Module 1: Introduction to Systems Engineering Principles
1. Overview of Systems Engineering and Its Role in Mechanical Design
• Definition: Systems Engineering (SE) is an interdisciplinary field of engineering that
focuses on designing, analyzing, and managing complex systems. It integrates various
disciplines and specialty groups into a coherent system throughout its life cycle.
• Role in Mechanical Design:
o Systems Engineering ensures that all components of a system, such as mechanical
structures, electrical subsystems, software, and sensors, work together seamlessly.
o It provides a holistic approach, focusing on both the technical and non-technical
aspects of system design, such as cost, schedule, and risk management.
• Application in Mechanical Design:
o In mechanical design, SE is used to develop and integrate subsystems (e.g.,
actuators, sensors, control systems) in products like robots, manufacturing
systems, or consumer electronics.
o It involves defining requirements, modeling the system, performing trade-off
analyses, and verifying the system through rigorous testing and validation.
Key Stages in Systems Engineering Process:
• Requirements definition: Establishing the system’s functional and performance
requirements.
• Concept development: Exploring various solutions and defining a conceptual design.
• System architecture design: Structuring the system into manageable parts and defining
interactions.
• Implementation and integration: Realizing the design in physical hardware and
software.
• Verification and validation: Ensuring the system meets its requirements and performs
as expected.
2. Comparison of Systems Engineering with Traditional Design Approaches
Traditional Design Approaches:
• Linear Process: Traditional design often follows a more linear process where each stage
is completed sequentially—i.e., design, fabrication, testing.
• Siloed Approach: Different engineering teams (e.g., mechanical, electrical) work
independently without much cross-discipline communication or integration.
• Less Flexibility: Modifications or changes in one part of the system often lead to costly
rework or redesign in other parts.
Systems Engineering Approach:
• Iterative Process: Systems Engineering promotes iterative development, allowing
continuous feedback and refinement at each stage. It emphasizes adjusting designs based
on evolving requirements and unforeseen challenges.
• Holistic View: SE integrates all aspects of a system (mechanical, electrical, software,
human factors) from the very beginning. It ensures the system is designed and tested as a
unified whole.
• Focus on Interdisciplinary Coordination: SE places a strong emphasis on
communication between disciplines to optimize the design.
• Risk Management: One of the core strengths of SE is its focus on identifying and
mitigating risks early in the design process, thus preventing costly failures during
production.
Key Differences:
Aspect Traditional Design Systems Engineering
Process Linear and sequential Iterative and flexible
Integration Siloed discipline-based Cross-disciplinary integration
Flexibility Low – changes require significant redesign High – continuous refinement
Focus Component-level design System-level design
Risk Management Reactive (after failure) Proactive (preventing failure)
3. Key Principles of Systems Engineering
Functional Decomposition:
• Definition: Breaking down a complex system into smaller, manageable subsystems or
components. This allows for easier design, analysis, and management.
• Application: In robotics, functional decomposition could break down the robot’s tasks
into smaller functions, such as sensing, actuation, and control.
Example:
For an industrial robot, the main functions could be:
o Sensing: Cameras, LIDAR, force sensors
o Actuation: Motors, servos
o Control: Algorithms for path planning, motion control
Modularity:
• Definition: Dividing a system into smaller, independent modules that can be designed,
tested, and modified independently but still function together as a whole.
• Benefits:
o Flexibility: Easier to update individual components without disrupting the entire
system.
o Scalability: Easy to add or remove components as needed.
o Reusability: Modules can be reused across different projects or applications.
Example:
A modular robotic arm design where the gripper, arm, and control system are separate
modules. This way, the gripper can be swapped out for different tasks (e.g., welding vs.
assembly).
System Hierarchy:
• Definition: Organizing the system into hierarchical levels, with high-level subsystems
performing broader functions and lower-level subsystems providing more specialized
tasks.
• Benefits:
o Simplification: Complex systems are easier to understand when broken down
into hierarchies.
o Management: Easier allocation of responsibilities and resources.
Example:
A factory automation system might have high-level subsystems like Process Control,
Robotic Handling, and Quality Inspection, with each having its own set of specialized
lower-level subsystems.
4. Design Considerations in Systems Engineering
Trade-offs:
• In mechanical design, trade-offs refer to balancing competing objectives (e.g.,
performance vs. cost, speed vs. precision). Systems engineers must evaluate the pros and
cons of different design alternatives and select the one that best meets the overall system
goals.
• Example: Choosing between a high-speed actuator that costs more vs. a slower, cheaper
actuator. The decision depends on the performance requirements of the system and the
project budget.
Cost-effectiveness:
• Cost analysis is a critical part of SE. It involves balancing the system’s cost with the
required performance. This requires assessing the total cost of ownership, including
design, manufacturing, maintenance, and disposal costs.
• Example: In selecting an actuator, the engineer must not only consider the purchase cost
but also factors like energy consumption, maintenance needs, and the lifespan of the
actuator.
Life Cycle Analysis:
• A life cycle approach examines the system’s performance across its entire lifespan, from
conceptual design to disposal. This is essential for understanding long-term costs,
sustainability, and potential for upgrades.
Example:
When designing a robotic system for industrial use, SE involves analyzing the system’s
energy consumption, wear-and-tear on components, and how easily the system can be
upgraded as technology advances.
5. Case Study: Real-World Application of Systems Engineering in Robotics
Case Study: Collaborative Robot (Cobot) in Manufacturing:
• Problem: A manufacturing company wanted to automate part of their assembly line
using a robotic arm. The challenge was integrating the robot with human workers,
ensuring safety while maximizing productivity.
• Systems Engineering Approach:
1. Requirement Definition:
▪ The robot should perform tasks like pick-and-place and screwing, working
alongside human operators.
▪ The system must meet safety regulations and be flexible for future
upgrades.
2. System Architecture:
▪ The robot design was modular, with separate components for vision,
actuation, and control.
▪ Human safety was integrated through proximity sensors and force-limiting
algorithms.
3. Design & Integration:
▪ The robot was tested in collaboration with operators to ensure ease of use
and safety.
▪ Integration with the manufacturing line included communication protocols
to synchronize the robot’s actions with the workers’ tasks.
4. Testing & Validation:
▪ Extensive testing was conducted to ensure the robot could handle various
loads and work in different environments.
• Outcome:
The system reduced assembly time by 30% while increasing worker safety. It also
allowed for easy future upgrades to add new capabilities, such as quality inspection with
vision systems.
Summary of Key Points:
• Systems Engineering offers a structured, holistic approach to designing complex
mechanical systems like robots, ensuring integration and performance across all
subsystems.
• Key principles such as functional decomposition, modularity, and system hierarchy
help manage complexity.
• Trade-offs, cost-effectiveness, and life cycle considerations are crucial when making
design decisions.
• Systems Engineering provides an iterative, flexible framework that allows engineers to
respond to challenges and improve designs over time, leading to more efficient and
reliable systems.
Next Steps:
• In the next module, we will delve deeper into mechanical systems and actuators,
exploring their role and selection in robotic systems.
