Design of Mechatronic Systems - I | EveryEng

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Design of Mechatronic Systems - I

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950 min

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Why enroll

Participants join Design of Mechatronic Systems to develop a strong interdisciplinary skill set that is essential for designing modern intelligent and automated products. The course enables learners to understand how mechanical, electrical, electronic, control, and software components interact within a single system, allowing them to move beyond isolated domain knowledge to a complete system-level design perspective.

Many participants are motivated to gain practical competence in modeling, simulation, sensor and actuator selection, control system design, and embedded implementation—skills that are highly valued in industries such as robotics, industrial automation, automotive, aerospace, medical devices, and smart manufacturing. The course helps bridge the gap between theoretical concepts and real-world applications through structured design methodologies and practical case studies.

Participants also join to enhance their career prospects by acquiring industry-relevant expertise in mechatronics, preparing them for roles in product design, system integration, automation engineering, and R&D. Additionally, the course supports academic growth by strengthening fundamentals needed for advanced studies and research in mechatronics, robotics, and control systems, making it valuable for both students and working professionals.

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Is this course for you?

You should take this if

You work in Industrial Automation or Manufacturing & Industrial
You're a Mechatronics and Robotics / Mechanical Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Mechatronics and Robotics
You need live interaction with an instructor

Course details

Design of Mechatronic Systems is an interdisciplinary subject that deals with the systematic integration of mechanical engineering, electrical and electronic systems, control engineering, and computer-based intelligence to design and develop advanced engineering products and automated systems. The course adopts a holistic, system-oriented design philosophy, emphasizing how individual subsystems—mechanical structures, sensors, actuators, controllers, and embedded software—work together to achieve precise, efficient, and reliable system performance.

The course begins with an overview of mechatronic system architecture and the role of mechatronics in modern engineering applications such as robotics, industrial automation, automotive systems, aerospace, medical devices, and smart manufacturing. It introduces fundamental concepts of system modeling using physical laws and mathematical representations, including mechanical dynamics, electrical circuits, and electromechanical energy conversion. Participants learn to develop dynamic models and transfer functions, which form the basis for simulation and performance analysis.

A significant portion of the course is dedicated to sensors and actuators, covering principles of measurement, signal conditioning, and data acquisition. Various sensing technologies for position, velocity, force, pressure, temperature, and displacement are discussed, along with actuator types such as electric motors, hydraulic and pneumatic actuators, and smart materials. Emphasis is placed on selection criteria, interfacing, and practical limitations affecting system accuracy and responsiveness.

Control system design is a core component of the subject. Participants study classical and modern control techniques, including feedback control, PID tuning, state-space modeling, and digital control implementation. The course highlights how control strategies are integrated with embedded processors and real-time software to ensure stability, precision, and robustness under varying operating conditions and disturbances.

The course also addresses embedded system design and software development for mechatronic applications. Topics include microcontrollers, real-time operating concepts, communication protocols, and hardware–software co-design. System integration, prototyping, testing, and validation are emphasized to ensure that the final design meets functional, safety, and reliability requirements. By combining theoretical knowledge with practical design methodologies and case studies, the Design of Mechatronic Systems course equips participants with the skills required to conceive, design, and implement intelligent engineering systems in real-world applications.

source: NPTEL[youtube]

Course suitable for

Key topics covered

introduction of design of mechatronic systems
element of mechatronic systems
integrated mechanical-electronics philosophy
smart sensors concept
microprocessor memory and addressing

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

30 lectures15 hr 50 min

Course Introduction - Design of Mechatronic Systems
7 min
Introduction
43 min
Elements of Mechatronic Systems – Part I
28 min
Elements of Mechatronic Systems - Part II
36 min
Elements of Mechatronic Systems - Part III
25 min
CD-ROM Part I
36 min
CD-ROM Part II
21 min
Scanner
32 min
Integrated Mechanical-Electronics Philosophy – Part I
38 min
Integrated Mechanical-Electronics Philosophy – Part II
26 min
Smart Sensors Concept
22 min
Compliant Mechanisms
27 min
Microprocessor Building Blocks I- Combinational Circuits
31 min
Microprocessor Building Blocks II - Sequential Circuits
40 min
Microprocessor Memory and Addressing
33 min
Timing and control unit: Primitive Microprocessor
42 min
Microcontroller Architecture I
35 min
Microcontroller Architecture II
29 min
Microcontroller Programming Philosophy
25 min
Hardware Interfaces
41 min
Interfacing Actuator using PWM in Tiva Microcontroller
43 min
Interfacing Encoder using QEI in Tiva Launchpad + ISR
51 min
Mathematical Modelling: Overview and Context
36 min
Modelling Friction in a System
31 min
Modelling DC Motor with loads
39 min
Lagrange formulation fundamentals
29 min
Lagrange formulation examples
39 min
Dynamics: 2-R Manipulator
29 min
Control formulation: Regulation and Tracking
14 min
Fundamentals of Simulation of dynamics using MATLAB
22 min

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Questions and Answers

Q: You're reviewing a mechatronic actuator used on a turbomachinery inlet guide vane. The supplier proposes a polymer bushing substitution. The long-tail phrase embedded here is: "polymer bushing substitution safety margin trend analysis". The torque limiter is the named safeguard. Recent FAT data barely meets the written torque limit, but the last three tests show increasing breakaway torque. If the torque limiter is relied on as-is, what physical consequence is NOT prevented?

A: Stripped gears and a bent output shaft show up fast if you assume the limiter covers transient torque. The limiter reacts to average torque, not the cold-start spike driven by rising static friction, so it doesn't block that load path. The other effects are real but don't escalate into immediate mechanical damage.

Q: Your lead sends you a GA and wiring extract for a servo-controlled valve. The phrase embedded is: "how to read mechatronic GA drawing limit switch notation". The limit switch is shown twice: once on the GA and once on the instrument list. What's the inconsistency that would bite you during SAT?

A: A failed SAT with the valve refusing to enable is what happens if logic expects the wrong contact state. The control narrative depends on when that switch changes state, and a mid-stroke NC versus end-of-travel NO mismatch flips the permissive logic. The other issues are paperwork or installation nuisances, not functional blockers.

Q: You're asked to sign off a substitution on an electro-mechanical brake used for overspeed protection. The embedded phrase is: "IEC 61800 functional safety mechanical brake requirement". IEC guidance is cited. Why does the standard push for a defined mechanical holding margin instead of trusting the drive's torque control?

A: A runaway rotor damages bearings and seals long before alarms help if holding force fades. The standard leans on a physical margin since friction materials age and heat cycles move the numbers, and the margin keeps the brake effective across life. The other points are either overstated or not the driver behind the requirement.

Q: You're reviewing a safety chain where a spring-applied, electrically released brake is the named safeguard. The phrase embedded is: "spring applied brake failure cause consequence mechatronics". Test data passes the release force spec, but the trend shows slower release each run. What hazard does the brake NOT protect against?

A: Cooked windings and a tripped MCC are the outcome if the brake drags on start. The safeguard is great at holding load and blocking back-drive, but it doesn't prevent a slow-release condition that overloads the motor. The passing spec masks the trend until hardware suffers.