Mechatronic Design Project: Industry 4.0 and Shaft Design

This mechatronic design project addresses several key areas within mechanical engineering and the context of Industry 4.0. The assignment begins with an essay exploring the relationship between mechatronic design and the trends in manufacturing, specifically Industry 4.0, discussing the definition of mechatronic design, Industry 4.0, the contribution of mechatronic design to Industry 4.0 and future of mechanical and mechatronic engineering. The project then proceeds with a detailed analysis of rotating shafts, including force and stress analysis, material selection, and design considerations for various load conditions. The assignment requires the student to specify suitable materials for the shaft, perform force analysis, stress analysis, and determine shaft geometry while considering design factors. The project also includes gear and power transmission system analysis. The final part of the project involves a detailed design of a drive system used in a coal crushing and conveying system, including force analysis, torque, shear, and bending moment diagrams, and shaft diameter calculations. The project encompasses multiple aspects of mechanical design, material selection, and engineering analysis in the context of real-world applications.

MECHATRONIC DESIGN
By Name
Course
Instructor
Institution
Location
Date

q = 466
Question 1 (1.5/10):
Mechatronics is a method used in the optimization of the design of electromechanical products and
encompass technological principles among them thermodynamics, computer science, electrical
engineering as well as mechanical engineering among others. Mechatronics is a philosophy of design,
an integrating approach to design in engineering. The main factor is mechatronics is the inclusion of
such areas through the process of design. Through a method of simulation of interdisciplinary ideas and
methods, mechatronics offers ideal conditions for increasing the synergy, hence offering a catalytic
impact for the new solutions to situations that seem technical complex. Mechanics design is supportive
of the concepts of the concurrent engineering (Rüßmann et al., 2015).
It is of importance that the knowledge as well as information needed during the design of a mechatronic
product be properly coordinated among various groups of experts. The mechatronic design process is
composed of three stages of phases including modeling and simulation, deployment as well as
prototyping. All modelling depending on the first principles or otherwise the more detailed physics
ought to be more modular within the structure.
Industry 4.0 defines a subset of the fourth industrial revolution which concerns industry. The fourth
industrial revolution is composed of areas that are not often grouped as industries among the smart cities
for example. In as much as the term industry 4.0 and the fourth industrial revolution are normally used
interchangeably, industry 4.0 defines the concept of factories where machines are augmented using
wireless connectivity as well as sensors, linked to a system which may visualize the whole production
line, making decisions and control on its own (Zhong et al., 2017). In a nutshell, industry 4.0 provides a
description of the trend towards data exchange as well as automation in manufacturing technologies as
well as processes that are inclusive of cyber-physical systems, industrial internet of things, the internet
of things, cognitive computing, cloud computing as well as artificial intelligence. The concept is
inclusive of:
 smart factory
 smart manufacturing
 light out
 industrial internet of things
Taking into considering the Industrial revolution 4.0 as the being the integration of IoT, cloud
computing, big data and encompasses AI at various levels, finally, mechatronics designs may still hang
up on one of the corner fields. So the result is that mechatronics design process may contribute by
allowing an interaction design process at the front of the computer as well as individual devices itself
might be informative on which might be the missing parts or those that have issues on their areas of
working and hence provide an opportunity for development of consent towards handling the same.
By default of what these engineering and engineering system are, their future tend to be quite bright
(Stock and Seliger, 2016). They are already famous and are anticipated to gain more fame in the
foreseeable future. Mechatronics for instance is the field that deals with integration of electronics and
mechanical principles into one device. This term defines a system that had already incorporated the two
branches in within an effective manner. This as well exemplifies that an ideal mechanical segment
having poor electronics would in the end result in an entirely poor system.

Question 2 (1.5/10):
Figure 1-1 shows a rotating shaft carrying two steady loads F1 and F2 at C and D, respectively, which is
supported by two bearings at A and B, respectively. The detailed graph near the location B shows the sizes
of the shaft at its different portions AB and BC as well as the radius of the fillet in the shoulder.
For this direct design problem, as the mechanical engineer, you are only required to specify a suitable material
to the shaft via a design analysis (Force Analysis and Stress Analysis), considering the value of external loads,
and a design factor of 2.0 + q/1000.
Figure 1-1 A rotating shaft carries two steady loads
254 + q/100 mm
127 + q/200
mm
D
F2 = 800 +
q/100 (N)
152
+ q/100 mm
F1 = 400 +
q/100 (N)
25.4
mm
35.05
mm
1.52 mm

254+
q/100
mm
254 +
q/100
mm
152.4 +
q/100
mm
254 mmdia.
406.4 mm dia.
Question 3 (3/10):
Figure 1-2 A shaft as a part of a drive for an automated transfer system in a metal stamping plant
The shaft in Figure 1-2 is a part of a drive for an automated transfer system in a metal stamping plant. The
shaft rotating at 400 + q/100 rpm carries a spur gear B having 96 teeth with a diametral pitch of 6 (the
number of teeth per inch of pitch diameter). The teeth are of the 20°, full-depth, involute form. Gear Q
delivers 15 + 0.q kW to gear B, Sheave D delivers the power to its mating sheave as shown. Use AISI 1040
cold drawn steel.
You are required to:
a) Carry out a force analysis to determine the forces including acting on the shaft at all power transmitting
elements
b) Compute reactions at the bearings
c) Draw the complete torque, shear, and bending moment diagrams
d) Give a suggested geometry at point C of the shaft and specify the minimum acceptable diameter for the
shaft at this point with implementing a design factor of 2.5 + q/1000.
Neglect the weight of the elements on the shafts, unless otherwise noted.