Mechatronic Systems Research Articles

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.

Transforming construction: The growing role of mechatronics in building our infrastructure

Mechatronics, the synergistic integration of mechanical engineering, electrical engineering, control engineering, and computer science, is progressively transforming the construction industry. This paper explores how mechatronic technologies are being applied across the construction lifecycle to enhance productivity, quality, safety, sustainability, and cost-effectiveness. Core mechatronic technologies changing construction include automated material handling systems, advanced construction robotics, sensor networks for monitoring, laser scanning for accurate modeling and control, and building information modeling (BIM) software. Mechatronics offers multifaceted benefits spanning from enhanced labor productivity and construction velocity to superior quality control, safety, and process optimization. However, realizing the immense potential of mechatronics in construction requires overcoming key challenges including high upfront costs, lack of technical skills, organizational resistance, integration difficulties, and reliability concerns. With thoughtful leadership and implementation, mechatronics promises to revolutionize construction, shifting it towards more automated, streamlined, and optimized techniques. This paper delineates the tremendous potential of mechatronics in construction regarding benefits, technologies, and challenges. The outlook is promising for intelligent mechatronic systems to profoundly enhance productivity, quality, and safety as construction progresses towards greater automation and optimization.

Fabrication of Intelligent Braking System

Abstract: The braking system was designed and applied on a car to make the driving process safety using embedded system design. Most of the accident occurs due to the delay of the driver to hit the brake, so in this project work braking system is developed such that when it is active it can apply brake depending upon the object sensed by the Proximity sensor and speed of vehicle. Currently, vehicles are often equipped with active safety systems to reduce the risk of accidents, many of which occur in the urban environments. The most popular include Antilock Braking Systems (ABS), Traction Control and Stability Control. All these systems employ different types of sensors to constantly monitor the conditions of the vehicle, and respond in an emergency situation. An intelligent mechatronic system includes an Proximity wave emitter provided on the front portion of a car producing and emitting Proximity waves frontward in a predetermined distance. An Proximity receiver is also placed on the front portion of the car operatively receiving a reflective Proximity wave signal. The reflected wave (detected pulse) gives the distance between the obstacle and the vehicle and RPM counter gives speed of vehicle. The microcontroller is used to control the braking of the vehicle based on the detection pulse information to push the brake pedal and apply brake to the car stupendously for safety purpose.

Flatness‐based control in successive loops for mechatronic motion transmission systems

AbstractMechatronic systems with nonlinear dynamics are met in motion transmission applications for vehicles and robots. In this article, the control problem for the nonlinear dynamics of mechatronic motion transmission systems is solved with the use of a flatness‐based control approach which is implemented in successive loops. The state‐space model of these systems is separated into a series of subsystems, which are connected between them in cascading loops. Each one of these subsystems can be viewed independently as a differentially flat system, and control about it can be performed with inversion of its dynamics as in the case of input–output linearized flat systems. In this chain of subsystems, the state variables of the subsequent ( )‐th subsystem become virtual control inputs for the preceding ‐th subsystem and so on. In turn, exogenous control inputs are applied to the last subsystem and are computed by tracing backwards the virtual control inputs of the preceding subsystems. The whole control method is implemented in successive loops, and its global stability properties are also proven through Lyapunov stability analysis. The validity of the control method is confirmed in the following two case studies: (a) control of a permanent magnet linear synchronous motor (PMLSM)‐actuated vehicle's clutch and (ii) control of a multi‐Degrees of Freedom (multi‐DOF) flexible joint robot.

Pipe Organ Design Including the Passive Haptic Feedback Technology and Measurement Analysis of Key Displacement, Pressure Force and Sound Organ Pipe

In this work, an organ pipe instrument with a mechatronic control system including the Passive Haptic Feedback technology is implemented. The test bed consists of a motorized positioning stage mounted to a brace that is attached to a bridge on a platform. A simple pneumatic mechanism is designed and realized to achieve the same dynamics pressure for each measurement attempt on the keyboard. This system contain pipes, an air compressor, valves, and a piston connected to applied force pressure on the keyboard of the organ pipe. The pneumatic components, like valves and pressure regulators, mounted on the profile plate are connected to the main air supply line via flexible tubing or hoses to the air compressor and mechanical trucker. The pneumatic system has many types of valves that regulate the air speed, air flow, and power. The combination of valves and air compressor control the air flow and the mechanism of piston and pressure on the keyboard. The mechanical actuator presses the key to be tested, and a load cell detects the applied key force. A laser triangulation measurement system based on a Laser Displacement Sensor measures the displacement of the key during the key depression. The velocity of the key motion is controlled by the pneumatic actuator. A miniature-sized strain gauge load cell, which is mounted on a musical keyboard key, measures the contact force between the probe and the key. In addition, the quality of the audio signal generated by the organ instrument is estimated using the Hilbert transform.

Dynamic Decoupling Method Based on Motor Dynamic Compensation with Application for Precision Mechatronic Systems

Motors are widely employed in mechatronic systems, especially in precision multiple degrees of freedom motion systems. In most applications, the dynamic equation between the motor instruction and the actual driving force is simplified as a constant. Subsequently, the static decoupling method can be utilized to design the feedback controller. However, in high-precision mechatronic systems, motor dynamics cannot be neglected, and the static decoupling performance is compromised due to discrepancies between motors. In this paper, a dynamic decoupling method is developed to improve the decoupling performance of the multiple-input multiple-output systems. The effects of transmission delays, motor dynamics, and discrepancies between different motors are taken into consideration in the dynamic decoupling method. Furthermore, a data-driven optimization method is developed to estimate the parameters of the dynamic decoupling controller. The effectiveness and superiority of the proposed method are demonstrated through numerical simulations. The experimental results show that the dynamic decoupling control method can achieve a 97.75% performance improvement at least compared to the static decoupling control method.

A CNN-BiLSTM-Attention approach for EHA degradation prediction based on time-series generative adversarial network

As a representative integrated system for power-by-wire (PBW) systems, Electro-hydrostatic actuator (EHA) has series of advantages such as high power density, compactness, and high efficiency, which is one of the important development directions of future hydraulic system field. However, due to its high integration and high reliability requirements, it is challenging to conduct degradation studies in short period of time with limited data samples. For this type of high integrated mechatronics system, Prognostics and Health Management (PHM) is one of the key works to ensure its safety and reliability, especially the performance degradation prediction presented in this paper. To deal with the small size of EHA data, a time-based data enhancement method for expanding the performance data set is proposed based on Time Generative Adversarial Network (TimeGAN). Considering the complex of working state and system performance, the relationship between the EHA operation data and its health indicator is then analyzed using the CNN-BiLSTM-Attention model, so as to generate the health indicator combine with TimeGAN synthesis data. Finally, CNN-BiLSTM-Attention model with multi-input channels is developed, and EHA data as well as TimeGAN synthesized EHA data are incorporated into the model. The results show that this method can greatly improve the prediction accuracy of EHA performance, and provide a novel method for performance degradation prediction of integrated mechatronic system.

Model study of the controlled rectifier of mechatronics systems

The article discusses the types of semiconductor converters for mechatronics systems and the possibilities of their model research using MATLAB software. A model study of a three-phase controlled rectifier as a regulated power source is considered. The rectifier model includes units for measuring the constant component of the load current and measuring the constant component of the load voltage, a unit for measuring the amplitude and phase of the first harmonic of the supply current, a unit for measuring the active supply current, and a unit for measuring the active and average thyristor currents. An important aspect of the research is the ability to perform a spectral analysis, taking into account that the energy conversion process is associated with the distortion of the current and voltage forms. It is possible to quantify these distortions when expanding non-sinusoidal currents and voltages into a Fourier series when performing spectral analysis using MATLAB.

STUDY OF THE EFFICIENCY OF THE FUNCTIONING PROCESS OF THE MECHATRONIC SYSTEM OF ENSURING THE MICROCLIMATE OF ANIMAL PREMISES

The development of the livestock industry is the basis of Ukraine's food security. One of the ways to solve this problem is to improve the conditions of keeping animals, including improving the microclimate of livestock and poultry premises. Modern animal husbandry technologies make high demands on the microclimate in livestock premises. According to scientists, animal husbandry specialists and technologists, animal productivity is determined by 50...60% feed, 15...20% by care, and 10...30% by the microclimate in the livestock premises. Deviation of the microclimate parameters from the established optimal limits leads to a decrease in milk yield by 10...20%, an increase in live weight – by 20...35%, an increase in the departure of young animals to 5...40%, and a decrease in laying hens – by 30%...35%, costs of an additional amount of feed, shortening the service life of equipment, machines and the buildings themselves, reducing the resistance of animals to diseases, negatively affecting the service personnel. The article presents a structural and technological scheme of a mechatronic system for ensuring a normative microclimate of livestock premises, which allows to increase the efficiency of ensuring a normative microclimate of livestock premises by using a mechatronic system for controlling the process of air disinfection using ultraviolet radiation of bactericidal lamps. According to the results of numerical modeling of the air heat exchanger of the indirect-evaporative type, the distribution of the temperature field, vector field of velocities and absolute air humidity in channels of different shapes (square, equilateral triangle, circle) was established. The calculated coefficient of thermal efficiency of the heat exchanger with triangular shaped channels is the whitest in contrast to square and round shapes. A comparative analysis of humidity distribution in channels of different shapes confirms that the absolute humidity of the thermal air flow decreases earlier in the indirect-evaporative type heat exchanger with triangular channels.

SY-MIS Project: Biomedical Design of Endo-Robotic and Laparoscopic Training System for Surgery on the Earth and Space

Despite the location (Earth or Space), surgical simulation is a vital part of improving technical skills and ensuring patients' safety in the real procedure. The purpose of this study is to describe the Space System for Minimally Invasive Surgery (SY-MIS©) project, which started in 2016 under the supervision of the Center for Space Systems (C-SET). The process connects the best features of the following machines: Biomedik Surgeon, Space Biosurgeon, SP-LAP 1, and SP-LAP 2, which were defined using the VDI 2221 guidelines. This research uses methods based on 3 standards: i) Biomedical design: ISO 9001-13485 / FDA 21 CFR 820.30 / ASTM F1744-96(2016); ii) Aerospace human factors: HF-STD-001; iii) Mechatronics design: VDI 2206. The results depict the conceptual biomedical design of a novel training system named Surgical Engineering and Mechatronic System (SETY©), which integrates the use of 2 laparoscopic tools and 2 anthropomorphic mini-robotic arms (6 DOF). It has been validated by the Evaluation of Technical Criteria, getting a total score of 90% related to clinical assessment, machine adaptability, and robustness. The novelty of the research lies in the introduction of a new procedure that covers the simultaneous use of laparoscopic and robotic systems, named Hybrid Cyber-Physical Surgery (HYS©). In conclusion, the development of SY-MIS© promotes the use of advanced technologies to improve surgical procedures and human-machine medical cooperation for the next frontier of habitability on other planets. Doi: 10.28991/ESJ-2024-08-02-01 Full Text: PDF

Nondimensional analysis and experimental assessment of the PII1/2DD1/2 position control of a rotary axis

Fractional Order controllers, based on derivatives and integrals of non-integer order, represent a propitious and promising research area since they can improve the performance of mechatronic systems compared to traditional Integer Order PID controllers without requiring hardware upgrades, but only using their higher tuning flexibility. Nevertheless, Fractional Order controllers are still rarely applied in real automation tasks, since their tuning is more complex and in general requires a model-based optimization for full exploitation of their capabilities. Recently, the PII1/2DD1/2 controller has been proposed, extending the classical PID by introducing a half-integral and a half-derivative term. A Bode plot-based tuning method has been presented for this controller, deriving the PII1/2DD1/2 parameters from a given set of PID gains. This method enables a significant reduction in tracking error for position control of a mechatronic axis without the need for complex model-based optimizations. In this paper, the previous results of this PII1/2DD1/2 tuning methodology have been generalized by employing a nondimensional approach. This approach highlights the conditions under which the benefits of this Fractional Order controller over the PID are most significant. The findings have been validated through experimental tests on a rotary axis, confirming the correctness and usefulness of the method.

Mechatronic automatic control system of electropneumatic manipulator

Mechatronic systems of electropneumatic automation are one of the main classes of industrial automation systems. A laboratory stand for the study of the mechatronic system of automatic control of the pneumatic manipulator and a computer model for preliminary experiments on the adjustment of the automatic control system were developed. Manual and software control modes are provided for research of indicators of safety and quality of management in both modes. To implement the software control mode, a microcontroller part of the laboratory stand based on ADuC841 was developed, with the help of which it is possible to simulate a part of a certain technological process, to detect and eliminate faults in the automatic control system. A study of automatic control systems using a traditional relay-contactor control system, based on GrafCet technology and using a virtual controller. The combination of computer modeling of technological processes and physical modeling of executive mechanisms is a kind of digital double that displays its state, parameters and behavior in real time. The use of a laboratory stand in combination with an adequate simulation model reduces the complexity of developing control systems for practical applications, and also contributes to the formation of students' creative component, ability to analyze the results, and make decisions in unusual situations, which will increase their theoretical and practical training. The study of mechatronic systems of pneumatic manipulators will allow to increase their efficiency and productivity, to optimize their speed and accuracy for various applications in production. The interaction of mechatronic systems of pneumatic manipulators with other technologies, such as machine learning, artificial intelligence, IoT is the basis for creating more integrated and intelligent systems.

Search for Optimal Parameters in the Control Structure of a Surgical System for Soft Tissue Operations Based on In Vitro Experiments on Cardiovascular Tissue

The surgical robots currently used in cardiac surgery are equipped with a remote center of motion (RCM) mechanism that enables the required spherical workspace. The dynamics model of the surgical robot’s RCM mechanism presented in this work includes a direct current (DC) motor, an optimal proportional–integral–derivative (PID) controller, and a LuGre friction model that takes into account the Stribeck effect and surface deformation. A finite element method (FEM) analysis of transients was carried out using the energy hypothesis of von Mises with an optimal input signal from the mechatronic system with a PID controller obtained using the Runge–Kutta differentiation method in the Dormand–Prince ordinary differential equations variant (ODE45). Five criteria were adopted for the objective function: the safety factor related to the stress function in the time-varying strength problem, the first natural frequency related to stiffness and the resonance phenomenon, the buckling coefficient in the statics problem related to stability, the static factor of safety, and the displacement of the operating tip. The force inputs to the dynamics model were derived from in vitro force measurements on cardiovascular tissue using a force sensor. The normality of the statistical distribution of the experimental data was confirmed using the Kolmogorov–Smirnov statistical test. The problem of multi-criteria optimization was solved using the non-sorter genetic algorithm (NSGA-II), the finite element method, and the von Mises distortion energy hypothesis. Velocity input signals for the transient dynamics model were obtained from a second in vitro experiment on cardiovascular tissue using the minimally robotic invasive surgery (MIRS) technique. An experienced cardiac surgeon conducted the experiment in a modern method using the Robin Heart Vision surgical robot, and a system of four complementary metal–oxide–semiconductor (CMOS) optical sensors and ariel performance analysis system (APAS-XP 2002) software were used to obtain the endoscopic tool trajectory signal. The trajectory signal was accurate to ±2 [mm] in relation to the adopted standard, and it was smoothed using the Savitzky–Golay (SG) polynomial smoothing, whose parameters were optimally selected using the Durbin–Watson (DW) statistical test.

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.

Optymalne sterowanie hybrydowe układem giroskopowym

The paper analyses the selection of optimal controllers (LQR, SMC and PD) for a mechatronic gyroscope system used in scanning-tracking heads of mobile objects such as spacecrafts, unmanned land vehicles, flying drones or self-guided missiles. The integral of the absolute value of the deviation error of the set motion from the real moving object and the integral of the square of the state and control have been taken as the quality criterion. The results of computer simulation studies are presented.

Mechatronic Spatial Atomic Layer Deposition for Closed‐Loop and Customizable Process Control

AbstractA customized atmospheric‐pressure spatial atomic layer deposition (AP‐SALD) system is designed and implemented, which enables mechatronic control of key process parameters, including gap size and parallel alignment. A showerhead depositor delivers precursors to the substrate while linear actuators and capacitance probe sensors actively maintain gap size and parallel alignment through multiple‐axis tilt and closed‐loop feedback control. Digital control of geometric process variables with active monitoring is facilitated with a custom software control package and user interface. AP‐SALD of TiO2 is performed to validate self‐limiting deposition with the system. A novel multi‐axis printing methodology is introduced using x‐y position control to define a customized motion path, which enables an improvement in the thickness uniformity by reducing variations from 8% to 2%. In the future, this mechatronic system will enable experimental tuning of parameters that can inform multi‐physics modeling to gain a deeper understanding of AP‐SALD process tolerances, enabling new pathways for non‐traditional SALD processing that can push the technology towards large‐scale manufacturing.

Integration of Mechatronic Functions on Additively Manufactured Components via Laser‐Assisted Selective Metal Deposition

AbstractThe current industrial revolution derives much of its momentum from value creation based on interconnected products and related data based services. Such products must fulfill both mechanical and electrical requirements, making them mechatronic systems. The production of such systems via additive manufacturing (AM) processes offers advantages in achievable complexity, reduction of the amount of individual components, and cost‐effective as well as sustaina ble production of small quantities. In this work, a process chain is presented that allows for refining additively manufactured 3D structures made from industry‐standard materials into mechatronic components by creating electrically conductive structures directly on their surfaces. The process chain is based on masking the component's surface and selectively removing the masking according to the circuit geometry using laser radiation. In a wet–chemical bath process, the surface is then exposed to palladium nuclei, the masking is fully removed and metal layers (copper/nickel/gold) are deposited by electroless plating. The procedure is developed using stereolithography as a model process for AM and transferred to four additional AM methods. In all cases, despite markedly different surface properties, good selectivity of metal deposition is observed as well as adhesion strength and conductivity comparable to industrially common injection‐molded laser direct structured mechatronic interconnect devices.

ПЕРСПЕКТИВЫ ПРОЕКТИРОВАНИЯ И ПРИМЕНЕНИЯ МЕХАТРОННОГО СТАНОЧНОГО ОБОРУДОВАНИЯ В ГИБРИДНОМ ПРОИЗВОДСТВЕ

World trends and prospects of development of technological equipment complexes are considered. The applied stages and phases of machining equipment design are analyzed by means of constructing design schemes traditional for machine mechanics. It is proposed to create technological machine tool complexes by layout synthesis with the help of element base, which should contain functional technological and service modules, and the service purpose of the machine tool should include the nomenclature of manufactured surface modules. It is shown that the prospects of application of energy flows for intensification of machining processes should be analyzed at the early stages of design, using thermal and electrophysical criteria to study the emerging relations in the system. It is suggested to start designing mechatronic systems of machine tool complexes from the analysis of structural relations of information technologies in hybrid production including traditional and additive technologies.

The intersection of mechatronics and precision engineering: Synergies and future directions

The convergence of mechatronics and precision engineering has sparked significant interest due to its potential to revolutionize various industries, ranging from manufacturing to healthcare. This review explores the synergies between these two domains and outlines potential future directions for research and application. Mechatronics, an interdisciplinary field combining mechanical engineering, electrical engineering, computer science, and control engineering, focuses on the design and development of intelligent systems with integrated sensing, actuation, and control capabilities. Precision engineering, on the other hand, emphasizes the fabrication of high-accuracy components and systems, often at micro or nanoscales, to meet stringent performance requirements. The intersection of mechatronics and precision engineering offers numerous synergistic opportunities. One such opportunity lies in the development of precision actuators and sensors with embedded intelligent control systems, enabling precise motion control and feedback mechanisms in complex systems. Furthermore, advancements in microfabrication techniques allow for the integration of sensors and actuators directly onto precision components, leading to miniaturized and efficient mechatronic systems. In manufacturing, this synergy facilitates the creation of highly automated and flexible production processes capable of producing intricate and high-quality products with minimal human intervention. In healthcare, it enables the development of precision medical devices for diagnostics, surgery, and drug delivery, enhancing patient outcomes and reducing the invasiveness of procedures. Future directions in this interdisciplinary field include exploring novel materials and manufacturing techniques to further improve the precision and performance of mechatronic systems. Additionally, advancements in artificial intelligence and machine learning are poised to enhance the autonomy and adaptability of mechatronic systems, enabling them to learn from data and adapt to changing environments in real-time. the intersection of mechatronics and precision engineering holds great promise for addressing complex engineering challenges and driving innovation across various industries. By leveraging their complementary strengths, researchers and engineers can unlock new opportunities to create smarter, more efficient, and more precise systems with transformative impacts on society.

Special Issue on Robotic, Mechatronic and Information Systems for Decommissioning

The Fukushima Daiichi Nuclear Power Plant accident, triggered by the Great East Japan Earthquake and the tsunami, has had a major impact on societies across the world. The subsequent focus on decommissioning efforts has attracted worldwide attention. It has been consistently asserted since the aftermath of the accident that the decommissioning of the Fukushima Daiichi Nuclear Power Plant will take approximately 30 to 40 years. The promotion of decommissioning work means that we will continue to face the problems with uncertainties in the work, as sometimes referred to as Unknown Unknowns. Typical elemental technologies required in remotely operated robotic systems for decommissioning include mobile mechanisms and their control, handling mechanisms and their control, information communication, operation interface (information presentation and command input), shielding (radiation resistance) and so on. Although many tasks using remotely operated robotic systems have been carried out with noteworthy results, there are lingering issues yet to be clarified. To ensure the safe and effective execution of various types of decommissioning tasks over a period of several decades, continuous research and development of each elemental technology are imperative, and these technologies must be integrated into a system appropriately to the assumed tasks. In addition, human resource development and the transfer of knowledge and experience are also important issues. From such viewpoint, this special issue is titled “Robotic, Mechatronic and Information Systems for Decommissioning.” It contains papers and development reports on robotics, mechatronics, information processing, and information systems technologies relevant to decommissioning work. It also features recent activities of nuclear emergency response organizations. We hope this special issue will acquaint readers with the latest research and development results and organizational activities related to decommissioning. At the same time, we hope that we were able to provide readers interested in robots, mechatronics, and information technology with an opportunity to become aware of the issues and necessary perspectives related to decommissioning and nuclear disasters. Lastly, we would like to thank the editorial board of the Journal of Robotics and Mechatronics, the editorial team of Fuji Technology Press, and the reviewers for their support in the planning and publication of this special issue. Their dedicated efforts are deeply appreciated.