Diseño Mecatrónico

Proceso de Diseño Mecatrónico

MCTG1013

Marcelo Fajardo-Pruna, PhD Francisco Yumbla, PhD

mrfajard@espol.edu.ec fryumbla@espol.edu.ec
ORCID ID: 0000-0002-5348-4032 ORCID ID: 0000-0003-4220-010X
SCOPUS ID: 57195539927 SCOPUS ID: 57201852791
Mechatronics:
Synergetic Integration of Different Disciplines
Mechanical and Information Processing
Conventional vs. Mechatronic Design
Mechatronic System Integration
Multi-Level Control Architecture

• Level 1
• low level control (feedforward, feedback for damping,
stabilization, linearization)
• Level 2
• high level control (advanced feedback control strategies)
• Level 3
• supervision, including fault diagnosis
• Level 4
• optimization, coordination (of processes)
• Level 5
• general process management
Mathematical Models

• Mathematical process models for static and dynamic

behavior are required for various steps in the design of
mechatronic systems, such as simulation, control design,
and reconstruction of variables.

• There are two ways to obtain these models:

• Theoretical modeling based on first (physical) principles
• Experimental modeling (identification) with measured
input and output variables
Simulation Methods
Real-Time Simulation
Hardware-In-the-Loop (HIL)

• The hardware-in-the-loop simulation (HIL) is characterized

by operating real components in connection with real-time
simulated components.

• Usually, the control system hardware and software is the

real system, as used for series production. The controlled
process (consisting of actuators, physical processes, and
sensors) can either comprise simulated components or real
components,
PC-Based Hardware-in-the-Loop Simulation
Control Prototyping

• For the design and testing of complex control systems and

their algorithms under real-time constraints, a real-time
controller simulation (emulation) with hardware (e.g., off-the-
shelf signal processor) other than the final series production
hardware (e.g., special ASICS) may be performed.

• The process, the actuators, and sensors can then be real.

This is called control prototyping
Real-Time Simulation
Integrated Design Issues

• Concurrent engineering of the mechatronics approach relies

heavily on the use of system modeling and simulation
throughout the design and prototyping stages.

• It is especially important that it be programmed in a visually

intuitive environment.
• block diagrams, flow charts, state transition diagrams,
and bond graphs.
Integrated Design Issues

• Mechatronics is a design philosophy: an integrating

approach to engineering design.

• Mechatronics makes the combination of actuators, sensors,

control systems, and computers in the design process
possible.

• Starting with basic design and progressing through the

manufacturing phase, mechatronic design optimizes the
parameters at each phase to produce a quality product in a
short-cycle time
Modeling vs. Experimental Validation
Hardware and Software Integration
Concurrent Engineering

• Concurrent engineering is a design approach in which the design

and manufacture of a product are merged in a special way.
• It is necessary that the knowledge and necessary information
be coordinated amongst different expert groups.

• The characteristics of concurrent engineering are

• Better definition of the product without late changes.
• Design for manufacturing and assembly undertaken in the
early design stage.
• Process on how the product development is well defined.
• Better cost estimates.
• Decrease in the barriers between design and manufacturing.
Concurrent Engineering
Mechatronic System Design (MSD)

• Design is an engineering philosophy that can vary between

different schools of thought.

• MSD should follow a well-defined iterative design steps that

incorporate synergetic design. It should include the
following operations:
1. User and system requirements analysis
2. Conceptual Design
3. Mechanical, software, electronics, and interface design
4. System modeling and simulation
5. Prototyping and testing
Mechatronic System Block Diagram
Design Stages

• Stage 1: Define the Objective and Specifications

• Stage 2: Analyze and Design

• Stage 3: Build and Test

Stage 1: Define the Objectives & Specifications

1. Identify the problem.

2. Research and literature review

3. Set the initial system specifications.

Design Stage 2: Analyze and Design

4. Establish a general block diagram and a flow chart

• Specify system I/O
• Specify control algorithm to use
5. Choose appropriate components
• Sensors and actuators; Controller
• Drive and signal conditioning circuits
6. Concurrent/Synergistic Design
• Mechanical structure; Electronic system;
Software/controller; Interface
7. Model and simulate the system
Stage 3: Build and Test

8. Emulate the controller hardware

9. Build prototype, test, and evaluate (modify if needed)

Synergistic Design
Mechatronic Design Process
Computer-Aided Systems: Important Features

• Modeling:
• Block diagrams for working with understandable multi-
disciplinary models that represent a physical phenomenon.

• Simulation:
• Numerical methods for solving models containing differential,
discrete, linear, and nonlinear equations.

• Project Management:
• Database for maintaining project information and subsystem
models for eventual reuse.

• Design:
• Numerical methods for constrained optimization of
performance functions based on model parameters and
signals.
Computer-Aided Systems: Important Features

• Analysis:
• Frequency-domain and time-domain tools

• Real-Time Interface:
• A plug-in card is used to replace part of the model with actual
hardware by interfacing to it with actuators and sensors.

• Code Generator:
• Produces efficient high-level source code (such as C/C++)
from the block diagram. The control code will be compiled and
used on the embedded processor.

• Embedded Processor Interface:

• Communication between the process and the computer-aided
prototyping environment.
Mechatronic Key Elements

• Information Systems
• Modeling and Simulation
• Optimization
• Mechanical Systems
• Electrical Systems
• DC and AC Analysis
• Power
• Sensors and actuators
• Real-Time Interfacing
Information Systems

• Information systems include all aspects for information

exchange
• Signal processing, control systems, and analysis
techniques

• The following are essential for mechatronics applications

• Modeling and Simulation
• Automatic control
• Numerical methods for optimization.
Information Systems: Modeling

• Modeling is the process of representing the behavior of a

real system by a collection of mathematical equations and
logic.
• Models can be static or dynamic
• Static models produce no motion, heat transfer, fluid
flow, traveling waves, or any other changes.
• Dynamic models have energy transfer which results in
power flow. This causes motion, heat transfer, and other
phenomena that change in time.
• Models are cause-and-effect structures—they accept
external information and process it with their logic and
equations to produce one or more outputs.
• Parameter is a fixed-value unit of information
• Signal is a changing-unit of information
• Models can be text-based programming or block diagrams
Information Systems: Simulation

• Simulation is the process of solving the model and is

performed on a computer.

• Simulation process can be divided into three sections:

• Initialization
• Iteration,
• Termination.
Mechanical Systems

• Mechanical systems are concerned with the behavior of

matter under the action of forces.
• Such systems are categorized as rigid, deformable, or fluid
in nature.
• Rigid-bodies assume all bodies and connections in the
system to be perfectly rigid. (i.e. do not deform)
• Fluid mechanics consists of compressible and
incompressible fluids.
• Newtonian mechanics provides the basis for most
mechanical systems and consists of three independent and
absolute concepts:
• Space, Time, and Mass.
• Force, is also present but is not independent of the other
three
Electrical Systems

• Electrical systems are concerned with the behavior of three

fundamental quantities:
• Charge, current, and voltage
• Electrical systems consist of two categories:
• Power systems and Communication systems
• An electric circuit is a closed network of paths through which
current flows.
• Circuit analysis is the process of calculating all voltages and
currents in a circuit given as is based on two fundamental
laws :
• Kirchhoff ’s current law: The sum of all currents entering
a node is zero.
• Kirchhoff ’s voltage law: The sum of all voltage drops
around a closed loop is zero.
Electrical Systems: Power

• Energy is the capacity to do work various

• Potential, kinetic, electrical, heat, chemical, nuclear, and
radiant.
• Power is the rate of energy transfer, and in the SI unit
system, the unit of energy is the joule and the unit of power
is the watt (1 wat, 1 joule per second).
Sensors

• Sensors are required to monitor the performance of

machines and processes
• Common variables in mechatronic systems are
temperature, speed, position, force, torque, and
acceleration.
• Important characteristics: the dynamics of the sensor,
stability, resolution, precision, robustness, size, and
signal processing.
• Intelligent sensors are available that not only sense
information but process it well
• Progress in semiconductor manufacturing technology
has made it possible to integrate sensor and the signal
processing on one chip
• Sensors are able to ascertain conditions instantaneously
and accurately
• These sensors facilitate operations normally performed
by the control algorithm, which include automatic noise
filtering, linearization sensitivity, and self- calibration.
Actuators

• Actuation involves a physical action on a machine or

process. They can transform electrical inputs into
mechanical outputs such as force, angle, and position.
• Actuators can be classified into three general groups.
1. Electromagnetic actuators, (e.g., AC and DC electrical
motors, stepper motors, electromagnets)
2. Fluid power actuators, (e.g., hydraulics, pneumatics)
3. Unconventional actuators (e.g., piezoelectric,
magnetostrictive, memory metal)
Real-Time Interfacing

• Real-time interface provides data acquisition and control functions

for the computer.

• Reconstruct a sensor waveform as a digital sequence and make it

available to the computer software for processing.

• The control function produces an analog approximation as a

series of small steps.

• Real-time interfacing includes:

• A/D and D/A conversions
• Analog signal conditioning circuits
• Sampling theory.
MECHATRONIC APPLICATIONS
Automotive Industry

• Vehicle diagnostics and monitoring. Sensors to detect the

environment; monitor engine coolant, temperature and quality;
Engine oil pressure, level, and quality; tire pressure; brake
pressure.
• Pressure, temperature sensing in various engine and power
locations; exhaust gas analysis and control; Crankshaft
positioning; Fuel pump pressure and fuel injection control;
Transmission force and pressure control.
• Airbag safety deployment system. Micro-accelerometers and
inertia sensors mounted on the chassis of the car measures car
deceleration in x or y directions can assist in airbag deployment.
• Antilock brake system, cruise control. Position sensors to facilitate
antilock braking system; Displacement and position sensors in
suspension systems.
• Seat control for comfort and convenience. Displacement sensors
and micro actuators for seat control; Sensors for air quality,
temperature and humidity, Sensors for defogging of windshields.
Robots
Aerospace Industry

• Landing gear systems; Cockpit instrumentation; Pressure

sensors for oil, fuel, transmission; Air speed monitor;
Altitude determination and control systems.
• Fuel efficiency and safety systems; Propulsion control with
pressure sensors; Chemical leak detectors; Thermal
monitoring and control systems.
• Inertial guidance systems; Accelerometers; Fiber-optic
gyroscopes for guidance and monitoring.
• Automatic guided vehicles, space application; Use of
automated navigation system for NASA projects; Use of
automated systems in under water monitoring and control
Consumer Products
Consumer Industry

• Consumer products such as auto focus camera, video, and

CD players; Consumer electronic products such as washing
machines and dish washers.
• Video game entertainment systems; Virtual instrumentation
in home entertainment.
• Home support systems; Garage door opener; Sensors with
heating, ventilation, and air-conditioning system; Home
security systems.
Production Machines
Industrial Systems and Products

• Monitoring and control of the manufacturing process; CNC

machine tools; Advanced high speed machining and quality
monitoring.
• Rapid prototyping; Manufacturing cost saving by rapid
creation of models done by CAD/CAM integration and rapid
prototyping equipment.
• Specialized manufacturing process such as the use of
welding robots; Procedure for automatically programming
and controlling a robot from CAD data.
3D Printing
Health Care Industry

• Medical diagnostic systems, non-invasive probes such as

ultrasonic probe. Disposable blood pressure transducer;

• Pressure sensors in several diagnostic probes. Systems to

control the intravenous fluids and drug flow;

• Endoscopic and orthopedic surgery. Angioplasty pressure

sensor; Respirators; Lung capacity meters.

• Other products such as Kidney dialysis equipment; MRI

equipment.
Mechatronic System Example: DC Motor
Conclusion

• Mechatronics design can lead to high quality and cost-

effective products
• Traditional sequential manner do not possess optimum
design capabilities.
• Concurrent design results in the development of intelligent
and flexible mechatronic system
• Increasing demands on the productivity of machine tools
and their growing technological complexity call for improved
methods in future product development processes.
 Diseño Mecatrónico
Proceso de Diseño Mecatrónico
MCTG1013