infrared (IR) pulses are emitted toward the subject and reflected
back to a separate masked detector.
 The microprocessor simultaneously moves the lens and the mask until the
reflected pulse passes through the mask slot and hits the detector.
 The detector sends a feedback signal to the microprocessor, which stops the lens
at the in-focus position.
 This feedback mechanism allows continuous adjustment and provides higher
accuracy than the simpler system in Fig. (a).
 It is suitable for longer distances and ensures precise focusing under different
conditions.
Mechatronics Approach:
 A mechatronics approach is a multidisciplinary system design method that
integrates mechanical, electronics, computer, and control engineering to develop
products and systems that are more efficient, flexible, and reliable than
traditional sequential designs.
Key Characteristics of the Mechatronics Approach
 Integration:
It combines mechanical, electrical, electronics, control, and computer
engineering into a single coordinated system.
 Concurrency:
Different engineering disciplines collaborate simultaneously from the early
stages of development.
 Holistic Design:
The entire system, including mechanical parts, electronics, sensors, software,
and control algorithms, is designed as a unified whole.
 Intelligence and Automation:
Sensors and feedback control systems are incorporated to create intelligent and
automated products.

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 Software-Controlled Systems:
Programmed software coordinates and controls all hardware components in the
mechatronic system.

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