Industrial Mechatronics Course

Lesson 1 • System Integration Overview

Introduces the architecture of a complete mechatronic system and the interfaces between subsystems. Sets the integrative perspective reinforced in every subsequent chapter.

Lesson 2 • Mechanical Subsystem Fundamentals

Covers basic mechanical elements found in industrial machines. Connects mechanical behaviour to sensor and actuator selection in later chapters.

Lesson 3 • Electrical Fundamentals for Mechatronics

Reviews DC and AC circuit theory essential for powering and controlling mechatronic devices. Provides the electrical foundation for sensor and actuator chapters.

Lesson 4 • Introduction to Mechatronics Concepts

Defines mechatronics and its role in modern industry. Establishes vocabulary and system-thinking mindset used throughout the course.

Lesson 1 • Temperature and Environmental Sensors

Examines thermocouples, RTDs, and environmental detectors used for process monitoring. Reinforces signal conditioning concepts introduced in Chapter 1.

Lesson 2 • Sensor Principles and Classification

Explains transduction principles and sensor taxonomy. Grounds students in how physical phenomena are converted to electrical signals.

Lesson 3 • Force, Pressure, and Flow Sensing

Addresses strain gauges, pressure transducers, and flow meters common in industrial processes. Builds measurement skills applied in hydraulic and pneumatic chapters.

Lesson 4 • Sensor Calibration and Signal Conditioning

Teaches calibration procedures and analogue signal conditioning circuits. Ensures measurement accuracy before data enters the control system.

Lesson 1 • Electric Motor Types and Characteristics

Compares DC, AC induction, stepper, and servo motors by torque-speed behaviour. Provides the actuator knowledge base for drive and control chapters.

Lesson 2 • Motor Drive and Power Electronics

Covers H-bridges, variable frequency drives, and PWM techniques for motor control. Bridges electrical fundamentals to practical drive circuit implementation.

Lesson 3 • Hydraulic Actuator Systems

Explains hydraulic cylinders, motors, and valve control for high-force applications. Connects fluid power principles to system sizing and safety.

Lesson 4 • Pneumatic Actuator Systems

Addresses compressed-air cylinders, grippers, and control valves for fast, lightweight actuation. Prepares students for pneumatic circuit design exercises.

Lesson 1 • PLC Wiring, I/O Configuration, and Diagnostics

Teaches field device wiring, I/O addressing, and fault diagnostics. Prepares students for commissioning and troubleshooting real control panels.

Lesson 2 • Data Handling and Maths Instructions

Covers move, compare, and arithmetic instructions for data manipulation in PLCs. Enables students to implement setpoint control and recipe management.

Lesson 3 • Structured Text and Function Block Programming

Introduces IEC 61131-3 structured text and function block diagram languages. Expands programming versatility beyond ladder logic for complex algorithms.

Lesson 4 • Ladder Logic Programming Fundamentals

Introduces contacts, coils, timers, and counters in ladder diagram language. Provides the core programming skill set expanded in advanced PLC sections.

Lesson 1 • PID Controller Theory and Implementation

Derives proportional, integral, and derivative actions and their combined effect. Students implement PID blocks in PLC and simulate process responses.

Lesson 2 • Control System Stability Analysis

Uses Bode plots and gain/phase margin concepts to assess controller stability. Equips students to diagnose oscillation and instability in live systems.

Lesson 3 • Controller Tuning Methods

Applies Ziegler-Nichols, step-response, and auto-tune methods to set PID parameters. Develops practical tuning judgment for diverse industrial processes.

Lesson 4 • Open-Loop vs. Closed-Loop Control

Contrasts feedforward and feedback architectures using real industrial examples. Establishes why closed-loop control is essential for precision automation.

Lesson 1 • Network Diagnostics and Cybersecurity Basics

Introduces network diagnostic tools and fundamental cybersecurity practices for OT environments. Ensures students can identify faults and apply basic protective measures.

Lesson 2 • Industrial Communication Fundamentals

Explains OSI model layers, network topologies, and communication protocols relevant to automation. Provides the networking vocabulary used throughout this chapter.

Lesson 3 • Fieldbus Protocols and Wiring

Covers PROFIBUS, DeviceNet, and Modbus wiring, addressing, and configuration. Connects hardware installation skills to network commissioning tasks.

Lesson 4 • HMI Design and SCADA Integration

Teaches HMI screen development, alarm management, and SCADA data acquisition. Links field device data to operator visualisation and historical logging.

Lesson 1 • Coordinated Multi-Axis Motion Profiles

Programmes trapezoidal and S-curve velocity profiles for synchronised axes. Enables students to design smooth, high-throughput motion sequences.

Lesson 2 • Robot Kinematics and Workspace Analysis

Covers forward and inverse kinematics for articulated and SCARA robots. Establishes the geometric foundation for robot programming and path planning.

Lesson 3 • Robot Safety and Collaborative Applications

Addresses safety-rated monitoring, collaborative robot standards, and risk assessment. Prepares students to deploy robots safely alongside human workers.

Lesson 4 • Robot Programming and Path Planning

Teaches teach-pendant programming, offline simulation, and path optimisation. Develops practical robot programming skills for pick-and-place and welding tasks.

Lesson 1 • System Design Review and Documentation

Covers P&ID reading, electrical schematic review, and bill-of-materials verification. Ensures students can validate designs before physical installation begins.

Lesson 2 • Fault Diagnosis and Corrective Action

Applies structured troubleshooting methods to electrical, mechanical, and software faults. Integrates skills from all prior chapters into systematic fault resolution.

Lesson 3 • Preventive and Predictive Maintenance

Introduces scheduled maintenance tasks and condition-monitoring techniques such as vibration analysis. Shifts students from reactive to proactive maintenance strategies.

Lesson 4 • Panel Building and Field Wiring

Teaches control panel layout, wire routing, labelling, and field device termination. Develops hands-on wiring skills essential for commissioning activities.