Mechatronic Products Research Articles

Integrated optimisation method for controlled dynamic mechanical systems

It is difficult to consider the interaction among mechanical parts, mechanical system and control system when carrying out design optimisation of mechatronic products which are usually controlled dynamic mechanical systems. A cosimulation based integrated optimisation method, which achieve topology optimisation of mechanical parts, mechanical system optimisation and controller parameter optimisation in one optimisation process, is presented. The proposed optimisation process considers the interaction among mechanical parts, the mechanical system and the control system within a controlled dynamic mechanical product. The principles of the optimisation process and a software framework are given. Different discipline software tools can run automatically in the presented framework. With the integrated optimisation process, the mechanical properties of the parts, the dynamics performance of the mechanical system and the overall dynamic properties of the mechatronic product can simultaneously achieve the optimum. The effectiveness is verified by a controlled crank-connecting rod mechanism with a flexible connecting rod.

Integrating Environmental Impacts with SysML in MBSE Methods

The continuously growing integration of mechanics, electronics, and informatics into modern products introduces a considerable complexity into product development activities. Model-Based Systems Engineering (MBSE) methods are one approach to handle this complexity. Eco-design methods, which are also increasingly important due to sustainability focus of many companies, is not fully implemented or even not taken into account at all in MBSE methods. Therefore, this paper aims at integrating the environmental impacts of a mechatronic product in a MBSE method using Systems Modelling Language (SysML).

Parametric optimization in virtual prototyping environment of the control device for a robotic system used in thin layers deposition

The paper deals with the optimal design of the control system for a 6-DOF robot used in thin layers deposition. The optimization is based on parametric technique, by modelling the design objective as a numerical function, and then establishing the optimal values of the design variables so that to minimize the objective function. The robotic system is a mechatronic product, which integrates the mechanical device and the controlled operating device.The mechanical device of the robot was designed in the CAD (Computer Aided Design) software CATIA, the 3D-model being then transferred to the MBS (Multi-Body Systems) environment ADAMS/View. The control system was developed in the concurrent engineering concept, through the integration with the MBS mechanical model, by using the DFC (Design for Control) software solution EASY5. The necessary angular motions in the six joints of the robot, in order to obtain the imposed trajectory of the end-effector, have been established by performing the inverse kinematic analysis. The positioning error in each joint of the robot is used as design objective, the optimization goal being to minimize the root mean square during simulation, which is a measure of the magnitude of the positioning error varying quantity.

Discussion of Robot Application Laboratory Construction

Robot is a typical mechatronics product and the best teaching and research platform for the students in automated control, electric information, mechanical engineering, sensor and measuring technology, computer hardware and software, artificial intelligence, etc. In the background of emphasizing education should return to engineering itself, this work discusses the thought and background, constructing principles, constructing goal and constructing plan of the robot engineering practice innovation laboratory in university engineering courses. Its final goal is to widen the students' comprehensive domain knowledge, develop multi intelligences, improve their innovation, practice and the ability of self-constructing knowledge.

Controllability of Radial Magnetic Bearing

The magnetic bearing works on the principle of magnetic levitation. Integration of the geometric and control designs is the current trend in mechatronic products. Conventionally, in control of rotors in the vertical direction, it must be supported at two places by radial magnetic bearings. A thrust magnetic bearing is also provided to prevent axial movement of the shaft. In the present work, control design methodology of four pole pair active magnetic bearings has been proposed. This work is dealing with the modeling, investigations and controlling of radial magnetic bearing system. Considerations based on the four pole pair's model with switched mode power supply. Investigations of radial forces in two axes model and performance response are carried out through the PID controller system. The response is presented for standstill and dynamic conditions using the implemented Simulink software. Simulation results showed that rotor is in standstill position with constant air gap of 1mm. This validates bearing design dimensions and system parameters designed for control of four pole pair radial magnetic bearing considering 1mm air gap length.

Model Factory for Additive Manufacturing of Mechatronic Products: Interconnecting World-class Technology Partnerships with Leading AM Players

The additive manufacturing (AM) model factory's aim is to establish a leading-edge learning academy for the digital and generative production of innovative mechatronic products, where the complete value chain is integrated on a single site. Short courses and deep dives enable easier access to the state of the art technologies and increase the awareness for their potentials. Anchored in key industries such as automotive, aerospace, and medical by major OEMs and regional SMEs, the AM model factory cooperates with world-class partners and leading market players. This paper displays the model factory's setup, selected technologies, exemplary courses, and benefits.

Modular Inspection Equipment Design for Modular Structured Mechatronic Products – Model Based Systems Engineering Approach for an Integrative Product and Production System Development

Quality control is an essential part of the production of modular mechatronic systems. Especially the quality inspection of the overall system at the end of the production is of extraordinary importance. The associated inspection equipment can also be a mechatronic system, which is often explicitly designed and manufactured for one product with a large expenditure of time. In order to have the needed inspection equipment ready by the start of production (SoP) and to consider additional requirements to the product, which are produced by the inspection equipment concept, an integrative mechatronic product and inspection equipment development procedure is needed. Furthermore, the inspection system has to consider the modularity of the system and often has to be designed in a modular way. Nowadays, the development of complex mechatronic systems is often carried out with the help of model-based systems engineering (MBSE) methods. Consequently, the inspection equipment should also be designed with the help of MBSE. This paper describes an integrative product and inspection equipment procedure for modular mechatronic systems with the help of MBSE. Especially the peculiarity of the modularity is described and validated with the help of an application example.

A customer requirement driven framework for design synthesis - applied to a washing machine

Abstract: In order to maximize the success of a product, the customers’ wishes need to be integrated into the entire product design process. The design of a mechatronic system can be divided in a 3 different phases, requirements engineering, architectural design and detailed design. During the requirement phase, customers needs are translated into engineering characteristics. In the architectural phase, the topology, consisting of the number and type of components, as well as some key properties (size, material) of the different components, is chosen. This phase has a major impact on the final product performance. Since (mechatronic) products need to meet an ever increasing number of performance specifications and constraints, recently computational design synthesis approaches have been developed to support design engineers. These types of methods use computational power and computer models to search the design space in an automatic way. However, as these methods focus entirely on maximizing the functional performance, the customers’ actual wishes and needs may slip to the background. This article presents a novel computational design synthesis approach which integrates design space exploration and Quality Function Deployment during the architectural design phase. The proposed method allows to generate architectures that maximize customer satisfaction. The effectiveness is illustrated by an industrial case study: the design of the mechanical architecture for a washing machine.

Design models in the development of mechatronic systems: virtual prototyping and mechatronic module development process

Modelling and simulation tools support to reduce the number of physical prototypes in the development of multidomain systems. Virtual prototyping of the multidomain systems is one of the essential steps to decrease the time of the product development. In mechatronic systems, mechanical, electrical and software domains cannot be developed independently from each other at the beginning of the earliest design phases. Integrated, virtual and mathematical models are developed as they are less time consuming and are less expensive than physical prototypes. This paper explores design process of mechatronic product development with the aid of models. V-model is used as a basic approach in the design process. Virtual model of an electromechanical system is developed by using Bond graph method and the response of the system is simulated in a software tool 20-sim. This development process is summarised in a model from design integration to simulation of the system. Furthermore, the overall design process of the system is illustrated in a model that is based on mechatronic module development. That includes mainly the allocation of requirements to individual domains and illustrating the steps in the design process.

Towards Agile Engineering of Mechatronic Systems in Machinery and Plant Construction

Agile procedures (e.g. Scrum) are commonly used in rapidly changing environments of software engineering. Experts appreciate improvements in interdisciplinary collaboration, lead times and development costs by applying agile techniques as artifacts, meetings, roles and visualisation methods. Up to now, the use of agile procedures is still limited to IT-projects, due to a lack of profound knowledge in transferring agile techniques into interdisciplinary projects. This contribution presents the research work on Agile Engineering, a counterpart of Lean Product Development, by the systematic integration of agile techniques into the development process of mechatronic production systems. Thereto, an introduction and state of the art is given concerning the industry sector of machinery and plant construction as well as agile methodologies. The main focus of the paper is represented by the classification and comparison of Agile Engineering as well as the main features of integrating agile techniques into the mechatronic engineering process. According to the advanced research insights of the last years, Agile Engineering is a new enabler of success for establishing an agile production, providing promising approaches for coping with change and uncertainty efficiently.

Interdisciplinary Development of Production Systems Using Systems Engineering

Currently Systems Engineering is used in product development to support interdisciplinary collaboration and to manage rising complexities at a given time and cost frame. Production system development is facing similar challenges. Especially production systems for mechatronic products and Cyber Physical Systems demand interdisciplinary approaches. Therefore this paper investigates how Systems Engineering can be applied to cope with these arising challenges in production system development. On the basis of a comparison between current production system development procedures and Systems Engineering methodologies, potential improvements are identified and a tailored production system development approach is presented.

ModelTracer: User-friendly Traceability for the Development of Mechatronic Products

The development of complex mechatronic systems demands an integration of models throughout the virtual product development process. Systems engineering is an approach for enabling the development of successful interdisciplinary products. Traceability, one of the most important aspects of systems engineering, is a method for explicit documentation of logical relationships between development artifacts. In this paper we present a prototype traceability tool, ModelTracer, which aims to reduce the cognitive effort for the creation and maintenance of traceability models in systems engineering.

Axiomatic Design Applied to the Development of a System for Monitoring and Teleoperation of a CNC Machine through the Internet

The new era of manufacturing, called industry 4.0, will require the intensive use of mechatronics products. In this context, there are Cyber- Physical Systems and Internet of Things (IoT). These are represented by platforms that are integrated through connectivity protocols that permit a wide sharing of information among different devices. The design of these applications requires a methodology that sets requirements by reducing the complexity inherent in the development of these systems. As such, the Axiomatic Design (AD) has the capacity to simplify this kind of design process. This work studies the application of Axiomatic Design to the planning of a system for monitoring and teleoperation through the Internet of a Romi-Galaxy 15M machine tool with CNC Fanuc 18i-Ta, using the open standards OPC-UA and MTConnect. As a result, the functional requirements (FR) were formulated and, consequently, the design parameters (DP), which are represented by classes in an object-oriented application.

Redesign of Mechatronic Products for Functional Adaptability by Identification of Shared Components and Synthesis of Interfaces

Redesign of Mechatronic Products for Functional Adaptability by Identification of Shared Components and Synthesis of Interfaces

Modular Platform Design for Mechatronic Systems using Axiomatic Design and Mechatronic Function Modules

This paper introduces a method for the design of modular product platforms (MPP) for highly integrated mechatronic products applying axiomatic design and a system decomposition into mechatronic function modules (MFM). In the first step, using an extended axiomatic design approach, the complex system is decomposed into MFM. The application of axiomatic design ensures a strong function-orientation which is required in mechatronic system development. In the second step, the MFM are designed for use in a product platform. The methodology is applied in a case study considering the design of a MPP for electromechanical steering systems for use in personal vehicles.

Advances in standardized approach to ECAD/MCAD collaboration

Adopting the mechatronics as contemporary most emerging engineering discipline the integration of mechanical and electrical computer aided design (CAD) (MCAD/ECAD) systems remains a big challenge in concurrent engineering because their data models and functionality have been developed continuously further apart. Market research confirms that an integrated tool chain for ECAD and MCAD design is prerequisite for a better mechatronic development process. This paper presents the overview of various integration approaches with different degree of maturity and describes the concept of deep integration for mechatronic products conducted by ProSTEP iViP Association which combines existing standards in engineering collaboration context. Version 3 of the current ProSTEP iViP Recommendation PSI 5 entitled “ECAD/MCAD-Collaboration” provides a comprehensive specification for collaboration between the ECAD and MCAD worlds. A considerable number of vendors have now implemented the underlying data schema and integrated it in the corresponding products. As a result, users can now choose the solutions that best meet their particular needs from an increasingly wide range of efficient systems for collaborative product development within the ECAD and MCAD fields.

Embedded Systems via Using Microcontroller

Paper deals with microcontrollers which are embedded inside the mechatronic products. Main purpose is to obtain intelligent behavior of products and adding of new functions to products. Paper shows steps to data capturing into microcontroller for data processing and using as feedback control of processes around the products.

Knowledge Push Technology for Complex Mechatronic Products Design Based on Ontology and Variable Precision Rough Set

In this paper, we present a new knowledge push technology for complex mechatronic products design based on ontology and variable precision rough set (VPRS). Ontology can explicitly represent knowledge semantics and let designers exchange knowledge about design and the product development process; while using the knowledge reduction method based on the VPRS method, the design knowledge repository is simplified and design rules also be distilled from the reduct design knowledge repository. On the basis of the above approach, multiple designers can efficiently share design knowledge and can obtain appropriate design knowledge during all design processes. Finally, a case is employed to validate the proposed method of this paper.

Ontological modelling of knowledge management for human–machine integrated design of ultra-precision grinding machine

ABSTRACTDespite the rapid development of computer science and information technology, an efficient human–machine integrated enterprise information system for designing complex mechatronic products is still not fully accomplished, partly because of the inharmonious communication among collaborators. Therefore, one challenge in human–machine integration is how to establish an appropriate knowledge management (KM) model to support integration and sharing of heterogeneous product knowledge. Aiming at the diversity of design knowledge, this article proposes an ontology-based model to reach an unambiguous and normative representation of knowledge. First, an ontology-based human–machine integrated design framework is described, then corresponding ontologies and sub-ontologies are established according to different purposes and scopes. Second, a similarity calculation-based ontology integration method composed of ontology mapping and ontology merging is introduced. The ontology searching-based knowledge sharing method is then developed. Finally, a case of human–machine integrated design of a large ultra-precision grinding machine is used to demonstrate the effectiveness of the method.

Ontology-based coupled optimisation design method using state-space analysis for the spindle box system of large ultra-precision optical grinding machine

With the increasing complexity of mechatronic products, traditional empirical or step-by-step design methods are facing great challenges with various factors and different stages having become inevitably coupled during the design process. Management of massive information or big data, as well as the efficient operation of information flow, is deeply involved in the process of coupled design. Designers have to address increased sophisticated situations when coupled optimisation is also engaged. Aiming at overcoming these difficulties involved in conducting the design of the spindle box system of ultra-precision optical grinding machine, this paper proposed a coupled optimisation design method based on state-space analysis, with the design knowledge represented by ontologies and their semantic networks. An electromechanical coupled model integrating mechanical structure, control system and driving system of the motor is established, mainly concerning the stiffness matrix of hydrostatic bearings, ball screw nut and rolling guide sliders. The effectiveness and precision of the method are validated by the simulation results of the natural frequency and deformation of the spindle box when applying an impact force to the grinding wheel.