International Journal of Mechatronics and Manufacturing Technology

Authors: Amitesh K. Rawat, Sukanya Mahajan, Devansh Patel

Abstract: Circular manufacturing aims to minimize waste generation and maximize resource utilization through reuse, remanufacturing, and recycling of materials and products. Mechatronic systems, integrating mechanical structures, electronics, sensors, control, and intelligent software, play an important role in enabling automated circular processes. Modern recycling plants, smart disassembly lines, and remanufacturing cells depend on robotic manipulators, sensor-based sorting, adaptive control systems, and cyber-physical monitoring platforms. This paper presents a comprehensive review of mechatronic technologies applied in circular manufacturing and recycling industries. Key components such as sensor fusion, robotics, AI-enabled inspection, and automated material handling are discussed. System architectures for circular production loops and reverse logistics are analyzed. Applications in e-waste recycling, plastic recovery, metal remanufacturing, and component refurbishing are presented with case insights. Challenges like heterogeneity of waste, uncertain product conditions, and economic viability are examined. The study concludes that intelligent mechatronic integration significantly enhances efficiency, traceability, and sustainability of circular manufacturing systems, although further advances in adaptive perception and modular robotics are still required for large-scale deployment.

Keywords: Circular manufacturing, Recycling automation, Mechatronic systems, Smart disassembly, Remanufacturing, Sensor-based sorting

Authors: Shivraj Chautala

Abstract: Laser-assisted precision manufacturing systems have emerged as an important class of advanced production technologies for machining difficult-to-process materials and micro-scale components. By combining localized laser heating or modification with conventional machining or micromachining processes, these systems significantly improve material removal, surface integrity, dimensional accuracy, and tool life. Modern manufacturing sectors such as aerospace, biomedical, electronics, and energy increasingly demand highprecision parts with complex geometries and superior surface finish, which traditional machining alone often struggles to achieve. Laser-assisted systems address these challenges by altering the thermal and mechanical properties of workpiece material during processing, thus enabling efficient and damage-free machining. This paper reviews the working principles, system architectures, laser types, process mechanisms, and applications of laser-assisted precision manufacturing. The integration of lasers with CNC machines, robotics, and microfabrication platforms is discussed, along with recent developments such as adaptive beam shaping, femtosecond laser micromachining, and hybrid additive-subtractive processes. Advantages, limitations, and industrial case studies are also analyzed. Finally, future trends including AI-controlled laser systems and digital manufacturing integration are highlighted.

The review concludes that laser-assisted precision manufacturing systems represent a key enabling technology for next-generation smart factories and high-performance material processing.

Keywords: laser-assisted machining, precision manufacturing, laser micromachining, hybrid manufacturing, advanced materials processing

Authors: Rahul Bhandari , Binod Jaiswal

Abstract: Material handling is a critical component of modern manufacturing and logistics systems. Conventional conveyor systems rely on fixed programming and manual monitoring, which often leads to inefficiencies, errors, and higher operational costs. The integration of Artificial Intelligence (AI) in conveyor systems has introduced a new paradigm of intelligent material handling, allowing autonomous decision-making, real-time optimization, and predictive maintenance. This paper reviews recent advancements in AI-based conveyor systems, focusing on their architecture, control strategies, communication models, and industrial applications. It also explores challenges such as system integration, data security, and reliability. Case studies and simulation results demonstrate significant improvements in throughput, accuracy, and flexibility when AI conveyors are implemented. The findings indicate that AI conveyors can significantly contribute to smart factory initiatives, aligning with Industry 4.0 and beyond.

Keywords: AI conveyors, intelligent material handling, smart manufacturing, autonomous control, predictive maintenance, Industry 4.0

Authors: Ritu Sharma, Devanand Kulkarni, Meena Chaudhary, Arvind Tiwari

Abstract: Hybrid manufacturing systems combine additive manufacturing (AM) and subtractive manufacturing (SM) processes within a single platform or coordinated workflow to achieve high precision, geometric complexity, and surface quality. Additive processes allow fabrication of complex near-net shapes, while subtractive processes ensure dimensional accuracy and surface finish. This paper presents a comprehensive review of hybrid manufacturing technologies, system architectures, process planning strategies, material considerations, and industrial applications. Integration approaches such as single-machine hybrid platforms and sequential hybrid chains are discussed. Advantages like material efficiency, design freedom, and repair capability are analysed along with challenges including thermal distortion, toolpath planning, and machine calibration. Case studies from aerospace, biomedical, and tooling industries demonstrate the practical adoption of hybrid manufacturing. The study also outlines future trends including AI-assisted hybrid process planning and digital twin-based control. Hybrid manufacturing is expected to become a key enabling technology for Industry 4.0 and sustainable manufacturing systems.

Keywords: Hybrid manufacturing, additive manufacturing, subtractive machining, CNC-AM integration, process planning, repair manufacturing, Industry 4.0

Authors: Rajanish M , Vinay D L , Dibyanshu Jagnania , Garvit Sharma , Rinish Mehta , Ishaan

Abstract: In this work, Diglycidyl Ether of Bisphenol-A (DGEBA) / Tri-Ethylene Tetra Amine (TETA) system is used as the epoxy matrix and unidirectional glass fabric is used to reinforce the polymer matrix by hand layup and vacuum bagging process. The glass fibre reinforced composites panels are prepared with three different fibre orientations of 0°, 45° and 90°. The specimens, after preparation, are tested for impact properties at different angles of the laminate. To study the influence of the alumina micro-particles the second set of composites are prepared with alumina micro-particles filled epoxy and tested for the impact properties. The results have then been compared and studied to understand variation in the modification of matrix and the orientation of fibres in the composite. Results from this work have shown improved impact properties by the addition of alumina fillers in the matrix. Also, the impact properties were found higher in the longitudinal direction of the FRP composite due to the presence of fibres. Experimental procedures are carried out as per ASTM standards.

Keywords: GFRP, Bisphenol-A (DGEBA), Tri-Ethylene Tetra Amine (TETA), Micro-Particles

Authors:-Dip Kumar Saha, Md. Robiul Islam

Abstract:-Bearing is an essential component for every rotary mechanical and electromechanical system. It acts as an anti-friction element for the system that also helps to reduce energy consumption. Due to rapid industrial growth, the maintenance work has also been increased. To lessen production downtime and increase productivity management are much more focused on the maintenance section. That’s why condition-based maintenance is getting popularity day by day instead of traditional maintenance techniques. In condition monitoring, the bearing can play a vital role. As in maximum cases, the machine vibration is transmitted through the shaft that is passed through bearing, the fault analysis of bearing can be a good technique for machine condition monitoring purposes. This paper is here to evaluate the failure of ball bearing especially inner race fault under different operating conditions. The bearing data collected from the Society for Machinery Failure Prevention Technology (MFPT) is used to establish a suitable diagnosis technique. Alongside bearing defect analysis, this paper is also here to explain traditional condition-based maintenance techniques available for machine maintenance.

Keywords: Condition monitoring, Spectrum analysis, Spectral Kurtosis, Envelop analysis, Bearing Fault.

Authors: Rahul.M, DR.Sadiq.A, Prof. Shamnad.M

Abstract: The automated production processes grasping devices and method play a crucial role in the handling of many parts, components and products. There will be different type of grasping as well as releasing principles are used by the grippers. This includes the experimental study of a new contactless gripper. It generates air flow to create an upward lifting force. This force can be used to pick up a work piece placed underneath the gripper without any contact. In comparison with conventional pneumatic noncontact grippers, the uniqueness of the swirl gripper lies in that it is electrically (rather than pneumatically) activated. Study is being carried out for clarifying the mechanism of the gripper. The swirl gripper is under investigation considered and a better model is being generated for creating a better lift. The rpm is being considered as a major factor of study. The variation of pressure distribution according to rpm change is considered. The characteristics of the pressure distribution, based on experimental analysis on the swirling flow is conducted.

Keywords: Swirl, Grippers, Swirl Gripper, Noncontact gripper

Authors:-Hanuman Madhukar Tekale*, Prof. Dr. Ramkisan S. Pawar

Abstract:-This paper investigates the heat transfer enhancement in solid cylindrical and cylindrical with perforated fins in inline and staggered arrangement in rectangular channel. The channel had a cross-sectional area of 250-100 mm2. The experiments covered the following range: Reynolds number 13,500–42,000, the clearance ratio (C/H) 0, 0.33 and 1, the inter-fin spacing ratio (Sy/D) 1.208, 1.524, 1.944 and 3.417. Nusselt number and Reynolds number were considered as performance parameters. Correlation equations will be developed for the heat transfer and friction factor. Computational Fluid Dynamics analysis is done by using ANSIS FLUENT 14.5 software. The Numerical and computational analysis shows that the use of the cylindrical perforated pin fins leads to heat transfer enhancement than the solid cylindrical fins. Heat transfer Enhancement varies depending on the clearance ratio and inter-fin spacing ratio. Validation of Numerical and Computational Analysis will be done.

Keywords: - Heat Transfer, Cylindrical perforated Fins, Solid cylindrical fins, Staggered Arrangement, Nusselts number, Reynolds number Fins.

Author: Sahdev Thakur

Abstract: Human–robot collaboration (HRC) is becoming a core component of smart factories under the Industry 4.0 paradigm. Collaborative robots, or cobots, are designed to work safely alongside humans, combining human flexibility and intelligence with robotic precision and endurance. This paper presents a review of technologies enabling cobots in modern manufacturing environments, including sensing, control algorithms, safety systems, artificial intelligence, and human–machine interfaces. Applications across assembly, material handling, quality inspection, and logistics are discussed. The benefits such as productivity enhancement, ergonomic improvements, and workforce augmentation are examined, along with challenges like safety certification, human trust, skill requirements, and integration complexity. Case studies and industrial scenarios are analyzed to understand real-world deployment issues. The paper also highlights emerging trends such as AI-driven adaptive collaboration, digital twins, and cloud robotics. The review shows that cobots significantly improve flexibility and efficiency in smart factories but require multidisciplinary design approaches to ensure safe and effective interaction. Future research directions are suggested toward intelligent perception, intuitive programming, and ethical workforce integration.

Keywords: Human–robot collaboration, cobots, smart factories, Industry 4.0, collaborative automation, intelligent manufacturing

Authors: Tajamul Pasha , Hulagappa B , Tejasvi S , S M Khydas , Nizamudheen A , Rohan S

Abstract: Composites are made by addition of one or more materials combined at macroscopic level. By varying the percentage of composition of materials the strength and toughness can be obtained as per the end applications. The present work is to fabricate an E-glass epoxy composite using MY740 epoxy along with varying percentages of CaCO3 as filler material. The filler materials are added at different percentages of 2.5 wt% and 5 wt% and the mechanical properties such as tensile strength, impact strength, flexural strength and fracture toughness of the composites are determined. Using the graphs, the failure modes of the composites are determined. It is found that the addition of fillers increases the tensile strength, but decreases the impact energy. Varying strengths are obtained at Flexural and Fracture test based on the filler percentage and temperature. ANSYS modelling is carried out to verify the fracture toughness of the composite. The SEM analysis is also carried out to determine the failure at microstructural level.

Keywords: E-glass epoxy, CaCO3 fillers, Mechanical properties, Scanning Electron Microscope

Authors:-N.V. Athawale, Dr. R.S. Pawar, Prof. K.T. Patil

Abstract:-

Solar air Dryer (SAD) are used for drying agricultural products during sunshine periods but for drying products during off sunshine period the solar air dryers are equipped with latent heat storage medium. Various latent heat storage media are being researched by various scientist, engineers and scholars across the world.
In this paper the SAD equipped with and without reflecting mirrors on both side of collector and Acetamide as a latent heat storage medium is fabricated and thermal performance of Acetamide as a latent heat storage medium is checked by finding out values of 1) The temperature at various locations in SAD 2) The time duration of heat supply by Acetamide and 3) Time required to dry 250 gm of Potato chips. Experimental set up is placed towards south at Aurangabad (Maharashtra-India) with Latitude 19.817444, Longitude 284.6699, and Elevation 0.0.From the analytical results it is observed that the useful heat energy given by SAD with Reflecting mirrors is more than SAD without reflecting mirrors by 1.888 KJ. The temperature of drying chamber after sunset at 6:00 PM (When m= 0.064Kg/Sec) in SAD with PCM was 32 °C more than SAD without PCM. The present set up gives heat to product up to 3 hours after sunset. SAD with reflecting mirrors and PCM takes 3 hours less time to dry Potato slices up to safe moisture level than SAD without reflecting mirrors and PCM.

Keywords: Solar Air Dryer, Latent heat Storage medium, Acetamide, Reflecting mirrors, Potato chips, etc

Authors: Sumant Ughade , Hirmukhe S.S

Abstract: Generally, Vertical Pressure Vessels are efficient for tube sheet applications, however, in certain cases of space constraint, it is imperative to adjust and place a tube sheet horizontally. This creates an uneven stress distribution though, and as the filter sheets start clogging, gravity effects ensure that the sheets at bottom start clogging more than the ones on the top. This in turn means that the delta pressure on the bottom side is more than on the top side. Hence, along with the axial push that the filter sheet experiences, it will also have a slight bending component, and this combination will create a non-uniform stress profile on the assembly. The aim of this paper is to use FEA and determine limits on the non-uniform stress profiles for the operating conditions, so that safety equipments can be designed according to the outputs as per ASME code alarms.

Keywords: Pressure Vessel Design, ASME Code, FEA, Modal Analysis, etc.

Authors: Mashuka Jahan, Md. Shariful Islam

Abstract: Polymer materials such as Polycarbonate (PC), Polymethyl methacrylate (PMMA) and Polypropylene(PP) have numerous applications in armor which includes body and face shield, helmet, windows of the armored vehicle, car bumper etc. The most challenging part of these applications is to ensure the safety of the people. These materials are often subjected to impact loading, so it is important to study the failure of these materials under impact loading. In this paper, an analytical model is developed to predict the maximum impact force for low velocity impact and numerical simulation is carried out to predict the same for polypropylene material. The low velocity impact behavior of polypropylene is investigated up to the elastic limit by using commercially available software ABAQUS 6.13.The type of the simulation was explicit. The maximum force for 20J energy was 18.01 kN and the results are close to the theoretical values.

Keywords: Polycarbonate (PC), Polymethyl methacrylate (PMMA), Polypropylene(PP)

Authors: Prasenjit Chatterjee, M. Senthilkumar

Abstract: Control systems play a vital role in industrial automation by ensuring stability, accuracy and efficiency in dynamic processes. Among various control strategies, the Proportional–Integral–Derivative (PID) controller is widely used due to its simplicity, reliability and effectiveness in diverse industrial applications. This paper presents a comprehensive review of PID control systems in industrial automation. The study covers fundamental principles, controller tuning methods, industrial applications, implementation challenges and future advancements. Integration of PID control with modern technologies such as embedded systems, artificial intelligence and Industry 4.0 platforms is also discussed.

Keywords: PID Control, Industrial Automation, Feedback Systems, Process Control, Mechatronics

Authors: Dr. K. Raghavendra Prasad, Ms. Moumita Chatterjee

Abstract: Smart machines represent a transformative evolution in modern engineering systems, integrating sensing, actuation, computation and communication capabilities to achieve autonomous and adaptive behavior. Sensors and actuators form the fundamental building blocks of such machines, enabling perception of environmental conditions and execution of appropriate physical responses. This paper presents a comprehensive review of sensors and actuators used in smart machines, their working principles, classifications, applications, design considerations and integration challenges. The role of intelligent control, Industry 4.0 technologies, Internet of Things (IoT), and cyber-physical systems in enhancing smart machine capabilities is also discussed. Tables and schematic figures are included to provide conceptual clarity. The study aims to highlight future trends and research opportunities in smart sensing and actuation for next-generation manufacturing and robotic systems.

Keywords: Smart machines, Sensors, Actuators, Mechatronics, Automation, Industry 4.0

Authors: Dr. V. Sreenivasa Murthy, Ms. Rituparna Ghosh

Abstract: Mechatronics system integration represents a crucial engineering activity that enables the seamless interaction of mechanical components, electronic control units, embedded software and communication systems. With the rapid evolution of automation, robotics and smart manufacturing technologies, the need for efficient system integration techniques has become increasingly important. This paper presents a comprehensive discussion on mechatronics system integration techniques including hardware integration, software coordination, control architecture design, communication networking and real-time implementation. The paper also highlights modern integration approaches such as cyberphysical systems, digital twins and Industry 4.0 frameworks. Conceptual tables and schematic 2D figures are included to provide clear visualization of integration strategies. Challenges, design considerations and future research directions are also explored.

Keywords: Mechatronics integration, System architecture, Automation, Control systems, Industry 4.0

Authors: Arindam Bhattacharya, S. Karthikeyan

Abstract: Machine vision systems have emerged as a fundamental component of modern automated manufacturing environments for quality inspection and defect detection. These systems integrate optics, sensors, embedded processors and intelligent algorithms to enable real-time monitoring and evaluation of product quality. This paper presents a comprehensive study on machine vision technologies applied in industrial quality inspection. The architecture, components, inspection techniques, image processing methods, artificial intelligence integration and challenges are discussed in detail. Furthermore, recent trends such as deep learning-based inspection, edge vision systems and smart factory integration are explored.

Keywords: Machine Vision, Quality Inspection, Image Processing, Industrial Automation, Mechatronics, Deep Learning

Authors: Dr. P. Lakshminarayana, Ms. Debolina Banerjee

Abstract: Artificial Intelligence (AI) has emerged as a transformative technology in the field of mechatronics, enabling machines to perform intelligent decisionmaking, adaptive control and autonomous operation. The integration of AI techniques such as machine learning, neural networks, fuzzy logic and computer vision into mechatronic systems has significantly enhanced system performance, reliability and flexibility. This paper presents a comprehensive analysis of AI applications in mechatronic systems including intelligent sensing, predictive maintenance, robotic control and smart manufacturing. Various system architectures, design methodologies and implementation challenges are discussed. Conceptual tables and schematic 2D figures are provided to illustrate AI integration frameworks. Future research directions focusing on edge intelligence and collaborative robotics are also highlighted.

Keywords: Artificial Intelligence, Mechatronics, Machine Learning, Robotics, Smart Manufacturing

Authors: Rakesh P. Deshmukh, Nidhi S. Borkar, Aman D Verma

Abstract: Tele-operated manufacturing allows human operators to control machines and robots at remote or hazardous locations. However, lack of physical sensation in remote manipulation reduces precision, increases cognitive load, and causes operational errors. Haptic feedback systems address this limitation by providing tactile and force information to the operator, thereby improving perception of contact, stiffness, and texture during remote tasks. This paper reviews the architecture, technologies, and applications of haptic feedback in tele-operated manufacturing environments. The study discusses kinesthetic and tactile feedback methods, actuator and sensor technologies, control strategies, and stability challenges due to communication delay. Applications such as remote machining, robotic assembly, welding, and hazardous material handling are analyzed. Advantages including improved dexterity, safety, and training effectiveness are highlighted, along with technical challenges such as bandwidth limitations, device ergonomics, and system integration complexity. Future directions involving virtual reality integration, AI-assisted haptics, and digital twins are also explored. The review concludes that haptic-enabled teleoperation will be a key enabler for Industry 4.0 and smart manufacturing, particularly in remote, space, underwater, and nuclear industries. Keywords: Tele-operation, haptic feedback, remote manufacturing, force feedback, tactile sensing, human–machine interaction, smart factories, robotics

Authors: Anita Rawat, Rakesh P. Sharma, N. K. Verma

Abstract: High-precision actuators are essential components in modern engineering systems such as micro-robotics, biomedical devices, precision manufacturing and aerospace mechanisms. Conventional actuators based on electromagnetic or hydraulic principles often face limitations in miniaturization, resolution and response speed. Smart materials such as piezoelectric ceramics, shape memory alloys (SMAs), magnetostrictive materials and electroactive polymers (EAPs) have emerged as promising candidates for next-generation precision actuation. These materials possess intrinsic coupling between electrical, thermal or magnetic fields and mechanical deformation, enabling compact actuators with high positioning accuracy. This paper reviews the design principles, material characteristics and modeling approaches for high-precision actuators using smart materials. Different smart material classes are compared in terms of strain capability, response time, force density and controllability. Design strategies including multilayer structures, flexure amplification mechanisms and hybrid actuation are discussed to overcome limitations such as small stroke and hysteresis. Applications in micropositioning, adaptive optics and surgical instruments are also presented. Challenges such as nonlinear behavior, temperature sensitivity and long-term reliability are analyzed. The review concludes that smart-material-based actuators can achieve nanometer-scale resolution and high bandwidth when properly designed, though cost and durability still require improvement.

Keywords: Smart materials, high-precision actuators, piezoelectric actuator, shape memory alloy, magnetostrictive actuator, micro-positioning, adaptive structures

Authors: Rekha Pandey¹, Depesh Kulkarni², Mohit Pratap Singh, Ayesha Khanna

Abstract: Force-controlled robotic assembly is becoming very important in modern automated manufacturing where precision and adaptability are required. Traditional position-based robotic assembly often fails in tasks involving uncertainty, part variation, or contact-rich interactions such as insertion, fastening, and fitting. Force control allows robots to regulate interaction forces during contact, enabling safer and more accurate assembly. Recently, machine learning techniques have been introduced to improve adaptability and learning capability in force-controlled assembly systems. These approaches allow robots to learn contact dynamics, predict force responses, and optimize assembly strategies from data rather than relying only on rigid models. This paper reviews the principles of force-controlled robotic assembly and discusses how machine learning methods such as neural networks, reinforcement learning, and hybrid approaches are applied. Challenges like sensor noise, data requirement, and real-time computation are also analyzed. Applications in smart manufacturing, electronics assembly, and collaborative robots are presented. The review highlights that machine learning significantly improves robustness and flexibility in robotic assembly, although practical deployment still requires addressing reliability and safety issues.

Keywords: force control, robotic assembly, machine learning, reinforcement learning, smart manufacturing, contact dynamics

Authors: Khim Singh Negi , Rajeevranjan Tiwari

Abstract: The rapid development of autonomous machines such as drones, mobile robots, and smart vehicles has created a growing demand for self-powered sensing technologies. Traditional sensors rely on batteries or external power sources, which limit operation time and increase maintenance requirements. Energyharvesting sensors (EHS) provide a promising solution by converting ambient energy, such as mechanical vibrations, thermal gradients, solar radiation, or radiofrequency signals, into electrical energy. This paper reviews the state-ofthe-art in energy-harvesting sensors for autonomous machines, discussing various energy-harvesting mechanisms, integration strategies, and performance metrics. The paper also examines challenges, recent advances, and potential applications in robotics, industrial automation, and wearable devices. Case studies demonstrate the practical impact of EHS on improving the autonomy and reliability of machines. Finally, future directions for research are proposed to enhance energy efficiency and sensor integration.

Keywords: Energy-harvesting, autonomous machines, self-powered sensors, piezoelectric, thermoelectric, triboelectric, robotics, IoT.

Authors: Raman Tripathi , Sanjay Chaudhary

Abstract: Industry 5.0 is emerging as the next evolution of manufacturing, emphasizing human-centric, sustainable, and resilient production. Cyber-Physical Production Systems (CPPS) form the backbone of Industry 5.0 by integrating physical production systems with advanced computational intelligence, data analytics, and real-time connectivity. This paper presents a comprehensive review of CPPS technologies, architectures, and applications in Industry 5.0. It examines the integration of humans, robots, and AI-driven systems for collaborative and flexible manufacturing, highlighting key benefits, challenges, and future research directions. The study also proposes a framework for CPPS implementation in human-centric production lines, supported by illustrative tables and figures.

Keywords: Industry 5.0, Cyber-Physical Production Systems, Human-Robot Collaboration, Smart Manufacturing, Digital Twin, IoT, Resilient Manufacturing

Authors: Ketaki G. Dabade  , Neha H. Mahajan , Ruchi D. Patil , Sayali S. Ingawale ,Tanaji B. Shinde

Abstract: In past few decades there have been rapid advances in Nano-technology which have led to emergence of neophyte generation of heat transfer fluids called “Nano-fluids.” These fluids contain suspension of nanometer sized (1- 100nm) particles to enhance thermodynamic and physical properties. Nanolubricants are a special type of nano-fluids which are mixture of nanoparticles in base oil to improve heat transfer and energy efficiency in several areas including automobile, nuclear, space and power generation. This paper presents the application of nanoparticles in various corners of engine, so the performance of engine can be improved. We have presented the several conclusions which were made by different researchers by doing some experimental work. Some of the researchers worked on Radiator, some of them on lubricant and some of them are worked on heat recovery. These reviews will help to finding out the new gaps and technology to improve better I.C. engines in coming era.

Keywords—: Nanotechnology; Nano-fluid; Thermodynamic and physical properties; Thermal conductivity