Mechatronic Control Research Articles

Mechatronic module design of the control system for the tractor gearbox

This article describes the mechatronic control device for the manual gearbox system and points out disadvantages of the transmission controls located in the operator’s cab. The block diagram of the gearbox control unit is presented. The choice of the device elements is proved. PETG plastic part models of the mechatronic module printed on a 3D printer are proposed. The technical characteristics of the mechatronic module of the gearbox control system for the transport and technological vehicle are described.

Технология диагностирования транспортных средств

In the article, using the example of a mechatronic control system for the engine and transmission of vehicles (automobiles), the features of the technology of their diagnosis are shown. In an electronic transmission control system, the object of regulation is mainly an automatic transmission. Also, the laws of control (programs) of gear shifting in an automatic transmission ensure the optimal transfer of engine energy to the wheels of the vehicle (TC), taking into account the required traction and speed properties and fuel economy. At the same time, the programs for achieving optimal traction-speed properties and minimum fuel consumption differ from each other, since the simultaneous achievement of these goals is not always possible. Therefore, depending on the driving conditions and the desire of the driver, using a special switch, you can select the "economy" program to reduce fuel consumption, the "power" program - to improve traction and speed properties, or the "manual" program to switch gears by the driver. In turn, self-diagnostic capabilities include: system identification and electronic control units (ECU) (ECU); recognition, storage and reading of information about static and single malfunctions; reading current real data, including environmental conditions and specifications; modeling of system functions; programming of system parameters. The individual programs for the test block are stored in the plug-in modules, while the correction and data transfer in the system is carried out via the data interface. Note also that the diagnostic process begins with the initialization of the systems - their detection in the electrical equipment of the vehicle. Upon successful initialization, it is possible to: read the error memory; erase the error memory; view the data of the next detected system or exit to the main menu; change the readings of the selected category; correct the current time; correct the current date and perform a number of additional functions.

Trier separator of seed material of small seed oil crops

The purpose of the research is to analyze the terrier separators of seed seeds of small-seeded crops and to develop an appropriate mechatronic control system, the use of which will perform the separation process with lower specific operating costs and higher productivity. The presented analysis of the technical support of the process of separation of seed material of small-seeded crops allows to assert the need to improve trier separators based on automated control of their parameters using photo or video recording of the process of separation of seed material with further processing. It is established that the definition of formal performance indicators of a cylindrical honeycomb trier is not trivial. The article develops a structural and technological scheme of a mechatronic system of a trier separator. The difference between the proposed system and the traditional one is that the camera fixes the trajectory of the seed flight. This information is processed in the control unit, which in turn changes the speed of the gear motor and, as a consequence, the drum with cells, the tilt angle of the tray, the angle of rotation of the damper with the stepping motor of the metering hopper. These manipulations with the operating parameters of the indented separator make it possible to adjust it to changes in the composition of the seed mixture, thereby increasing the quality of separation. In addition, due to the automatic adjustment of the operating parameters of the indented separator, the participation of the plant operator in the separation process is practically leveled, which reduces labor costs.

АВТОМАТИЧЕСКИЕ ТРАНСМИССИИ. КОМПЛЕКС АЛГОРИТМОВ ТЕХНОЛОГИИ «CLUTCH-TO-CLUTCH SHIFTS»: АНАЛИЗ АРХИТЕКТУРЫ, ОБОБЩЕННАЯ СТРУКТУРА, РАЗВИТИЕ. ЧАСТЬ 2

The article continues the series of the author publications, which considers the main provisions of the “Clutch-to-Clutch Shifts” (CTC) technology — technology for automatic controlling the switching of automatic transmission (AT) stages, used in the global mass production of vehicles, hybrid and battery electric vehicles. It provides high-quality shifts, brought to the level of continuously variable transmissions. Development of power units in recent years has led to a rapid increase in the number of AT stages, which is accompanied by a complication of kinematic schemes, designs, control algorithms and, in general, an increase in the role of mechatronic control systems (MCS) in ensuring their high technical level. Effectiveness of the CTC technology depends on the perfection of the algorithms used. But their composition is not specified, which, with a large amount of information, makes it difficult for potential users to navigate in this set. In this paper, we propose (for the first time in the Russian language) the generalized structure of a set of standard algorithms necessary for the implementation of this technology in the AT MCS, which is developed on the basis of their selection from a pre-formed database of patents and publications on the theory and technology of AT control, following classification and grouping by functional purpose. For each item of the structure, there are links to patents with matching names. Detailed descriptions of several typical CTC algorithms in the AT MCS of General Motors patents are given.

Mechatronic Control Devices for a Modern Ship’s Magnetic Compass

One of the disadvantages of existing main magnetic compasses (МС) is the presence in their readings of an error from pitching due to the influence of centripetal and tangential accelerations when the MC is placed at a certain distance from the center rocking of the ship. This error can be unacceptably large, especially when using the compass in high latitude environments. This effect can be compensated by using a gyroscopic angular rate sensor (ARS), which measures the angular yaw rate of the ship. The work is devoted to the results of research and simulation of two correction system, which is introduced into the measuring circuit of the MC. Each of the correction systems presented in this work can be considered as mechatronic control device for a modern MC, one of them is positional, and the other is according to the angular yaw rate of the ship. The paper shows the advantages and disadvantages each of systems. So, a feature of the positional correction system is the need to use ARS of a tactical accuracy class (for example, a fiber-optic gyroscope). At the same time, the yaw rate correction system makes it possible to use a cheap micromechanical gyroscope (MMG). Despite the use ARS of various accuracy classes, both proposed correction systems allow achieving similar results, which leads to an obvious conclusion about the advisability of using the correction system with MMG, which allows to significantly reduce the cost of the MC, as well as to reduce its weight and dimensions.

Автоматические трансмиссии. Комплекс алгоритмов технологии «Clutch-to-Clutch Shifts»: анализ архитектуры, обобщенная структура, развитие. Часть 1

The article continues the series of the author publications, which considers the main provisions of the “Clutch-to-Clutch Shifts” (CTC) technology — technology for automatic controlling the switching of automatic transmission (AT) stages, used in the global mass production of vehicles, hybrid and battery electric vehicles. It provides high-quality shifts, brought to the level of continuously variable transmissions. Development of power units in recent years has led to a rapid increase in the number of AT stages, which is accompanied by a complication of kinematic schemes, designs, control algorithms and, in general, an increase in the role of mechatronic control systems (MCS) in ensuring their high technical level. Effectiveness of the CTC technology depends on the perfection of the algorithms used. But their composition is not specified, which, with a large amount of information, makes it difficult for potential users to navigate in this set. In this paper, we propose (for the first time in the Russian language) the generalized structure of a set of standard algorithms necessary for the implementation of this technology in the AT MCS, which is developed on the basis of their selection from a pre-formed database of patents and publications on the theory and technology of AT control, following classification and grouping by functional purpose. For each item of the structure, there are links to patents with matching names. Detailed descriptions of several typical CTC algorithms in the AT MCS of General Motors patents are given.

Control of Pneumatic Actuator for Automated Mechanical Transmission Dry Friction Clutch Base on the Pulse Width Modulation Signal

To ensure quality of dry friction clutch engagement in automated mechanical transmission during vehicle starting-up and maneuvering the control range of clutch actuator has to be maximum wide. It depends on the consistency of the clutch actuator geometric parameters with the electrical characteristics of the used solenoid valves, the output stage of the controller and the PWM control signal frequency. In addition to precision electronic control the driver must be able to “manually” operate the dry friction clutch in emergency. That is why friction clutch must have two independent control circuits. The original automated drive with a duplicate pneumohydraulic circuit for the friction clutch is presented in the paper, as well as the research results of the PWM frequency influence on operating range of the clutch pneumatic actuator. The research was based on the analysis of semi-natural experiment for assessing the functional performance of the designed automated mechatronic control system for the truck mechanical transmission. Ecomat R360 controllers were used as a hardware base of the test bench information control system. The developed software for the controller with one-parameter feedback on the clutch release lever movement allows to provide the PWM signal of varying duty ratio to the proportional solenoid valve of the automated drive. A graphical representation of the research results was performed with visualization possibilities of CoDeSys V2.3. During the semi-natural experiment, the polynomial dependence between variation of the clutch actuator control range and the generated PWM signal frequency in the range up to 400 Hz was revealed as well as practical recommendations on the choice of the optimum PWM signal frequency are also given in activity. The research results can be used in an adaptive control algorithm for automated mechanical transmission of trucks and road trains to ensure precise control of the clutch actuator in the starting-up and maneuvering processes.

ДИАГНОСТИКА ФРОНТАЛЬНЫХ КОНСТРУКЦИЙ НА ОСНОВЕ МЕХАТРОННЫХ СИСТЕМ

The article considers the use of a mechatronic system for monitoring and diagnostics of frontal structures of buildings. Structural and functional diagram of the mechatronic control and diagnostics system of the frontal structure is presented. Calculation of frontal structure element based on finite element method is considered. The results of the theoretical calculation of the thermal flow of the frontal structure are presented. Recommendations are given on the use of the finite element method for calculating frontal structures according to various parameters.

Complex mathematical modelling of mechatronic modules of promising mobile objects

The characteristics of power sources affect the performance of autonomous electrically driven systems, such as unmanned aerial vehicles, aircraft missiles, guided bombs, torpedoes, space and aerospace vehicles, controlled gliding parachutes. The creation of control systems for the aircraft flight control surfaces of autonomous mobile objects is an urgent topic in modern research. This article provides how a mathematical model based on integrated approach is developed for an energy-efficient mechatronic module for control systems of promising mobile objects powered by various current sources; a comparison of the energy and dynamic characteristics of mechatronic modules of promising mobile objects for various power options is made. As a result, a new type of integrated power-supply source based on capacitive energy storage with floating charge from a primary chemical source of current has been developed. The proposed approaches, dependencies and algorithms can be used in the design of highly efficient mechatronic control algorithms for autonomous mobile objects of a new generation.

Substantiation of rational characteristics of mechatronic control systems of position Of wheel pairs

The article analyzes the schematic diagrams of rail vehicles with radial installation of wheelsets. Radial installation of wheelsets in curved sections of the track allows for optimal interaction of wheels and rails. This interaction is characterized by minimal lateral forces in the contact of the wheels and the rails and a decrease in wear of their contacting surfaces. Requirements are formulated for the characteristics of hardware and software that will ensure the technical implementation of mechatronic control systems for the position of wheel pairs of rail vehicles in the rail track in the horizontal plane. The devices included in the mechatronic automatic control system must represent a single closed system in which the parameters of various electrical, mechanical and hydraulic processes are inextricably linked. Due to the high requirements for reliability and time constraints to the formation and transmission of the control signal to the actuators, the operation of such a system for rail vehicles should be carried out in real time. A schematic diagram of a mechatronic positioning system for wheel sets is proposed, which allows them to be optimally mounted on a railses under various conditions of vehicle movement. On the example of movement a three-axle bogie of a 2TE116 diesel locomotive in the curve, comparative calculations are made. The calculation results showed the possibility of a significant reduction in the guiding forces and minimizing the attac angles of the wheelsets of the modernized bogy in comparison with the standard design bogy.

Effect of the payload mass on forces acting from the overhead crane drives during movement in the mode of suppressing uncontrolled oscillations

Using two-point Hermite splines, the reference spatial trajectory of a payload on a non-rigid pendulum suspension of an overhead crane was set as a combination of plane controlled oscillations in two mutually perpendicular movement directions of the bridge and the trolley. Under the absent uncontrolled payload oscillations, payload, suspension point coordinates and the rope deviation angles were calculated. Using the example of a constant spatial trajectory of the payload bypassing a single obstacle in the absence of uncontrolled oscillations, the payload mass effect on the forces acting from the side of the bridge drives and the trolley was investigated. The time dependences for horizontal components of the drive side forces were determined using an overhead crane simulation model developed in the Simscape Multibody Matlab application. Payload of various masses was repeatedly moved along the reference constant trajectory by rigidly setting the bridge and trolley movement trajectories. By virtual sensors, the forces acting from the drives on the bridge and trolley were evaluated. The payload mass effect on the maximum values of drive forces is established to be linear. The results can be used in the design and development of intelligent mechatronic control systems for overhead and gantry cranes.

Editorial of ‘Proceedings of 20th international conference of fluid power and mechatronic control engineering’

Editorial of ‘Proceedings of 20th international conference of fluid power and mechatronic control engineering’

Mechatronics and Remote Driving Control of the Drive-by-Wire for a Go Kart.

This research mainly aims at the construction of the novel acceleration pedal, the brake pedal and the steering system by mechanical designs and mechatronics technologies, an approach of which is rarely seen in Taiwan. Three highlights can be addressed: 1. The original steering parts were removed with the fault tolerance design being implemented so that the basic steering function can still remain in case of the function failure of the control system. 2. A larger steering angle of the front wheels in response to a specific rotated angle of the steering wheel is devised when cornering or parking at low speed in interest of drivability, while a smaller one is designed at high speed in favor of driving stability. 3. The operating patterns of the throttle, brake, and steering wheel can be customized in accordance with various driving environments and drivers’ requirements using the self-developed software. The implementation of a steer-by-wire system in the remote driving control for a go kart is described in this study. The mechatronic system is designed in order to support the conversion from human driving to autonomous driving for the go kart in the future. The go kart, using machine vision, is wirelessly controlled in the WiFi frequency bands. The steer-by-wire system was initially modeled as a standalone system for one wheel and subsequently developed into its complete form, including front wheel steering components, acceleration components, brake components, a microcontroller, drive circuit and digital to analog converter. The control output section delivers the commands to the subsystem controllers, relays and converters. The remote driving control of the go kart is activated when proper commands are sent by the vehicle control unit (VCU). All simulation and experiment results demonstrated that the control strategies of duel motors and the VCU control were successfully optimized. The feasibility study and performance evaluation of Taiwan’s go karts will be conducted as an extension of this study in the near future.

Условие абсолютной устойчивости системы управления электроупругим актюатором для наномехатроники

An electroelastic actuator for nanomechatronics is used in nanotechnology, adaptive optics, microsurgery, microelectronics, and biomedicine to actuate or control mechanisms, systems based on the electroelastic effect, and to convert electrical signals into mechanical displacements and forces. In nanomechatronic systems, a piezoactuator is used in scanning microscopy, laser systems, in astronomy for precision alignment, for compensation of temperature, gravitational deformations and atmospheric turbulence, focusing, and stabilizing the image. In this study, a condition for absolute stability of an electroelastic actuator control system for nanomechatronics under deterministic and random inputs is obtained. A number of equilibrium positions in an electroelastic actuator mechatronic control system are found, the totality of which is represented by a straight line segment. The electroelastic actuator’s deformation control system dead band relative width is determined for the actuator’s symmetric and asymmetric hysteresis characteristics. Under deterministic inputs and with fulfilling the condition for the derivative of the nonlinear hysteresis actuator deformation characteristic, the set of equilibrium positions of the electroelastic actuator control system for nanomechatronics is absolutely stable. Under random inputs, the system absolute stability with respect to the mathematical expectations of the electroelastic actuator mechatronic control system equilibrium positions has been determined subject to fulfilling the condition on the derivative of the actuator hysteresis characteristic.

Application of Hermite splines for load movement on a flexible crane suspension through a curvilinear trajectory

Analytical expressions of the coordinates of the load, the suspension point and the rope deviation angle, as well as their first three time derivatives were obtained by setting the desired load movement trajectory on a pendulum type flexible crane suspension using two-point Hermite splines with the quartic highest derivatives. A well-known mathematical model of the oscillatory system described by a linearized differential equation was used. With the described movements, the uncontrollable pendulum oscillations of the load are absent. The load moves exactly along a reference trajectory. The superposition of load movements in two mutually perpendicular planes solves the problem of synthesising the suspension point trajectory, which ensures the movement of load along an arbitrary smooth curvilinear trajectory in the horizontal plane. The second horizontal coordinate of the load was represented as an interpolation polynomial from the first horizontal coordinate. The division of the movement trajectory along the axis of the second horizontal coordinate into several sections of the same length provide the determination of the load movement and its derivatives at reference points, as well as the calculated suspension point trajectory. The developed technique is promising for application in intelligent mechatronic control systems for travelling and bridge-travelling cranes.

Mechatronic Control System for a Compliant and Precise Pneumatic Rotary Drive Unit

Robots that enable safe human-robot collaboration can be realized by using compliant drive units. In previous works, different mechanical designs of compliant pneumatic rotary drive units with similar characteristics have been presented. In this paper, we present the overall control approach that we use to operate one of these compliant pneumatic rotary drive units. We explain the mechanical design and derive the differential equation that describes the dynamics of the system. In order to successfully operate a pneumatic drive unit with three or more working chambers, the torque specified by the controller has to be split up onto the working chambers. We transfer the well-known field-oriented control approach from electric motors to the investigated pneumatic drive unit to create such a torque mapping. Moreover, we develop optimized torque mappings that are tailored to work with this type of drive unit. Furthermore, we introduce and compare two control algorithms based on different implementations of state feedback to realize position control. Finally, we present the step responses that we achieve when we implement either one of the control algorithms in combination with the different torque mappings.

Control of Mechatronic System Based on Multilink Robot-Manipulators

The task of controlling multi-link robots with manipulators for implementation of high-tech processes in industry has been considered in the paper. The paper presents sequential steps of using computer technology in construction of robotic-manipulators, including mathematical, algorithmic, and hardware and software tools for creating a multi-drive mechatronic system controlled by OMRON industrial microcontroller. A kinematic scheme of a robot manipulator has been described in the paper and it performs the following two types of movements – rotation around the z axis and rectilinear movement of a working element along a turning radius with precise positioning at a given point in the working space. Electromechanical design of the manipulator allows to ensure transportation of production objects in accordance with a given technological process. For designing the technological process of transporting production objects, a software module has been developed that makes it possible to automate description of basic operations for movement of the robot manipulator working body with subsequent automatic generation of a command sequence for a control program ensuring operation of electric drives in manipulator links in real time. To speed up the process of designing trajectory of the working body, a spatial simulation model of a robot-manipulator in the MatLab-Simulink environment has been developed. The paper considers a generalized diagram of a mechatronic control system for a robot-manipulator based on the OMRON programmable logic controller operating under control of a program developed in the programming environment Sysmac Studio Automation. A program for a programmable terminal with interface elements and animation elements has been developed for industrial use of the mechatronic system during adjustment and operation period. The paper provides an appearance of a robot-manipulator prototype. The developed mechatronic system of the robot-manipulator can be technologically oriented towards solving other problems of industrial production.

Design and Development of Spin Welding Machine for Thermoplastics

A new indigenous spin welding machine for thermoplastics with advanced mechatronic controls is conceptualised, designed in detail and a prototype is developed for joining of two thermoplastic parts in axis-symmetrical fashion. Manual spin welding machines for joining thermoplastic parts in axis-symmetrical manner are generally obtained by modifying drill type machines which causes the relative frictional rotation of parts under contact pressure exerted manually through a lever. The contact under relative motion causes the heat generation and results into fusion of parts. The joints from such machines exhibit inconsistency inherent in the manual process. The indigenous prototype machine is able to perform spin welding process with consistency. It enables the operator to choose and control the process parameters such as rotation velocity, time of rotation, spin pressure and cooling pressure.

An untethered soft chemo-mechanical robot with composite structure and optimized control

Endowing the animals with agile actions, natural muscle functions as a soft actuator, which is powered by chemical reactions of metabolism and controlled by electrical nerve-signals. Inspired by natural muscle, various types of soft chemical machines (SCM) have been recently developed, possessing advantages of light weight, fast actuation, compact integration, high power and low noise. In this paper, we propose a composite structure as a soft chemical engine (SCE), which is driven by the chemical decomposition of hydrogen peroxide (H2O2). The SCE directly converts chemical energy into mechanical work, achieving excellent performance of large actuation (∼33% volume expansion) and fast response (∼1 s). We advance the SCE with excellent performance to a soft chemical machine (SCM) with well-controlled functions, as a mechatronic control system. The soft robot possesses robust control with untethered operation and stable actuating cycles. We develop a model for the locomotion mechanisms, revealing that optimized mechatronic controls can significantly enhance the performance of SCM.

Intelligent Control Interfaces Using Extenics Multidimensional Theory Applied on VIPRO Platforms for Developing the IT INDUSTRY 4.0 Concept

Abstract The paper presents new concepts and approaches to achieving intelligent control interfaces for solving contradictory problems using Extenics multidimensional theory applied on VIPRO Versatile Intelligent Portable Platforms. VIPRO platform enables developing the IT Industry 4.0 concept through the design, testing and experimentation of new intelligent control interfaces on a classical mechatronic control system without the need to modify its hardware structure, and, from optimal decisions and information fusion between the intelligent control interfaces, resulting in a high degree of versatility and portability to a global communications network. The Cyber-Physical Systems as like a VIPRO Platform’s component, developed through advanced intelligent control interfaces integrate the dynamics of the physical processes with those of the software and networking, providing a powerful environment for modeling, design, and analysis techniques for an integrated whole IT Industry. The portability characteristics results allow test and improve the motion performance of the mechatronic system, and furthermore implement the intelligent control and decision interfaces on their own control system, applying Industry 4.0 components: cognitive computing including intelligence and signal processing, cyber-physical systems, internet of things and cloud computing, exemplified on an Extenics multidimensional control intelligent interfaces.