Design Of Mechatronic Systems Research Articles

Model‐based systems engineering and safety assessment: A workflow for mechatronic systems design

AbstractMechatronic systems become ever more complex because of their increasing number of interconnected safety critical components and sophistication. MBSE (Model‐based Systems Engineering) and MBSA (Model‐Based Safety Assessment) are the most commonly adopted approaches to deal with the design and safety analysis of mechatronic systems. Unfortunately, both approaches are normally adopted separately, especially in the earlier phases of system design, thus leading to a lack of communication between system engineers and the safety team. This work aims to fill that gap at a high level, that is, through process interaction. This paper proposes an enhanced V‐model for the design of safety‐critical mechatronic systems. It relates a system development process with specific safety assessment methods. Specifically, the proposed workflow details exchange flows between the RFLP (Requirements, Functional, Logical, Physical) method, the FHA (Functional Hazard Analysis), the FMEA (Failure Mode and Effects Analysis), the MBSA and simulation, and the FTA (Fault Tree Analysis). These analyses are complemented with multiphysics modeling and simulation to observe system behavior in functional and failure scenarios, with the aim of requirements verification. The design workflow has been applied to a winged Unmanned Aerial Vehicle to apply the parallel process and the necessary interaction of MBSE and MBSA approaches. The information flows between the individual activities proved effective for designing a safe system before the verification phase. The main benefit of the proposed workflow is providing both the design and safety team with some interaction points, thus avoiding a lack of safety‐critical analysis in the early phases of system design.

Mechatronics System Design and Implementation of a Pneumatic Hand Rehabilitation Device

Mechatronics System Design and Implementation of a Pneumatic Hand Rehabilitation Device

Improving the Step Response of Flexible Systems in the Presence of Real Nonminimum Phase Zeros

Abstract It is well known that real nonminimum phase (RNMP) zeros impose a tradeoff between the settling time and undershoot in the step response of flexible systems. Existing methods to alleviate this tradeoff predominantly rely on various advanced control strategies without delving into a broader mechatronic approach that combines physical system and control system design. To address this gap, this article proposes a proportional viscous damping-based physical system design in combination with feedback control and prefilter design. First, the effect of proportional viscous damping on RNMP zeros of flexible systems is established to propose a damping strategy that pushes all the RNMP zeros further away from the imaginary axis. Then, a step-by-step mechatronic system design process is presented to apply this damping strategy along with a full-state feedback control strategy and prefilter to a multi-degree-of-freedom (DoF) flexible system. The application of this design process yields simultaneous improvement in the settling time and undershoot in the step response of this flexible system.

Supporting circular economy strategies for design of sustainable mechatronic systems using MBSE

AbstractThe paper investigates approaches for implementing circular economy strategies, such as designing mechatronic products for longer service life by replacing, upgrading, or remanufacturing subsystems. The research aims at applying MBSE to provide the necessary support for dealing with the complexity of these approaches. Requirements and challenges for the development of MBSE support in this context are examined. An example of an EV battery system model shows the benefits and challenges of comprehensive system modelling and traceability in the context of circular economy strategies.

Synchronous integration method of mechatronic system design, geometric design, and simulation based on SysML

The benefits of integrated design using the Model Based System Engineering (MBSE) approach in the design process of mechatronic systems have gradually become apparent. The automatic generation of simulation models and geometric models based on System Modeling Languages (SysML) models enables system engineers to swiftly analyze and simulate system performance, visually depict design outcomes, and expedite the product development process. Due to the current system modeling's lack of model integration and geometric design functions, this paper proposes an integrated design and simulation method for mechatronic systems that can carry out complete model synchronization and verification, rapid geometric solution generation, and visual representation. Furthermore, a corresponding model synchronization integration framework is established. This framework primarily encompasses system de-sign, system simulation, and geometric design, with its model integration method being model transformation and model synchronization. The paper concludes with an example of the design process of a quadruped robot to validate the framework and its supported methods, providing a reference for other system design and integration endeavors.

A model-Based Mechatronic System Design and Integration Process

In contemporary mechatronic product development, embracing an interdisciplinary approach has become imperative to manage potential integration risks. This research paper introduces a viable solution that combines Automation Studio and the VDI 2206 methodology to design mechatronic systems. The study's findings highlight the efficacy of this interdisciplinary approach in effectively addressing early challenges associated with multi-domain integration. It enables simultaneous evaluation and resolution of limitations inherent in traditional design methods. Successfully applied to develop an automated garment folding machine with a PLC controller, the proposed process proves to be a valuable tool in optimizing mechatronic system development. The system, designed using this process, relies on a real-time computational model as its foundation, laying the groundwork for constructing a digital twin in the future. This ensures a comprehensive representation of the system, facilitating enhanced understanding and performance assessment during the development and operational phases. The adoption of such an approach signifies a significant step forward in advancing mechatronic engineering and ensuring the successful realization of complex and efficient systems.

Gyroscopic precession control for maneuvering two‐wheeled robot recoil stabilization

AbstractA two‐wheeled robot has high maneuverability and can spin around with a high velocity but is prone to roll over under a recoil force. Because the wheels are only used to control the maneuver speed of the robot. However, a two‐wheeled robot using a gyroscope does not need the control of the wheels and can maintain the stability of the robot under a recoil force during maneuvers even if the gimbal of the gyroscope is not controlled by a torque. In this study, the equations of motion of the gyroscopic robot are derived via Lagrangian equations, and the balancing performance of the uncontrolled gyroscope is simulated via Matlab to determine a desired configuration for mechatronics system design. Then, a linear‐quadratic regulator (LQR) is implemented to the chosen control moment gyroscope (CMG) configuration and compared in simulations of RecurDyn. LQR controller was used to prevent oscillating motions of double CMGs under the recoil force of a weapon. The simulation results showed that the gyroscopic two‐wheeled robot is improved using an LQR controller and powerfully balanced in static with excellent performance.

An Object-Oriented Approach to the Modular Design of Mechatronic Systems

The design of modern mechatronic systems involves multidisciplinary and high-level integration, creating challenging and complex tasks for industrial designers and engineers. Their development requires intricate interaction between heterogeneous subsystems, and necessitates coordinated trans-sectoral cooperation between mechanical, electronic, and software engineers. Although efforts have been made to create efficient methods to guide the design of mechatronic systems, no existing solutions solve the complexity of design problems experienced during their design. This article, therefore, proposes a structured step-by-step approach to guide the design of mechatronic systems using an object-oriented methodology. Three information streams are employed that flow through the logical layers of a mechatronic system to track requirements and define modular specifications during the design process. The proposed approach benefits those developing mechatronic systems by improving collaboration, minimizing errors, reducing chances of design failure, and helping meet the desired functionality and goal of multidisciplinary integration. To evaluate the proposed approach and demonstrate the practicability of the systematic framework, we present a case study of a library book returning system. Our results highlight the capability of the proposed approach to guarantee top–down consistency and traceability of derived specifications among logical layers and contribute to the successful integration of requirements during the design process of mechatronic systems.

Reluctance Based Actuator for Discrete Machine Hammer Peening

In machine hammer peening, an actuator system moves a ram in oscillating motion, which is oriented in angular position, preferably perpendicular, to a workpiece surface. On the tip of the ram, a hammer head with application specific shapes can be mounted. The hammer head is moved across the targeted workpiece surface area by means of a machine tool or an industrial robot. The impacts in defined patterns enable modifications of the surface integrity like smoothing the surface roughness or increasing fatigue strength by induced compressive residual stresses. This paper presents a novel DC-driven actuator system using a highly dynamic short-stroke linear reluctance motor to provide a time or trigger controlled hammer head movement including a system for process monitoring. In contrast to conventional systems, Deterministic Impact Peening (DIP) can be realized by position or speed related triggering of the impacts. The reluctance-based actuator with its geometrically optimized mechatronic system design provides performance characteristics favorable to known machine hammer peening systems. The position-controlled triggering of the hammer head is able to achieve uniform or defined local elastoplastic deformations on the workpiece surface, thus resulting in deterministic residual stress distributions.

Disassembly and Repairability of Mechatronic Products: Insight for Engineering Design

Abstract Designing mechatronic products requires interdisciplinary skills and as products become more complex, the design of mechatronic systems plays a critical role. To minimize waste production and pollution, a shift toward a circular economy is necessary, with mechatronic products being particularly impacted by such policies. Repairing plays a key part in achieving a circular economy. Through repairability, the product lifespan can be extended, and combined with maintenance the rate of product replacement can be reduced. Within this context, the goal of this paper is to propose a design methodology (based on the EN 45554:2020 standard) for generating and implementing eco-design rules for disassembly and repair. The methodology has four phases, the first one is the identification of target components (those that are more likely to fail during the lifespan). The second phase encompasses the experimental disassembly analysis which can be manual or virtual. The third phase is the assessment of the disassemblability index which includes the analysis of parameters that affect the disassembly phase. The last phase is the implementation of the eco-design methodology for all the components that do not meet the minimum repairability requirements. A case study of electro-mechanical ovens is presented, targeting replaceable components. The results show that the use of this framework and the eco-design actions derived from it are successful in improving the repairability of the product and increasing the disassemblability index (30% on average) through a virtual analysis. A sensitivity analysis has been conducted to study the impact of parameter weight modification. This research contributes to advancing repairability and supporting the circular economy paradigm in mechatronic product design.

A Mars quadcopter capable of autonomous flight and sample collection: Structure and avionics

The Mars rotorcraft is an aerial exploration platform capable of repeated take-offs and landings to extend the range of rover explorations. NASA’s Ingenuity helicopter is a full y functioning coaxial helicopter for technology demonstration. Increasing the rotor diameter or the number of blades can enhance the load capacity of the coaxial helicopter but would make it difficult to be folded. A more suitable configuration for Mars exploration is the multi-rotor aircraft, which has a stronger load capacity with the same rotor diameter. Although the aerodynamic performance and operational capabilities of the Mars multi-rotor aircraft have been partially considered, mechatronic system design and autonomous flight control have not been fully addressed. Harbin Institute of Technology and China Academy of Space Technology jointly proposed a deployable Mars quadcopter for air patrol and sampling with a sample mass of 100 g. This paper presents a concept for a Mars quadcopter and its mission operations, including operational procedures and flight modes, to provide a framework for future Mars flight sampling missions. We describe the structure and avionics architecture of the Mars quadcopter. Then, we present the hardware and software design of the guidance, navigation, and control (GNC) system to illustrate the autonomous flight control method. Finally, we introduce the deployment mechanism of the Mars quadcopter.

Design of a Flexible mechatronic system for mechanical impedance measurement of the wrist as one step towards robotic rehabilitation

Abstract Home rehabilitation is a great complement to inpatient rehabilitation, because it allows for more regular training, especially in rural areas, where the access to physiotherapists is limited. However, unsupervised training carries the risk of deviation from the prescribed protocol. An obvious solution is to introduce a technical means for rehabilitation and continuous monitoring of performance. This paper presents a robotic system for rehabilitation of three degrees of freedom of the wrist independently, implemented with only one actuator, optimizing the design and size of the system. The device provides measurements of joint torque-position dependence, allowing objective assessment of mechanical impedance and range of motion to evaluate the progress of rehabilitation. Derived from research on haptic devices, a measurement method was implemented to measure hand impedance in the high frequency range between 100 and 200 Hz using a combination of exciters and accelerometers in the handles. This allows continuous monitoring of gripping forces without the need for complex contact-based force sensors. In collaboration between the authors’ technical and medical universities, a set of two-level passive and active safety measures was implemented to ensure the safety of the system’s users. Therefore, the presented system shows the potential to evaluate the mechanical impedance of the wrist at both low and high frequencies and to monitor the progress during rehabilitation. In the next step, a baseline of wrist impedance will be measured in a target group of healthy volunteers in order to prepare for studies in motion-restricted subjects.

Complex Positioning System for the Control and Visualization of Photovoltaic Systems

This paper presents a proposal of a complex mechatronic system that enhances the effectivity of obtaining energy from renewable resources. The main focus is on the photovoltaic energy system, which obtains electricity from the conversion of solar radiation through photovoltaic crystalline silicon-based panels. The design of the complex mechatronic system consists of several steps. The structural design of the photovoltaic panel positioning unit in the form of a three-dimensional model is made in the selected modelling programming environment. Subsequently, a propulsion system is proposed for the designed structure, the functionality of which is verified in the programming environment Automated Dynamic Analysis of Mechanical Systems. The control system design using a programmable logical controller is also presented. The corresponding control algorithm is designed in the programming environment Step7 and covers the optimal positioning of photovoltaic panels. The developed application in the WinCC environment provides a visualization of the positioning control process. The conclusion is devoted to the assessment of the obtained results for the proposed complex mechatronic system for photovoltaic panel positioning in comparison with photovoltaic panels in fixed installation. The presented results were obtained by simulations.

Mechatronic Design of Two-Jaw Pleating End-Effector for Large-Scale Carbon Fibre Reinforced Polymer Manufacturing

Large-scale composite manufacturing processes, particularly vacuum injection moulding, are often hampered by expensive labour costs and low-levels of automation. The current process of manufacturing carbon fibre reinforced polymers (CFRP) for airplane fuselage workpieces requires experienced workers to spend hours manually placing, pleating and migrating multiple layers of fabrics in order to produce the desired composite part. A promising solution is to utilize robot platforms as assistants to alleviate the physical demands of the tasks. In this paper, we present the design and evaluate the performance of our novel Vacuum Infusion Moulding End-Effector (VIMEE) prototype in the pleating procedure of a simulated CFRP manufacturing vacuum bagging process, where our gripper system performs pleat loading, height detection and migration tasks. Experimental results show successful manipulation of nylon pleats by our mechatronic systems design. These results are promising, demonstrating our VIMEE design's potential value in vacuum injection moulding.

Improving the Energy Efficiency of a Ship’s Power Plant by Using an Autonomous Hybrid System with a PMSG

In ship systems, diesel power generators are used in various systems of autonomous power plants to ensure power supply security. This article presents an autonomous hybrid system of a ship power plant with a diesel generator with a permanent magnet synchronous generator and electricity storage in parallel topology (the permanent magnet synchronous generator is connected directly to the receiving network). The electricity storage through the active converter is connected to the receiving network in parallel with the permanent magnet synchronous generator. The decoupled control of the reactive and active power in the active converter enables stabilization of the voltage in the ship’s electrical power grid while ensuring the possibility of obtaining different operating regimes of the power plant at various stages of the ship’s operation. The innovative method of voltage stabilization presented in this article is based on the compensation of the unfavorable reaction of the permanent magnet synchronous generator armature through the optimal transmission of negative inductive reactive power from the active converter to the generator using the electromagnetic properties of the synchronous generator. The active converter controls the direction of the active power transmission between the DC source, the grid, and the permanent magnet synchronous generator. This paper proposes a hybrid autonomous power plant system using battery storage in place of a single diesel generator set against the commonly used two diesel generator sets, working in parallel, to increase the energy efficiency of the power plant by minimizing the specific fuel consumption of the diesel generator set. The article examines the possibilities of such a mechatronic system design based on analytical research and analysis of electromagnetic and energy characteristics using the Matlab-Simulink program.

Integrated topology and controller optimization using the Nyquist curve

The design of high-performance mechatronic systems is very challenging, as it requires delicate balancing of system dynamics, the controller, and their closed-loop interaction. Topology optimization provides an automated way to obtain systems with superior performance, although extension to simultaneous optimization of both topology and controller has been limited. To allow for topology optimization of mechatronic systems for closed-loop performance, stability, and disturbance rejection (i.e. modulus margin), we introduce local approximations of the Nyquist curve using circles. These circular approximations enable simple geometrical constraints on the shape of the Nyquist curve, which is used to characterize the closed-loop performance. Additionally, a computationally efficient robust formulation is proposed for topology optimization of dynamic systems. Based on approximation of eigenmodes for perturbed designs, their dynamics can be described with sufficient accuracy for optimization, while preventing the usual threefold increase of additional computational effort. The designs optimized using the integrated approach have significantly better performance (up to 350% in terms of bandwidth) than sequentially optimized systems, where eigenfrequencies are first maximized and then the controller is tuned. The proposed approach enables new directions of integrated (topology) optimization, with effective control over the Nyquist curve and efficient implementation of the robust formulation.

A novel magnetically levitated tip/tilt motion platform

This paper presents the mechatronic system design and control of a tip/tilt motion platform with a magnetically levitated mover tailored for dynamic rotational scanning operation. It employs a Lorentz force-based actuation system with five degrees of freedom and four spherical Halbach arrays on a fully passive mover. The system includes highly integrated optical proximity sensors for sensing the mover position in all degrees of freedom and a passive magnetic bearing for restraining the non-actuated degree of freedom. The actuation system enables a mechanical angular range of ±1° in both axes, with first structural modes of the 3D printed mover occurring at 1 kHz. A control system is designed for the five actively controlled degrees of freedom for obtaining a robustly stable and precise motion system. The resulting closed-loop system has a bandwidth of 200 Hz in the rotational and 100 Hz in the translational degrees of freedom and a small positioning uncertainty of 0.02% of the full motion range.

Design and Validation of a Testing 4D Mechatronic System for Measurement and Integrated Control of Processes

Measurements are crucial for research in the fields of microelectromechanical (MEMS), nanoelectromechanical (NEMS) and industrial applications. In this work, the design approach for the development and construction of a testing 4D mechatronic system, and respective validation, including the detailed description of the used components and parts as well as the performed tests for respective validation in the working environment, are presented. Because this is testing equipment, the measurement feature is presented and validated, in detail, making this system available and reliable for the mentioned purposes of use. An important result in this work is the possibility of on-site control or the remote control of the 4D mechatronic system for measurement and integrated control of processes, with the aim of reducing the cost of obtaining the necessary measurements.

Artificial Intelligence Capabilities for Effective Model‐Based Systems Engineering: A Vision Paper

AbstractBoth Model‐Based Systems Engineering (MBSE) and Artificial Intelligence (AI) have been challenged for their deployment in real‐world applications. Although MBSE remains the focal point of any systems engineering activities, its adoption still faces significant hurdles to demonstrate its return on investment. Recently, AI has received intensive attention, and its applications made their way into our daily life products. From an industrial perspective, within the context of the design and development of mechatronic systems, there is a lack of coherent foundation to enable the application of AI in MBSE. This vision paper discusses the role of AI in solving a set of MBSE challenges. As a result, we contribute by describing the actual MBSE adoption challenges and follow up with the characterization of the capabilities of AI in solving these challenges. With this initial work, we aim to trigger both AI and MBSE communities for further research discussions and industrial applications to help in achieving an intelligent design and development environment.

Development of a Virtual Bench for Modeling and Research of a Mobile Robot in Simintech

A virtual bench is designed for students studying simulation, model-oriented design of mechatronic systems and control devices. A review of existing virtual stands is performed. The training starts with simulation of a mobile robot (MR) with a single drive, for example, a transport robot moving along one coordinate, then simulation of MR with differential control moving on a plane, and then simulation of multicopters (quadcopter, hexacopter, octocopter). The virtual simulator consists of a model of MR with a single DC motor drive, MR controller, control panel. The drive model of the mobile robot in the state space is developed. Negative trends in the development of laboratory benches have been revealed: fast obsolescence of laboratory equipment; high cost; small range of equipment. Positive directions of their development have been identified: expansion of software capabilities (high-level languages) allowing to create any applications quickly and easily; appearance and improvement of special software used to create multimedia applications, as well as specialized software intended for design automation (AutoCAD, KOMPAS, Altium Designer, etc.) and mathematical calculations (Matlab, MathCAD, etc.). Software tools include SimInTech, MatLab/Simulink, LabVIEW, procedure-oriented languages VB, Delphi, Java, etc.; problem-oriented languages LISP, C++, C#, etc. In this connection, it is expedient to partially abandon traditional laboratory benches and switch to wider application of simulation modeling and computational experiment methods. Virtual laboratory benches should form the basis of such transition. As a result of simulation, the following parameters of MR model were obtained: MR displacement at 2.5 m, maximum gearbox angular speed 0.2 rad/s, maximum torque on gearbox output shaft 15 N∙m, maximum angular speed of DC motor 30 rad/s. Simulation of MR was performed in SimInTech program.