Mechatronic Products Research Articles

An integrated design methodology for extrinsic adaptive façades – Process model, standards, and case study

Adaptive façades (AFs) offer a range of benefits by automatically changing their properties to promote improved shading, ventilation, or communication features. These can enable reduced energy and resource consumption in buildings as well as optimized comfort. The design of AFs is significantly more complex than that of conventional façades, which among other things leads to increased development costs making the technology appear unattractive as of now. A suitable methodology can provide support in this regard, as it can support collaboration and stakeholder management. For this purpose, the authors derived 26 requirements identified in previous works. These included formal, design-related, integrated, and AF-specific requirements. Yet there is no suitable methodology in the current state of the art that meets these requirements. In this article, an integrated design methodology is developed in an interdisciplinary manner using a deductive research approach based on product-neutral processes in the sectors of architecture, engineering, and construction, and mechanical engineering. The highest-rated reference model is the V-model from mechatronic product development. This model is adapted and detailed in such a way that it is suitable for designing AFs. Suitable methods, AF-specific challenges, and tasks are added. The result is a novel integrated design methodology for AFs that deals with the entire design process from commissioning to construction documents. A case study is presented as a means of verifying the methodology.

Reliability, Availability, and Maintainability Assessment of a Mechatronic System Based on Timed Colored Petri Nets

The mechatronic industry is currently subject to huge changes challenging it to offer products matching individual customer requirements at competitive prices. The design of such products calls for sophisticated and complex components integration following different technologies. Since we are on the cusp of the Fourth Industrial Revolution, in which the world of mechatronic production, network connectivity, the Internet of Things, and cyber-physical systems are correlated, the complexity of these systems increases exponentially, and we are talking about advanced mechatronic systems. To assist these changes, various methods, sweeping all project phases, are used by business houses. Predictive dependability assessment in the earlier design stage is considered a powerful metric used to evaluate the performances of different kinds of mechatronic products before the production phase. Altogether, dependability analysis ties the design directly to the desired functionality, operability, and integrity of the system. This paper explores an approach to assessing the dependability attributes, reliability, availability, and maintainability (RAM), of repairable mechatronic systems based on timed colored Petri nets and a Monte Carlo simulation, integrating simultaneously diverse components technologies: mechanical, electronic, and software. The proposed approach is tested taking the case of a regenerative braking system. The methodology appears to be efficient for evaluating predictive RAM indicators (MTTFF, MTTR, MTBF…) for the whole system and for each individual component separately.

Utilization of the system architecture in the context of validation in the business-to-business (B2B) sector

AbstractThe European Green Deal aims to reduce global emissions by minimizing the use of resources. Early validation of products helps to reduce rework, costs and therefore resources. However, validation of complex mechatronic products is challenging due to interdependencies. Companies are applying systems engineering to meet this challenge. Current validation approaches are insufficient in the early design phases. This paper presents an approach to validation using the system architecture in the B2B sector. A machine tool and a custom built machine are presented as evaluation examples.

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.

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.

Enhancing the Coupling of Real-Virtual Prototypes: A Method for Latency Compensation

Currently, innovations in mechatronic products often occur at the system level, requiring consideration of component interactions throughout the entire development process. In the earlier phases of development, this is accomplished by coupling virtual prototypes such as simulation models. As the development progresses and real prototypes of certain system components become available, real-virtual prototypes (RVPs) are established with the help of network communication. However, network effects—all of which can be interpreted as latencies in simplified terms—distort the system behavior of RVPs. To reduce these distortions, we propose a coupling method for RVPs that compensates for latencies. We present an easily applicable approach by introducing a generic coupling algorithm based on error space extrapolation. Furthermore, we enable online learning by transforming coupling algorithms into feedforward neural networks. Additionally, we conduct a frequency domain analysis to assess the impact of coupling faults and algorithms on the system behavior of RVPs and derive a method for optimally designing coupling algorithms. To demonstrate the effectiveness of the coupling method, we apply it to a hybrid vehicle that is productively used as an RVP in the industry. We show that the optimally designed and trained coupling algorithm significantly improves the credibility of the RVP.

Cyclic stress accelerated life test method for mechatronic products

AbstractThe reliability requirements for mechatronics continue to increase. Traditional life test methods make it difficult to obtain the data required to assess or predict the reliability of these mechatronic products within a reasonable time. Accelerated life tests can speed up the failure process of the product by using accelerated stress conditions. And then test data is obtained to predict the reliable life of the product under normal service conditions through modeling and analysis. The test efficiency of the accelerated life tests is higher than that of the life test. So, the method of accelerated life tests has become a solution for life and reliability prediction of highly reliable and long‐life mechatronic products. However, mechatronic products usually undergo cyclic stress during service. The use of cyclic stress as an accelerating stress in accelerated life tests can provide a realistic representation of service conditions and achieve higher test efficiency. Cyclic stress accelerated life test is an accurate and efficient solution for predicting the life and reliability of such mechatronic products. Current relative research is focused on constant stress, step stress and sequential stress accelerated life tests. A great challenge in engineering is modeling and analysis of cyclic stresses accelerated life tests. In this paper, we first describe the cyclic stress accelerated life test profile and its key parameters, then propose model assumptions and establish a modelling and analysis method for cyclic stress accelerated life test data, followed by an illustrative example to apply and validate the proposed method. The research results can provide technical support for the life and reliability assessment of mechatronic products under cyclic stress service conditions.

Learning by doing? The relationship between effort, learning effect and product quality during hackathons of novice teams

Abstract Design education prepares novice designers to solve complex and challenging problems requiring diverse skill sets and an interdisciplinary approach. Hackathons, for example, offer a hands-on, collaborative learning approach in a limited time frame to gain practical experience and develop problem-solving skills quickly. They enable collaboration, prototyping and testing among interdisciplinary teams. Typically, hackathons strongly focus on the solution, assuming that this will support learning. However, building the best product and achieving a strong learning effect may not be related. This paper presents the results of an empirical study that examines the relationship between product quality, learning effect and effort spent in an academic 2-week hackathon. Thirty teams identified user problems in this course and developed hardware and mechatronic products. This study collected the following data: (1) effort spent during the hackathon through task tracking, (2) learning effect through self-assessment by the participants and (3) product quality after the hackathon by an external jury. The study found that the team effort spent has a statistically significant but moderate correlation with product quality. The correlation between product quality and learning effect is statistically insignificant, suggesting that for this setting, there is no relevant association.

Vibration Control of Base-Excited Rotors Supported by Active Magnetic Bearing Using a Model-Based Compensation Method

Active magnetic bearings (AMBs) are a type of mechatronics product widely used in high-speed rotating machinery. Considerable research has been conducted on the vibration rejection of the AMBs-rotor systems at the base standstill. However, little attention has been paid to the case where the rotor operates under base excitations, such as turbines mounted on ships with wave excitation. The increased rotor vibration caused by base excitations is a great challenge to operational safety. To address this issue, a base acceleration feedforward compensation (BAFC) algorithm was proposed in this paper. Using the online base excitation data and the dynamic model of the rotor system, the proposed model-based algorithm determines the optimal compensation current in real time. Further, to reject the decreased compensation performance due to inaccurate modeling, a method for correcting the compensation error has been presented. Moreover, the effect of controller parameters on system stability was explored to avoid parametric instability during base excitations. By employing the BAFC algorithm in the experiments, the rotor vibration was reduced considerably under both the harmonic and random base excitations with a maximum vibration reduction of 85%, demonstrating the remarkable effectiveness of the BAFC algorithm.

Future Robust Product Portfolio Development: Modelling Innovation Potentials in Product Portfolios

The advancement of product portfolios is a challenging task for companies. The growing number of variants and a significant increase in interactions between mechatronic products create unprecedented complexities. Currently, there is no holistic approach to cope with this increased complexity and to enable the future robust advancement of the product portfolio.Therefore, a descriptive model for the advancement of product portfolios is required to map elements of the product portfolio in the early phase of product development. This work aims to build upon an initial descriptive model to support the modelling of innovation potential in the advancement of the product portfolio. This research is based on the Design Research Methodology to develop a descriptive support approach. Challenges and potential improvements were collected while synthesizing the initial descriptive model and an observational study with 29 individual product developers. Based on the descriptive study, product profiles were worked out to describe the higher product portfolio levels solution-openly. As an extension of this feature, common characteristics of different products in the product portfolio can be modeled in a summarized manner. The extended descriptive model was initially validated in an expert workshop with eleven participants.

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 concept evaluation approach based on incomplete information: Considering large-scale criteria and risk attitudes

Concept evaluation plays a pivotal role in complex mechatronic product development, and its results greatly influence the subsequent design and manufacturing. However, the inclusion of large-scale criteria introduces complex calculations and coupling relationships, which will affect the evaluation. Moreover, the limited availability of early design knowledge, risk attitudes and cognitive differences of decision makers (DMs) lead to incompleteness and uncertainty in evaluation information. To address these challenges, a concept evaluation approach based on incomplete information with considering large-scale criteria and risk attitudes is proposed. Initially, an evaluation criteria clustering approach based on interval three-way decision-making is proposed, which considers DMs’ cognitions and risk attitudes. Second, the uncertainty model of evaluation information is established according to the criteria cluster result, and the incomplete evaluation information is fused using the interval Dempster-Shafer evidence theory which takes conflicting evidence into consideration. Third, the optimal concept is selected using the combined criteria weighting approach and the interval acronym in Portuguese for interactive and multi-criteria decision making (I-TODIM). Finally, a pipe inspection robot is utilized as an engineering case to verify the effectiveness of the proposed approach. Approach comparison and sensitivity analysis demonstrate the reliability and robustness of the proposed approach when applied to large-scale criteria concept evaluation.

Integrating sustainability in the design process of urban service robots.

The concept of sustainability and sustainable development has been well discussed and was subject to many conferences of the EU and UN resulting in agendas, goals, and resolutions. Yet, literature shows that the three dimensions of sustainability (ecological, social, and economic) are unevenly accounted for in the design of mechatronic products. The stated reasons range from a lack or inapplicability of tools for integration into the design process, models for simulation, and impact analyses to necessary changes in policy and social behavior. The influence designers have on the sustainability of a product lies mostly in the early design phases of the development process, such as requirements engineering and concept evaluation. Currently, these concepts emerge mostly from performance-based requirements rather than sustainability impact-based requirements, which are also true for service robots in urban environments. So far, the main focus of research in this innovative and growing product branch lies in performance in perception, navigation, and interaction. This paper sets its focus on integrating all three dimensions of sustainability into the design process. Therefore, we describe the development of an urban service robot supporting municipal waste management in the city of Berlin. It is the set goal for the robot to increase the service and support the employees while reducing emissions. For that, we make use of a product development process (PDP) and its adaptable nature to build a specific development process suited to include the three dimensions of sustainability during the requirements engineering and evaluation activities. Herein, we show how established design methods like the life cycle assessment or life cycle costing can be applied to the development of urban service robots and which aspects are underrepresented. Especially, the social dimension required us to look beyond standardized methods in the field of mechanical engineering. Based on our findings, we introduce a new activity to the development process that we call preliminary social assessment in order to incorporate social aspects in the early design phase.

FUNCTION-ORIENTED DEVELOPMENT OF COMPLEX MECHATRONIC PRODUCTS FROM AN HTO PERSPECTIVE: A SYSTEMATIC LITERATURE REVIEW

AbstractA component-orientated approach is commonplace in the automotive industry where the development focus lies on components. However, current challenges in the industry necessitates a mindset change in the development. Shifting the perspective from the components to functions can help with changing requirements, manage increasing complexity, support cross-disciplinary development, and foster innovation. To successfully implement this approach, it is essential to address not only the technical aspects of the solution, but also the human and organizational aspects affecting the process for its long-term success.This paper investigates the function-oriented development methods of complex mechatronic products. A systematic literature review is conducted to analyse the current state of research. The existing function-oriented development approaches are summarized, the technological, human, and organizational perspectives are analysed, and the research gaps are highlighted. It is concluded that while function-orientation gains significance in industry and academia, and the importance of human and organizational factors are highlighted in the literature, they are not yet widely considered within the current function-oriented approaches.

Innovating the digital product development toolchain with digital twins at Helbling Technik AG

This teaching case examines how engineering consultants Helbling Technik AG overcame challenges in implementing a digital twin approach to mechatronics product development, saving costs, and reducing time to market. It challenges students to understand digital twins in mechatronic system development and their implications for processes, use cases, and service models. This real-world example is relevant for students and educators interested in the challenges and opportunities of digital twin implementation.

Modeling language for the function-oriented development of mechatronic systems with motego

As mechatronic products gain in popularity, methods for mastering the complexity of these systems in development become increasingly relevant, such as model-based systems engineering (MBSE). Main pillars of MBSE are method, language and tool. A method specifies procedures in product development. The application of the method is supported by a language and tool as the language specifies a system of symbols with which development artifacts can be represented in a software environment (i.e. tool). Currently, various MBSE methods exist, such as motego. Motego specifies a framework for the function-oriented seamless development of mechatronic systems from requirements to the physical realization down to mechanical and electrical contacts and the description of these via parameters and models. Central element in MBSE is the system model, which connects all relevant development artefacts. The system model is created with a language in a software environment such as Cameo Systems Modeler. In MBSE, the graphical systems modeling language SysML is widely established. The language elements in SysML are very abstract and numerous. As a result, the language is difficult to apply. However, its reasonable applicability is an essential prerequisite for the introduction of the motego methods in industrial practice. This results in the following research need: A specific modeling language for the motego method is needed that supports its reasonable application. Therefore, in this paper a modeling language is presented whose language elements are specifically adapted to the motego method. With the help of this domain specific language, the user is guided through method-compliant modeling.

Combining and evaluating function-oriented solutions in model-based systems engineering

Increasing complexity and shorter innovation cycles require a rethink in the development of mechatronic products. A function-oriented development process using model-based systems engineering (MBSE) methods promises to identify technical solutions via solution-neutral functional architectures. Since each function can typically be realized by multiple, alternative solutions the combinatorial number of overall system solutions explodes. Existing MBSE approaches enable to establish functional architectures as well as support the verification of solutions. However, evaluating different solution combinations with the current state of research involves repetitive and time-consuming modeling which leads to a heuristic selection of potentially suboptimal solutions. In this paper, we present a method for the systematic and function-oriented composition and model-based evaluation of solution combinations. Alternative solutions are structured based on a functional architecture, so that each possible solution combination can be composed and simulated with a minimum of effort, considering physical interactions and the efficiency. Based on simulation results, solution combinations can be verified against requirements and evaluated striving for the best solution combination. The elaborated method extends an existing MBSE approach and is illustrated by the running example of an electrical coolant pump of a passenger vehicle.

Customer-centric and function-oriented development of mechatronic systems

Successful products at least precisely meet the customers’ expectations and, in the best case, exceed them. To develop successful products, customer expectations must be translated into requirements. With the increasing functionalities of products in recent years, the customers’ expectations regarding product interaction and its behavior in different environmental conditions have also become more extensive. Current approaches of model-based systems engineering (MBSE) enable developing complex mechatronic products seamlessly from requirements to functions and solutions on a parameter level. However, there is a lack of approaches that systematically translate complex customer expectations into functional and design requirements as a starting point for further development.In this contribution we present a method and a corresponding meta-model that allows to systematically formalize the dependencies of different stakeholders and their expectations as well as different environmental conditions and constraints. From these dependencies, operating states are elicited that represent a set of simultaneously valid stakeholder expectations with their corresponding constraints. From these operating states, functional and design requirements are systematically derived as a basis for the model-based design of the system under development. Our meta-model is compatible to the established modeling language SysML, thus, existing approaches for the function-oriented model-based system development can benefit directly from these formally modeled requirements.Our publication signposts the potential for systematic and formal translation of customer expectations into operating states as well as requirements and thus enables a targeted, customer-centric and function-oriented development of mechatronic systems. We applied our method in an interdisciplinary, industrial project using the example of a thermal management system of a battery electric vehicle.

An Integration Matrix for Investigating the Impact of Design Changes in Mechatronic Products

In the design process, design changes are unavoidable due to the need to meet customers’ requirements and support future change through technology development. Although components are supposed to be renewed within existing designs, these changes can propagate into other parts due to their interfaces. Propagation makes it difficult for a designer to identify these changes. This study aimed to introduce the integration matrix (I-DSM), an approach to the design of mechatronic products that involves determining changes in existing products with an axiomatic design. Reverse zigzagging was used to break down the entire product to its lowest level. A design matrix (DM) was constructed and then transformed into a design structure matrix (DSM). The I-DSM consists of three layers: information technology, electrical technology, and mechanical technology. The breadth-first search (BFS) method was employed to ascertain the change propagation path in order to consider it. After this, the changing workload was analyzed, and the decision-making process was used to determine the best possible option. Finally, an automatic guided vehicle was used in a case study to demonstrate the use of this methodology by showing how changes in a product can affect it and how a designer can prioritize activities.

The implementation of the SBCE principles in the V-cycle steps for the development of a mechatronic product and its production system

The implementation of the SBCE principles in the V-cycle steps for the development of a mechatronic product and its production system