Mod-5 22 Eme13
Mod-5 22 Eme13
Mod-5 22 Eme13
Module-5
1. Insight into future mobility technology: Electric and Hybrid Vehicles, Component of Electric
and Hybrid Vehicles. Advantages and disadvantages of Electric Vehicles (EVs) and Hybrid vehicles.
2. Introduction to Mechatronics and Robotics: open-loop and closed-loop systems. Joints &
links, Robot anatomy, Applications of Robots in material handling, processing and assembly &
inspection.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 1
Elements of Mechanical Engineering (22EME13/23)
INTRODUCTION
1. In recent years, Greenhouse gas problem increases day by day and also the gasoline fuel rate
increases nearly about 100 Rs/liters.
2. In daily life routine, public transportation is very important but the fuel rate, some people avoid
using bikes or cars. So, many automobile manufacturer and new companies put their effort to
convert the conventional vehicle into electric vehicle that provide reliable solution.
3. A vehicle is propelled with electric motors and draw power from onboard electric source is an
electric vehicle. It is more durable and mechanically simpler than gasoline vehicle. It gives more
fuel efficiency than gasoline because it does not produce emission like internal combustion engine.
4. Automobile industry is not completely moving towards pure electric cars because there is
inherent problem of existing batteries technology. For storing the electric energy, most common
storage device used in Electric vehicle is battery. It can store large amount of energy in a small
volume and weight.
5. The recent report shows that there were more vehicles running on a gasoline product in past few
years but now the report has been changed with increasing the usage of Hybrid and Electric vehicle.
Presently people are more inclined towards the Hybrid vehicle but the future will be totally based
on electrification.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 2
Elements of Mechanical Engineering (22EME13/23)
ELECTRIC VEHICLES
Motor: The main function of motor is to convert supplied electric energy current in to mechanical
energy. Brushless DC motor (BLDC) have been much focused for many motor manufacturers.
These are more effective in term of System cost, size, higher in efficiency, excellent controllability
and also power saving than other motor.
Motor Controller: Brushless DC motor does not have brush and commutator, the electric vehicle which uses
brushless DC motor has to use motor controller which helps to control various properties of motor to take
Sufficient current and voltage applied to motor.
Battery: The main function of battery is to store electric energy. Most electric vehicle uses lead
acid battery. But in new type of electric vehicles, use lithium ion batteries because it can store more
energy than lead acid battery in same physical space. The efficiency and life span of battery is far
better than other type of Batteries. .
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 3
Elements of Mechanical Engineering (22EME13/23)
Transmission System: The transmission system transfers mechanical power from the electric
motor to drive the wheels thus the Vehicle moves.
Drivers: A mechanical drive consists of the Fuel tank (containing conventional fuels like
petrol/diesel/CNG), the Combustion Engine, the gear box and transmission to the wheels. An
electric drive consists of the Battery, an electric motor and Power Electronics for control.
The figure 5.1 shows the simple construction of electric vehicle. It consists of battery, motor
controller, motor which is connected to the transmission system.
1. Battery is the energy source which is charged by taking electric current from the power
source or Solar Energy. (Batteries are rechargeable).
2. After that controller control the flow of energy from energy source to the motor.
3. Motor transmit the power to the wheels of the vehicle by the use of transmission system.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 4
Elements of Mechanical Engineering (22EME13/23)
1. Battery Electric vehicle: This consists of an electric motor which is powered by battery
connected to it. Electric motor is used for the movement in this type of vehicle. It does not
produce emission. In traffic, BEV delivers high torque to the wheels and smoother acceleration
than internal combustion Engine.
2. Hybrid electric vehicle: Hybrid electric vehicle is a combination of electric motor and new
traditional internal combustion engine. This vehicle can work with both electric and gasoline
powered vehicle. When electric motor stop giving power then switch into Fuel mode. In HEV
low speed mechanical electric motor used specifically in city traffic. When vehicle use electric
power, there is no emission.
3. Range extended electric vehicle: Range extended electric vehicle mostly designed to run by
the battery but have gasoline generator to recharge battery when charging is low.
1. No fuel, No pollution.
2. It requires less maintenance.
3. Total operation is noise free.
4. It generates high starting torque.
5. We can charge at home.
6. Less Running cost than gasoline powered vehicle.
7. It helps to save fossil fuels.
1. It is quite expensive.
2. Not for long range travelling because availability of less number of electric charging power
station.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 5
Elements of Mechanical Engineering (22EME13/23)
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 6
Elements of Mechanical Engineering (22EME13/23)
A hybrid electric vehicle is a type of hybrid vehicle which combines a conventional internal
combustion engine with an electric propulsion system. Or in a technical way, a Hybrid Electric
Vehicle is a type of technology which indulges both mechanical drive train and electric vehicle.
Classification of Hybrid Electric Vehicle
1. Series Hybrid 2. Parallel Hybrid 3.Series- Parallel.
Series Hybrid:
The traction power is delivered by the electric motor, while the internal combustion engine, via a
generator, produces electric power to drive the electric motor. The excess power is then stored in
the battery pack.
Disadvantage: The Internal Combustion Engine Energy is converted twice before to drive the
wheels. Thus the system is more expensive than the parallel one.
Parallel Hybrid:
There is direct mechanical connection between Internal Combustion Engine (ICE) , Transmission
system and the wheels. In addition, this layout has an electric traction motor that drives the wheels
with the help of battery.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 7
Elements of Mechanical Engineering (22EME13/23)
The series layout and the parallel layout are merged together in order to have both
advantages.
1. Environmentally Friendly : One of the biggest advantages of a hybrid car over a gasoline-
powered car is that it runs cleaner and has better gas mileage, which makes it environmentally
friendly. A hybrid vehicle runs on twin powered engine (gasoline engine and electric motor) that
cuts fuel consumption and conserves energy.
2. Lighter Vehicle: Lightweight materials are used to make hybrid vehicles so that the electrical
energy will be sufficient enough to move the vehicle. This means less dependency on the gasoline
engine.
3. Braking Helps Recharge Battery: When you step on the brake pedal in a hybrid vehicle, it will
activate a mechanism which gives the battery a little extra recharge. This allows there to be more
time before the next manual recharge that you need to perform.
4. Financial Incentives: The federal government provides a tax credit to residents of any state that
own or lease HEV.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 8
Elements of Mechanical Engineering (22EME13/23)
The term "mechatronics" was first assigned by Mr. Tetsuro Mori, a senior engineer of the Japanese
company Yaskawa, in 1969.
The word, mechatronics is composed of mecha from mechanics and tronics from electronics. In
other words, technologies and developed products will be incorporating electronics more and more into
mechanisms.
Definition: Mechatronics is the synergistic integration of sensors, actuators, signal conditioning, power
electronics, decision and control algorithms, and computer hardware and software to manage complexity,
uncertainty, and communication in engineered systems.”
The two types of control systems are the open-loop control system and the closed-loop control systems.
1. Open-loop system: Open loop system is kind of system, where the output doesn’t change the
action of the system. It doesn’t have any feedback. ( Fig 5.6)
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 9
Elements of Mechanical Engineering (22EME13/23)
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 10
Elements of Mechanical Engineering (22EME13/23)
1. Sprinkler used to water lawn: The system is calibrated for fixed area & water valve is opened for
sprinkling purpose, but No further valve Adjustments made.
2. Automatic Toaster System: Quality of toast is dependent upon time calibrated; Depending upon
time setting bread is simply heated. The toast Quality is judged by user & has no effects on
Inputs.
3. Traffic light Controller: Traffic control road is dependent upon time the traffic on road becomes
mobile or Stationary depending on sequence of lamp glow. Sequence & Time are controlled by
relays (pre-determined) & Not dependent on rush on road.
Traffic light Controller
4. Automatic Washing Machine: Washing of clothes dependent on time calibrated & sequence of
operation, the output expected is cleanliness of clothes. If not clean will not be cleaned again.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 11
Elements of Mechanical Engineering (22EME13/23)
a. The driver observes the speedometer, and based on the speed shown by the speedometer he decides
whether the fuel supply should be increased or decreased or gear change is to be made. ( Feed back)
b. A feedback signal from the eye compares the desired speed in the memory of the driver.
c. Error signals are given to brain. Brain manipulates the error signals and gives it ton hand and leg
and increase the fuel.
a. The overhead tank has a fixed float (sensor) fixed at the desired height inside the tanks.
b. When the level of water in the tank falls, the float moves down and makes contact with fixed
contactor and circuit is closed and pump is switched ON.
c. When the level of water rises the float moves up and breaks the circuit and pump is switches OFF.
Thereby the required level of water is maintained in overhead tank.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 12
Elements of Mechanical Engineering (22EME13/23)
Introduction to Robotics
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 13
Elements of Mechanical Engineering (22EME13/23)
Robots: Robots are Programmable, Multifunctional devices that are designed to move parts, tools and
Specified devices or to do work.
Robotics: Robotics is defined as study of Designing & developing of Robots for Automatic Manufacturing
& Non- Manufacturing applications.
Robot Anatomy
Simple robot construction is shown in fig 5.8 which consists of following parts
1. Base
2. Links
3. Joints
4. End Effectors.
Types of Joints
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 14
Elements of Mechanical Engineering (22EME13/23)
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 15
Elements of Mechanical Engineering (22EME13/23)
1. Cartesian configuration
2. Cylindrical configuration
3. Polar/Spherical configuration
4. Jointed-arm/Revolve configuration
1. Cartesian configuration :
a. This Type of robot has 3 linear motions.
b. One Linear joint (L) & 2 Orthogonal joint (O). – L,O,O
c. It has 3 Mutually Perpendicular Axis.
d. Rectangular Work space can be seen in this type of Robots.
e. This Robot is also called as Rectilinear Robot/ X-Y-Z Robot/ Gantry Robot.
Features of Cartesian Robot.
a. Provides Rectangular Work space
b. Arm movement is limited
c. High Precision & accuracy
d. Carries Heavy Loads
Applications: Use to lift and move heavy loads, Pick & Place Arrangement.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 16
Elements of Mechanical Engineering (22EME13/23)
Cartesian configuration
2. Cylindrical configuration :
a. This Type of robot has TLO Joints
b. One Linear joint (L), Orthogonal joint (O) & Twisting Joint (T) – T, L, O.
c. Orthogonal slides which allow the arm to move up/down & in/out with respect to
the body.
d. Cylindrical Work space can be seen in this type of Robots.
e. This Robot is also called as Cylindrical Robot.
Features of Cylindrical Robot.
a. Provides more work space than Cartesian Robots.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 17
Elements of Mechanical Engineering (22EME13/23)
Cylindrical configuration
3. Spherical configuration :
a. This Type of robot has TRL Joints
b. One Linear joint (L), Rotary joint (R) & Twisting Joint (T).
c. The robot has a rotary base and a pivot that can be used to raise and lower a
telescoping arm.
d. The workspace within which This Robot can move is a partial sphere.
e. This Robot is also called as Polar Configuration Robot.
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 18
Elements of Mechanical Engineering (22EME13/23)
Spherical configuration
4. Jointed Arm configuration :
a. This Type of robot has TRR Joints
b. Two Rotary joint (R) & Twisting Joint (T).
c. The robot resembles like human arm.
d. The workspace within which This Robot can move is a Quasi spherical space
Features of Jointed arm configuration Robot.
a. Flexibility to reach over or under an object.
b. Versatile Configuration
c. Larger Work space
d. Complex Programming
e. Less stable.
Applications: Pick & Place arrangement, spray
painting, welding
Automatic assembly.
Applications of Robot
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 19
Elements of Mechanical Engineering (22EME13/23)
ii. Machine unloading in which the raw materials are fed into the machine without robot
assistance. The robot unloads the part from the machine assisted by vision or no vision.
Example: bin picking, die casting, and plastic moulding.
iii. Both Machines loading and unloading that involves both loading and unloading of the
work parts by the robot. The robot loads a raw work part into the process ad unloads a
finished part. Example: Machine operation, Forging, Heat Treatment.
1. Assembly: Combination of two or more parts to form new object is called as Assembly. This
process of assembly is done by robots.
2. Inspection: Separation of Poor quality products from good ones. This is done by 3 methods
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 20
Elements of Mechanical Engineering (22EME13/23)
Advantages
1. Cost-Effectiveness
2. Improved Quality Assurance
3. Increased Productivity
4. Work In Hazardous Environments
5. Less time to complete jobs assigned.
Disadvantages
1. Potential Job Losses
2. Skilled staff required to operate robots.
3. Investment Costs is high
4. Lack of emotions.
1. What is hybrid Vehicles? How they are different from conventional Gasoline vehicles.
2. List the Advantages of Electric vehicles compare to conventional vehicles.
3. Describe how hybrid vehicles are differ from Electric vehicles.
4. With help a line diagram describe the working principle of Electric vehicle
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 21
Elements of Mechanical Engineering (22EME13/23)
INTRODUCTION TO MECHATRONICS
INTRODUCTION TO ROBOTICS
Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 22