Mechatronic Systems Research Articles

Automated Drone Battery Management System—Droneport: Technical Overview

The popularity of using vertical take-off and landing unmanned aerial systems continues to rise. Although the use of these devices seems to be almost limitless, the main drawback is still the battery capacity and the need to replace or recharge it several times per hour. This article provides a technical overview of the development of an experimental mechatronic system for automatic drone battery management called Droneport. It was developed as a system with a landing platform, automatic battery exchange and recharging outside the drone, allowing a quick return to the mission. The first part presents its mechanical design, installed instrumentation and software environment. The next part is devoted to the description of the individual hardware components, highlighting the specific problems that had to be solved to optimize size, weight and robustness requirements. The final section summarizes our observations regarding the contribution of this tool to the autonomy of drones or UAVs in general.

Intelligent Braking System Using Electromagnetic Actuators

The accident prevention has been one of the leading areas of research today. Our paper is designed to prevent accidents due to loss of control, drunken driving, and rash driving, using circuitry aided by a microcontroller kit. This paper focuses on a system known as 'Intelligent braking system' (IBS) which employ several sensors to respond when emergency conditions occur. In our work, braking distance and the distance of the obstacle are taken into consideration along with the speed of the vehicle. The sensor detects speed of movement of the vehicle and the ultrasonic sensor senses the distance of the object in front of vehicle. These sensors provide real- time inputs to the microcontroller program. Using sensor, the system will sense the speed of the vehicle and with the microcontroller, it will calculate the distance required to bring the vehicle to a complete stop for that speed. An intelligent mechatronic system includes an ultrasonic wave emitter provided on the front portion of a car producing and emitting ultrasonic waves frontward in a predetermined distance. An ultrasonic receiver is also placed on the front portion of the car operatively receiving a reflective ultrasonic wave signal. The reflected wave (detected pulse) gives the distance between the obstacle and the vehicle and RPM counter gives speed of vehicle. The reflected wave gives the distance between the obstacle and the vehicle. Then a microcontroller is used to detect the pulses and apply brakes to the vehicle the breaking motors is incorporated to activate the brakes thereby achieving automatic breaking procedures. The system helps in conjunction with the driver judgment if the driver doesn’t sense the obstacle and applies the brake at the right time then the microcontroller initiates braking motor to apply the brakes automatically. Our future work deals with incorporating real time brake shoe wear system to provide enhanced feature for the intelligent braking system. • By looking at safety in terms of avoiding accidents in the first place. • And then protecting occupants when a crash is unavoidable. • We can prevent more accidents, save more lives, and reduce insurance and medical costs to society. Key Words: Braking system, Ultrasonic Sensor, Arduinoboard, Intelligent Mechatronic system, RPM counter, Microcontroller.

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.

Towards an integrated design methodology for mechatronic systems

Towards an integrated design methodology for mechatronic systems

Dynamic performance analysis based on the mechatronic system of power transmission line inspection robot with dual-arm

Dynamic performance of the power transmission line inspection robots (PTLIRs) is of great importance, which would heavily affect the stability of the robot during obstacle avoidance. In this paper, a detailed dynamic performance analysis method of PTLIR is presented by considering the effect on the mechatronic system caused by obstacle avoidance. First, the dynamic modeling of the robot and control system model of the revolute joint are given based on the mechatronic modeling. Then, dynamic characteristics of mechanical subsystem are analyzed by studying the change of the inertia matrix during obstacle avoidance. Next, to analyze the control subsystem performance, three kinds of pole assignment methods which used to tune the controller parameter are compared. Finally, a series of numerical simulations are performed, which prove the time-varying characteristic of load inertia during obstacle avoidance has a great influence on the dynamic performance of the robot, moreover, the changes of natural angular frequency and damping coefficient parameters could be used to evaluate dynamic performance. The main results of the paper can provide an effective tool to analysis dynamic performance of the PTLIR, which is meaningful to improve inspection stability.

Optimizing Cascaded Control of Mechatronic Systems through Constrained Residual Reinforcement Learning

Cascaded control structures are prevalent in industrial systems with many disturbances to obtain stable control but are cumbersome and challenging to tune. In this work, we propose cascaded constrained residual reinforcement learning (RL), an intuitive method that allows to improve the performance of a cascaded control structure while maintaining safe operation at all times. We draw inspiration from the constrained residual RL framework, in which a constrained reinforcement learning agent learns corrective adaptations to a base controller’s output to increase optimality. We first revisit the interplay between the residual agent and the baseline controller and subsequently extend this to the cascaded case. We analyze the differences and challenges this structure brings and derive some principle insights from this into the stability and operation of the cascaded residual architecture. Next, we propose a novel actor structure to enable efficient learning under the cascaded setting. We show that the standard algorithm is suboptimal for application to cascaded control structures and validate our method on a high-fidelity simulator of a dual motor drivetrain, resulting in a performance improvement of 14.7% on average, with only a minor decrease in performance occurring during the training phase. We study the different principles constituting the method and examine and validate their contribution to the algorithm’s performance under the considered cascaded control structure.

Effect of polydispersity in concentrated magnetorheological fluids

Magnetorheological fluids (MRF) are smart materials of increasing interest due to their great versatility in mechanical and mechatronic systems. As main rheological features, MRFs must present low viscosity in the absence of magnetic field (0.1–1.0 Pa.s) and high yield stress (50–100 kPa) when magnetized, in order to optimize the magnetorheological effect. Such properties, in turn, are directly influenced by the composition, volume fraction, size, and size distribution (polydispersity) of the particles, the latter being an important piece in the improvement of these main properties. In this context, the present work aims to analyze, through experiments and simulations, the influence of polydispersity on the maximum packing fraction, on the yield stress under field (on-state) and on the plastic viscosity in the absence of field (off-state) of concentrated MRF (φ = 48.5 vol.%). Three blends of carbonyl iron powder (CIP) in polyalphaolefin oil were prepared. These blends have the same mode, but different polydispersity indexes (α), ranging from 0.46 to 1.44. Separate simulations show that the random close packing fraction increases from about 68% to 80% as the polydispersity indexes increase over this range. The on-state yield stress, in turn, is raised from 30 ± 0.5 kPa to 42 ± 2 kPa (B ≈ 0.57 T) and the off-state plastic viscosity, is reduced from 4.8 Pa.s to 0.5 Pa.s. Widening the size distributions, as is well known in the literature, increases packing efficiency and reduces the viscosity of concentrated dispersions, but beyond that, it proved to be a viable way to increase the magnetorheological effect of concentrated MRF. The Brouwers model, which considers the void fraction in suspensions of particles with lognormal distribution, was proposed as a possible hypothesis to explain the increase in yield stress under magnetic field.

Realization of optimization design of electromechanical integration PLC program system based on 3D model

Abstract A three-dimensional simulation model of the electromechanical control system was built using the fuzzy control proportional–integral–derivative (PID) adjustment algorithm after an automatic electromechanical control system based on programmable logic controller (PLC) technology was optimized to achieve the practical use of electromechanical program control. First, the hardware of the electromechanical control system is discussed and designed. The findings demonstrate the viability of the mechanical and electrical integration PLC program optimization solution based on three-dimensional (3D) model. The system has a higher control and management efficiency, which is 30% greater than that of the conventional system. The mechatronic manufacturing system’s continuous operation efficiency enhancement can significantly lower the investment costs and boost the financial gains of industrial organizations. Traditional systems have a control and management efficiency of around 30%, but automatic electromechanical control systems based on PLC technology and created using 3D models have a control and management efficiency between 60 and 70%.

Numerical and experimental study of the dynamic behaviour of a polymer-metal worm drive

Polymer-metal worm drives are common in automotives and mechatronic systems. Despite this, there is a lack of studies on this type of transmission, especially when it comes to their dynamic behaviour. With the modern orientation of Industry 4.0 towards advancing technology in predictive maintenance, it is of a great importance to consider the study of the dynamic behaviour of this mechanism. It is first proposed to introduce an appropriate dynamic model to correctly simulate, by numerical means, the behaviour of a non-defective polymer-metal worm drive. For this purpose, it is necessary to correctly model the Gear Mesh Stiffness (GMS) of the gearing system. The GMS depends on the nature of the worm and worm gear materials. It is assumed that no deformation occurs in the steel worm, in contrast to the polymer worm whose viscoelastic behaviour must be accurately modelled. Generalized Maxwell Model (GMM) is chosen to model this behaviour. Eventually, the vibration signals from the numerical model are compared with those determined by the experimental tests. To obtain more similarities between the numerical and experimental signals, it is proposed to perform an optimisation. The procedure consists in using the Nelder-Mead simplex method to obtain a minimum residual objective function. After optimisation, an accuracy of 94% between the experimental and numerical results is achieved.

Feasibility of motion control of industrial robots, CNC machine tools and mechatronic systems. Part 2

The problem of realization of control systems in real time is investigated. The relationship between the complexity of control objects and the duration of the control cycle is revealed, according to which, as the complexity of control objects increases, the duration of the control cycle is reduced. This leads to an increase in requirements for the speed of control systems, which can be achieved by increasing the speed of the used electronic component base and other elements of the control system, as well as optimizing the architecture of the control system. One of the most promising directions in the development of real-time control systems for complex objects is the use of a memory-centric architecture of the control system. Keywords: motion control, industrial robot, machine tool, mechatronic system, control cycle, memory-centric architecture. andarmo@yandex.ru

Finite element analysis for fatigue phenomena in mechatronic shape memory alloy actuator

Shape memory alloy (SMA) characterized by several important thermo-mechanical functions. There are becoming a vital actuator in mechatronic systems that can react to electrical current and produce a mechanical action. However, the use of shape memory alloys encounters several challenges in order to integrate these materials in dynamic systems. The need for meticulous precision and short response time is required for the use of SMA actuators in mechatronic applications. On the other hand, the residual deformation cannot be avoided due to the nature of the use of these materials, the phenomenon of fatigue is very frequent that affects the performance and minimizes the life of shape memory alloy actuator. The study proposes a mechatronic system based on two springs of Ni-Ti SMA that controlled by an electric current for ensuring rapid and accurate displacement taking into account fatigue phenomena. Hence, an analysis of fatigue phenomena using a finite element technique has been proposed in order to optimize the usage of shape memory alloy in Mechatronic systems. The proposed model captures both thermo-mechanical behavior that superelasticity and shape memory effect in response to electrical current for SMA actuator. Consequently, the numerical results, analyze the concentration of stress using a finite element method and describe the heat transfer in the system to optimize the response time by improving the heating and cooling times. Model verification was performed using comparison of numerical results with experimental results. The main finding of the current work is the safeguarding of the Ni-Ti superelastic reaction in the proposed system as verified by the variation cycling up to 8% strain, much greater than naturally needed for mechatronic applications. Thus, the response time and the temperature stabilization time of SMA material in response to electric current has been optimized in order to meet the needs of the mechatronic applications.

State of Knowledge Correlation in Failure Analysis of Mechatronics Systems

Mechatronics systems of nuclear power plants (NPP) are safety-critical systems and, hence, accurate estimates of failures of such systems are essentially required. Failures of such systems depends on the correct functionality of their basic components. Component failure modes are identified by developing the models that can lead to failure of systems. Such failure modes are represented as “basic event” in the system models. For accuracy in measurement of failures, it is important to consider the epistemic correlation, in which, the state of the knowledge about failure parameters of the identical components is the same. The epistemic correlation is also termed as state of knowledge correlation. In this article, we provide methods to accommodate the epistemic correlation in the failure estimates for improved accuracy. The experimental results are shown on a case study of NPP mechatronics system.

Energetska optimizacija serijskog hibridnog električnog brodskog porivnog sustava

The electric ship propulsion system due to its economic advantages and, first of all, better mechanical properties than internal combustion engines (influence on ship manoeuvrability) have gained popularity in recent years. This paper presents an investigation of a series hybrid electric propulsion system where two sources of power are used: a permanent magnet synchronous generator and energy storage battery to supply electric propulsion system, which is a permanent magnet synchronous motor. Controlling the power flow from multiple power sources in a series hybrid mechatronic system is important to increase the energy efficiency of the propulsion system. Developing a suitable power flow control method is difficult due to the nonlinear nature of the power sources in the series system. In this paper a method of energy optimization of the system has been verified which allows to improve energy efficiency by reducing reactive power in the system. In this paper, an analytical study of the mechatronic system of a serial hybrid electric ship propulsion system is carried out based on the analysis of the steady-state electromagnetic and energy relations. The proposed control with energy optimization was compared with the commonly used FOC control. The analytical studies have been confirmed by performing simulation studies in Matlab-Simulink program. The proposed optimization method allows its use not only in ship electric drives but also in other autonomous electric drives using the series topology of the hybrid system.

Agile Transformation: A Case Study on Early Stage of Agile Adoption

Abstract Agile transformation is identified as a facilitator to keep pace with frequent changes within product development. Although initial research exists, the empirical literature on the implementation process of the agile approach, specifically using pilot projects as a change strategy, is scarce. The purpose of this article is to contribute to closing this gap by investigating into effects of piloting agile change projects. To shed light on agile pilots a project within the context of mechatronic system development in the high-tech industry was accompanied over six months. After the initiation of the members and a period of practicing agile a survey was performed. The interviewed team members are bringing up interesting findings, as although they had a different understanding of agile at the beginning of the pilot, they recognized agile values, principles and methods as supportive to the products cycle and specifically development time. Further findings are indicating that professional third-party support is a key success factor. Also piloting, as a change strategy for agile adoption, is proven to be supportive. Although piloting is proven a supportive strategy, the downsides, such as limited scalability caused by extraordinary setups, are identified and analyzed. The limiting factor of this single-case study is the small sample size of data due to the intention of the pilot project to limit impact and risk on the organization.

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.

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.

New Trends in the Control of Robots and Mechatronic Systems

In recent years, research into the control of robotic and mechatronic systems has led to a wide variety of advanced paradigms and techniques, which have been extensively analysed and discussed in the scientific literature [...]

Mathematical model of the closed-loop system of excavator bucket positioning

Purpose. Study on energy consumption of mechatronic systems of mining excavators during the full production cycle, development of energy efficiency criterium for the production cycle of mining excavators, which ensures an increase in the technical and economic indicators of the operation of powerful mining equipment. Methodology. Mathematical modeling of electro-mechanical system of “front shovel” excavator, determination indicators of the production cycle, development of the criterion of energy efficiency of the mining excavator’s operating cycle taking into account the theory of technical systems efficiency. Findings. A mathematical model of a complete electro-mechanical system of an excavator with “generator-engine” electric drive has been developed, which includes a model of the mechanical part of the excavator. The closed-loop bucket positioning system makes it possible to implement various movement trajectories during the operating cycle. Numerical characteristics of energy consumption and duration for various movement trajectories of the working bodies of the excavator are obtained. A new criterion of energy efficiency of mechatronic systems of mining excavators is proposed. Originality. For the first time, a mathematical model has been proposed of an integral electro-mechanical system of an excavator according to the “front shovel” scheme, which includes models of electric drives of all mechanisms and a synchronous drive motor, as well as a model of the mechanical part of the excavator; this makes it possible to increase the accuracy of determining the excavator’s energy consumption and the operating cycle time. A criterion of energy efficiency is proposed, which takes into account the amount of resource costs, the overall result and the duration of the excavator’s operating cycle. Practical value. A mathematical model of the electromechanical system of an excavator with an electric drive according to the “generator-motor” system has been developed, which, taking into account the solution of the direct and inverse problems of the kinematics of the mechanical system of the excavator, makes it possible to compare parameters of various trajectories of movement of the excavator. The implementation of a closed system for positioning the excavator bucket in three-dimensional space was proposed, which creates conditions for increasing the level of automation of mining excavators. A criterion of the energy efficiency of the excavator’s technological cycle is proposed, which takes into account resource costs and the technological cycle duration.

Performance evaluation of an electronically controlled tractor-operated applicator for liquid urea application

Currently, granular urea (most commonly used fertilizer) is applied through broadcasting by farmers in the field. Granular urea causes significant losses due to slower soil mineralization rates, as well as ammonia volatilization and immobilization. Hence, fertilizing crops is becoming an increasingly difficult task due to low use efficiency and in mulch field conditions, it becomes more severe. The research done on mechatronic systems of applying liquid fertilizer by spot injection in field is limited. In the present study, the performance of the developed tractor operated liquid urea applicator consisting of electronic metering mechanism was evaluated at the Research Farm of Punjab Agricultural University, Ludhiana, Punjab during 2020–22. Research was done at two different types of soil (S1: sandy loam, and S2: loam) for three different forward speeds (3.6, 2.7, 1.8 km/h). Results obtained from experiments indicated that both soil type and forward speed had a significant (P<0.05) effect on the application rate of liquid urea. The best results were obtained without affecting crop yield at a forward speed of the machine 2.7 km/h with the application rate of 1090.85 litre/ha and 1035.18 litre/ha, fuel consumption 4.13 litre/h and 4.02 litre/h and crop yield 39.50 q/ha and 39.63 q/ha, for soil type S1 and S2 respectively. The cost of operation of machine was found 1996.53 `/ha. Developed tractor operated liquid urea applicator would help in improving conventional practices which are not aligned with environmental protection (e.g. gaseous emissions and nutrient losses) and boost the adoption rate of mechanized fertigation in the crops.

From playground swings to sway control of cranes: An active pendulum experiment

Dynamics is a core discipline in Mechanical and Aerospace Engineering programs and with the ubiquitous nature of control in modern-day applications, the field of mechatronics has gained popularity. Mechatronics refers to the field of engineering which integrates the engineering disciplines of mechanical, control, electronics, and computing. To create a testbed to illustrate a tabletop mechatronics system, the paper details the design, and fabrication of an active pendulum whose length can be changed in real-time using solenoids. This permits illustrating two concepts: (1) damping of pendulum oscillations which emulates the sway of a crane and (2) amplification of the oscillations which emulates the pumping of a playground swing. The paper describes the steps prior to experimental validation which includes: modeling, system identification, signal processing, and controller implementation. Numerical simulations are used to prototype the controller and eventually to compare the simulation results to the experimental ones. The results of all the experiments illustrate a close match between the simulated and experimental results. To permit reproduction of the experiment, the design details and code to implement the controllers are posted in a public repository.