https://matjournals.net/engineering/index.php/IJMDT en-US International Journal of Machine Design and Technology https://matjournals.net/engineering/index.php/IJMDT/article/view/3366 <p><em>The global manufacturing landscape is undergoing an unprecedented paradigm shift driven by the convergence of cyber-physical systems, artificial intelligence (AI), and advanced robotics, collectively catalysed by the Fourth Industrial Revolution (Industry 4.0) and its emerging successor, Industry 5.0. Mechatronics, as an integrative engineering discipline that synergises mechanical engineering, electronics, computer science, and control theory, occupies a pivotal role at the intersection of these revolutions. This study presents a comprehensive review of the evolving role of mechatronics in facilitating and accelerating the industry 4.0 to 5.0 transition, with particular emphasis on three critical technological pillars: the internet of things (IoT), AI-driven robotics, and autonomous control strategies. Through a systematic survey of literature published between 2015 and 2025, this review examines how IoT-enabled mechatronic systems achieve real-time sensing, edge computing, and bidirectional data exchange across heterogeneous industrial networks. The study critically analyses the deployment of machine learning algorithms, including deep reinforcement learning (DRL), convolutional neural networks (CNNs), and transformer-based architectures in intelligent robotic platforms and flexible manufacturing systems. Furthermore, it investigates autonomous control paradigms such as model predictive control (MPC), adaptive control, multi-agent coordination, and digital twin frameworks that enable self-organising, fault-tolerant manufacturing ecosystems. The review identifies key challenges encompassing interoperability standards, cybersecurity vulnerabilities, energy efficiency, human-robot collaboration (HRC), and ethical considerations in autonomous decision-making. It delineates the conceptual boundary between Industry 4.0 (efficiency-centric, data-driven automation) and Industry 5.0 (human-centric, resilient, and sustainable co-creation), mapping how mechatronic innovations bridge these paradigms. Case studies from automotive, aerospace, pharmaceutical, and smart logistics sectors are synthesised to illustrate real-world deployment trajectories. The paper concludes with a forward-looking research agenda identifying open problems, emerging technologies such as neuromorphic computing and soft robotics, and strategic recommendations for researchers, engineers, and policymakers. </em></p> Ujjwala Yedage Pranesh Bamankar Amita Mane Priyanka Jadhav Copyright (c) 2026 International Journal of Machine Design and Technology 2026-04-04 2026-04-04 15 31 https://matjournals.net/engineering/index.php/IJMDT/article/view/3060 <p><em>Existing conveyor systems struggle to handle varied plastic material properties, causing frequent jams and operational downtime. There is a need for a reliable screw conveyor machine that ensures smooth material flow, minimizes waste, and boosts recycling efficiency. This study outlines the development and implementation of a designed screw conveyor machine for efficient plastic recycling, featuring a 0.58m shaft length and powered by a 120W electric motor. The machine incorporates an A39 pulley (1.015m length, 0.0125m diameter) and a hexagonal bolt assembly with a 0.3302m length. A 2mm mild steel sheet was cut to the required size to form the screw conveyor hopper with a 0.0006m³ and the hopper seams were welded using the Oxy-acetylene technique. The screw conveyor unit features dual 1.2kW band heaters, totaling 2.4kW of heating power to ensure optimal plastic melting. The screw conveyor cylinder has a diameter of 0.12m. The hopper was further attached to the screw conveyor frame, ensuring proper alignment and secure attachment using the oxy-acetylene technique. A shaft and support were further attached to the screw conveyor with proper precision and alignment. A die was created at the end of the pipe to facilitate the easy flow of molten plastic using a machining process. A hand grinding machine was employed to smooth out rough edges or surfaces. Paint was further applied to prevent rust and corrosion. Performance results indicate a drive force of 11.88N, velocity of 0.042m/s, and a mass of molten plastic of 4.55kg. The screw conveyor capacity is 0.1912kg/s, demonstrating effective plastic processing capabilities. The developed machine offers improved material handling, reduced energy consumption, and enhanced recycling efficiency, contributing to sustainable plastic waste management practices. </em></p> Akaninwor, G. C. Sibete, G. A. Olisa Yemi Philip Copyright (c) 2026 International Journal of Machine Design and Technology 2026-02-03 2026-02-03 1 14