It began as the integration of mechanisms with electronics. Since then, mechatronics has evolved, and for all practical purposes, includes nearly every engineering discipline.

By Andy Urda, Director Channel & Industry Marketing

Yaskawa Electric

In 1953, Yaskawa Electric began its active role in advancing technology in the field of motion control when the company introduced its servo motor line, the Minertia® Motor (named for minimum inertia). These servomotors made rotation exact to the proportion of conduction. Due to their very low inertia, they handle extremely fast starts and stops. Originally, they were applied to electrical actuators for the control of mechanical arms. Today, they are also found in many industrial automation applications. Yaskawa’s signature phrase of the late 1960’s and early 1970’s was “Mochintrol,” which was created from the combination of motor, machine, and control. Mochintrol became a registered trademark for the company in 1971.

In 1969, though, Yaskawa engineers took a completely different look at machine control. They were looking for a way to describe the trend of organically joining mechanisms with electronics. The result was the term “Mechatronics.” Yaskawa applied for a registered trademark for this term on August 26, 1970. It was registered on January 22, 1973.

However, the engineers and managers felt too far ahead of the time and did not spread the term. It wasn’t until the debut in 1987 of the magazine “Mechatronics” issued by Gicho (The Technical Investigations Society) that their concern changed. As the term gained widespread use, rather than contribute to confusion that might ensue if they persisted in maintaining exclusive rights to the term, Yaskawa chose to relinquish its trademark rights.

The Evolution of “Mechatronics”
Industrial networks grew out of the merging of mechanisms and electronics. Mechatrolink was inspired by Mechatronics. This high-speed motion control interface between machine controllers, servos, and variable frequency drives also moves data among third party controllers, sensors, I/O, and test and measurement devices.

Industrial networks grew out of the merging of mechanisms and electronics. Mechatrolink was inspired by Mechatronics. This high-speed motion control interface between machine controllers, servos, and variable frequency drives also moves data among third party controllers, sensors, I/O, and test and measurement devices.

The word Mechatronics has now reached global usage. It is the defacto term used to describe the blending of mechanical and electrical apparatus, as well as the inclusion and integration of computers, control systems and software with that apparatus. A Google search yields pages of links of companies with Mechatronics as part of their name. Such a search also brings up a number of colleges with courses focused on the subject. One educational and research site is that of the Mechatronics Research Unit, (MRO), which is currently working on a project known as the Elektroadhesive Robot Microgripper. This gripper can handle components less than 1 mm in diameter.

The term Mechatronics, though, continues to evolve. From describing a list of engineering disciplines that are brought to bear on a design, the term now includes how these engineering disciplines affect the manufacture, transport, and consumption of products. What was created to describe the synergy of electromechanical components on the factory floor has now moved to describe the synergy of engineering into everyday life.

Perhaps the best example of this is the modern automobile and its increasing number of control systems. According to a 2000 report from The Competitive and Sustainable Growth (GROWTH) Programme, a European research group, “The demand for ever-increasing safety and comfort, from ABS brakes to electric seats, has increased the number of electric motors in a typical car to 40. Future cars may contain upwards of 100 electric motors.”

Managing these electric motors are semiconductor chips with embedded control functions. The number of semiconductor chips used in cars is up an average of 8%. A typical car has over two hundred dollars worth of control chips, whereas the average cell phone has less than ten dollars1. A common application is car safety, such as vehicle stability control. A system of sensors and components detect when a car begins to lose stability. They send data to the control chips, which then work to prevent the car from rolling over. Other safety-oriented projects in development include sensors that alert a driver when it is safe to change lanes. Mechatronic technology also enables drive-by-wire functions, replacing traditional mechanical and hydraulic control systems with electromechanical actuators and human-machine interfaces, such as pedal and steering-feel emulators. In many cases, the steering column, intermediate shafts, pumps, hoses, fluids, belts and brake boosters and master cylinders can be eliminated from the vehicle. However, the challenge for automotive engineers is to use robust systems that are safe and reliable. Some question the wisdom of moving away from “time tested” mechanical and hydraulic systems to mechatronic systems that rely on chips and software that might fail. Anyone that has had their steering linkage or brakes go out in a moving car can appreciate these concerns. Therefore most car makers are looking at secondary systems such as parking brakes to prove this control concept before making wholesale changes to traditional components2.

Mechatronics and robotics

The robotics field continues to be a hotbed of development for mechatronic systems. Demonstrating their usefulness in non-industrial fields is the RoboBar, from Motoman. Handling bartender duties, this two-armed robot mixes and pours your favorite cocktail.

The robotics field has been the best showcase for mechatronics capabilities and benefits. Although it is not specifically mentioned on most mechatronics illustrations, some consider the robot to be the poster child for the Mechatronics Revolution in modern manufacturing. Robots have replaced humans in many dangerous and repetitive tasks. Along with other applied mechatronic approaches, they have allowed companies to stay in America and compete with inexpensive labor from other areas of the world.

Today mechatronics systems are mostly in factory automation and process automation fields. The advent of industrial computers, dedicated controllers and supervisor PCs have given operators “real-time” control and feedback. Variable speed drives on power conveyors move products along at high speeds. Smart sensors recognize patterns, and vision systems determine if a product is good or defective. Feedback is instantly transmitted to the control system to signal a servo-based actuator to remove the defective part. All production data are available to management regardless of where in the world these data were generated.

Industrial networks grew out of the merging of mechanisms and electronics. The idea of data moving through devices, machines, process and whole factories was initially developed by General Motors and Boeing in the early 1980s and resulted in the Machine Automation Protocol (MAP). The dream was to have a global standard that would interconnect all machines and processes, allowing “real-time” monitoring and control on the factory floor. MAP was not the answer, and some would say that a true open standard is yet to be achieved. However, several communication systems go a long way toward enabling effortless transmission of data, including Ethernet.

Some networks have grown from a focus on one finite task to encompass more functions. One example is Mechatrolink, inspired by Mechatronics itself. It is designed as a high-speed motion control interface between machine controllers, servos, and variable frequency drives. It has moved up in capabilities to work with third party controllers, sensors, I/O, and test and measurement devices.

The Future of “Mechatronics” Several development projects have the potential to spread the application of Mechatronics, with some key to unlocking the next generations of discoveries. One emerging area is Nanotechnology, also known as Microelectromechanical Systems (MEMS), “Nanoelectromechanical” Systems (NEMS), or “Nanomechatronics Systems” (NMS).

No longer bolted to the ground, the Honda ASIMO robot is humanoid in shape and can run. ASIMO is short for “Advanced Step in Innovative Mobility.”

In the medical field, these minuscule mechatronics wonders are being researched and tested to do what conventional medicine cannot do today. For example, science is investigating micro sized MEMs that can be injected into a person’s body to deliver treatment for an illness. Other engineers are investigating their use in fields from appliances to wind powered devices. The robotics field continues to be a hotbed of development for mechatronic systems. The use of such systems enables robots that are more human-like in appearance and capabilities. It first started with industrial robots tasked with doing non-industrial jobs, such as a bartender. Motoman’s RoboBar is an example. This two-armed robot mixes and pours your favorite cocktail.

Now, however, robots exist that are not bolted to the ground. Honda has ASIMO, short for “Advanced Step in Innovative Mobility.” ASIMO is unique in that it is humanoid in shape and can run. In the future, more robots will become part of our daily lives. As the current “baby boom” population ages, the need for assisted living and other care giving holds great promise for the future of consumer robotics.

Forecasting has its risks, but if trends stay true, mechatronics will play a big part in how we will do our work, enjoy our play, and heal our illness.

Yaskawa Electric – www.yaskawa.com

* www.honda.com
* www.motoman.com

Footnotes

* http://semico.com/mediacov/mar05_SemicoMediaCoverage_03-17-05_AZRepublic.pdf
* http://www.worldwidewords.org/turnsofphrase/tp-dri1.htm
* World Wide Words © Michael Quinion, 1996–2007.