Lecture Notes Set 1 - Introduction To Mechatronics System Design

MFE 3102
Design of Mechatronic Systems
Introduction to Mechatronic System Design

Dr Conrad Pace
MFE3102 Design of Mechatronic Systems

C. Pace
Page 1.1
A Design Problem
Design a suspension system for a Bus that can cope
with
Varying Load Conditions
Varying vehicle speeds
Varying driving conditions
How would we start approaching such a problem?

Understand
the
Problem
Identify
Possible
Solutions

C. Pace
Evaluate
Possible
Solutions
Develop
Selected
Solution
Page 1.2
A Design Problem Solution

Process
Understand the
Problem
Identify Possible
Solutions
Evaluate Possible
Solutions
Develop Selected
Solution
UNDERSTANDING THE PROBLEM

Analyse by
Specifying the problem
Building a representation of the problem that
helps us understand the critical characteristics of
the system to be developed MODELLING
Scope of Modelling
Helps us understand behaviour of problem at
hand
helps us understand what are the critical
parameters
helps us understand how system behaviour is
influenced by the system critical parameters

C. Pace
Page 1.3
A Basic Model for a basic Suspension

System
Analyse by specifying the problem - What
requirements would need to be specified?
Load (and its variation)
Speeds (operating range)
Driving conditions (road conditions vertical
disturbances to wheel, steering angle and steering
velocities, etc..)
Desired Operational characteristics (ex. Vertical
displacements, velocities and accelerations, etc..)
C. Pace
Page 1.4
A Basic Model for a basic Suspension

System Nature of Analysis
Analyse by modelling problem behaviour What model representation to use?
The model will depend on the behavioural
characteristics we are after
For the suspension system we are after the
dynamic behaviour of the vehicle in the vertical
direction
Model Type : Mathematical Model of the Dynamics
of a suspension

C. Pace
Page 1.5
A Basic Model for a Basic Suspension

System Dynamic Model
A Basic Physical model for defining the dynamics of interest
Time
dependent
vertical
movement
of vehicle
structure
Input
Vehicle
Suspension
Dynamics
Output
response
Time dependent
variation in
ground height

C. Pace
Page 1.6

A Simplified Physical Representation
Vehicle mass
carried by
suspension
Suspension
stiffness
Suspension
damping
Suspension
mass
Tyre
stiffness

C. Pace
Page 1.7

A Simplified Physical Representation
x2(t)
m2
(Output)
k2
Output (Vehicle
Body vertical
motion with time)
b2
m1
x1(t)
k1
x0(t)
(Input)
C. Pace
Input (Road
height variations
with time )
Page 1.8
Understanding the Problem The

objective of the system design
x2(t)
m2
What is the objective?

Vertical displacement x2(t)
should be kept as constant
as possible or vary very
gradually independent of
(Output)
k2
b2
x1(t)
m1
Rate of variation of x0(t)

Variation in other parameters
(ex. m2)
k1
x0(t)
(Input)

C. Pace
Page 1.9
Converting the basic Physical to a

Mathematical model
Free Body Diagrams
x2(t)
m2
m2
(Output)
k2
k2 ( x2 x1 )
m2 &x&2
b2
m1
k1
x2(t)
b2 ( x&2 x&1 )
x1(t)
m2 &&
x2 + b2 ( x&2 x&1 ) + k2 ( x2 x1 ) = 0
x0(t)
(Input)

C. Pace
Page 1.10
Converting the basic Physical to a

Mathematical model
Free Body Diagrams
k1 ( x1 x0 )
b2
m1
k1
x1(t)
x1(t)
m1
(Output)
k2
b2 ( x&2 x&1 )
k2 ( x2 x1 )
x2(t)
m2
m1 &x&1
m1 &&
x1 + k1 ( x1 x0 ) =
b2 ( x&2 x&1 ) + k 2 ( x2 x1 )
x0(t)
(Input)

C. Pace
Page 1.11
Interpreting the Mathematical Model

m2 &&
x2 + b2 ( x&2 x&1 ) + k2 ( x2 x1 ) = 0
m1 &&
x1 + k1 ( x1 x0 ) =
b2 ( x&2 x&1 ) + k 2 ( x2 x1 )
Output
Input

C. Pace
Page 1.12
Understanding System Behaviour
The objective now is to

Determine the parameters that constitute F(t)
(control parameters)
such that we get the desired behaviour of x2(t)
(performance parameter)
given the expected behaviour of x0(t) (constraint
parameter)
C. Pace
Page 1.13

What are the control parameters that
constitute F(t)?
k2, b2 (m1, m2, k1?)
How will x0(t) vary?

Step input?
Impulse?
Sinusoidal (frequency?)

C. Pace
Page 1.14

How will we determine an acceptability level
for x2(t) ?
Rise time?
Max. overshoot?
Settling time?
Frequency response
(amplitude ratio?)
Therefore Objective = determine values of

parameters k2 and b2 such that x2(t) behaves as
desired for specific inputs x0(t)
C. Pace
Page 1.15
What results would be expected?

We can optimise behaviour for specific values of
control and constraint parameters
BUT what when
m2 varies?
x0(t) varies significantly?
k1 varies (tyre pressure)?
As constraints vary
We either have to accept a compromise behaviour
for fixed values of k2 and b2 OR
We will need to adjust k2 and b2 to fit the
conditions
C. Pace
Page 1.16
Developing a system with better

behavioural characteristics
Revised objective
To design a solution such that k2 and b2 can be
varied
To KNOW how k2 and b2 should be varied
To determine what characteristics influence parameters
under control
To determine how such characteristics should influence
the parameters under control

C. Pace
Page 1.17
Developing a system with better

behavioural characteristics
Design problem now becomes one which is
not purely mechanical
Physically Change
Suspension
Parameters
VEHICLE
Measure Vehicle
Parameters (Load,
speed, etc.)
Determine required
Suspension
parameters
Actuation
Control
C. Pace
Measurement
(Sensing)
Page 1.18
Developing a System with better

behavioural Characteristics
X0
Adapt System
Parameters
k2
X0
k1
b2
Physical Process

C. Pace
m2
X2
Page 1.19
A Typical Solution for the Suspension

Problem

C. Pace
Page 1.20
10

Behavioural Characteristics
How will all this influence the design approach
of the suspension system?
Problem is no longer purely mechanical
Information flow plays a fundamental role
Energy transfer is conveyed through various
technological elements beyond mechanical means
All has to be properly integrated to maximise
system performance

C. Pace
Page 1.21

Design of such systems will require
Interpretation of information requirements (what, when and
how?)
Determines sensory and measurement system requirements
Defining Controller behaviour requirements

Defining Physical System behavioural requirements
Determines actuation system requirements
Defining interface requirements amongst elements in

information and energy transfer (physical) domains

C. Pace
Page 1.22
11

Design of such systems will require (continuedC)
Designing the various sub-systems within the framework of
the complete system requirements
Physical System
Measurement system
Control system
Actuation System
Evaluate the integration of the various sub-systems so as

to ensure desired system performance

C. Pace
Page 1.23
What is being gained by the integration

of Technologies in Design?
Enhanced Product Performance
Optimised performance under varying
conditions
Increased Functionality
Introduction of new functions and new system
abilities
Enhanced System Transparency

C. Pace
Page 1.24
12
Typical characteristics in
Mechatronic Systems
Generally complex systems which exhibit a high level of
integration with enabling technologies
Increased Functionality
Transfer of Function with numerous functions transferred to
an information processing domain of the system
Multi-program environments system adapts to changing
conditions
The System assumes responsibility for the process under
control with the user concentrating on higher level procedures
(the system operation is transparent to the user)
Typically operating in multi-sensor environments
C. Pace
Page 1.25
A Definition of Mechatronics
The synergistic integration of mechanical
engineering with electronics, intelligent
computer control in the design and
manufacturing of industrial products and
processes
Not a new technology butC.
An evolution in the application and integration of
technologies

C. Pace
Page 1.26
13
A Generalised Mechatronic System

Model
Two domains forming the backbone of any mechatronic
system
WORLD
Human-Machine Interface
Measured
Variables
Information
Domain
Manipulated
Variables
PROCESSOR
Information Flow
SENSORS
ACTUATOR
S
Energy Transfer
Energy Flow
Domain
SYSTEM
(Mechanics & Energy Converters)
Energy flow between
system and environment
ENVIRONMENT
C. Pace
Page 1.27
Enabling Technologies and Building

Blocks of Mechatronic Systems
Computer & Logic
Systems + Software &
Data Acquisition Technology
Information
Domain
Actuators
Sensors
Measurement
Technology + Signals
and System Analysis
Actuation
Technology + Signals
and System Analysis
Energy Transfer
Domain
Physical System
Modelling

C. Pace
Page 1.28
14
The Role of Information Flow and

Handling in Mechatronic Systems
Information Handling plays a fundamental role in
Mechatronic Systems
Provides the system with a means of handling and
managing information such as to achieve the enhanced
system functionality and performance
Three Stages of Information Handling
Receive
Information
Understand
And Interpret
Information
Take
Appropriate
Action
PERCEPTION
COGNITION
ACTION

C. Pace
Page 1.29
The Role of Information Flow and

Handling in Mechatronic Systems
A Basic Information Flow model
Microprocessor
and integrated
Control
Program
Input
Module
Signal
Conditioning
External
Influences
Output
Module
Signal
Conditioning
Actuator
Input
Module
Signal
Conditioning
Sensor
INFORMATION DOMAIN
C. Pace
Page 1.30
15
Mechatronic System Design

Mechatronic System Design Considerations
We have to focus on developing a complete
optimal system rather than developing a
mechanical system and trying to add on additional
technologies. In this respect the introduction of
enabling technologies should be taken into
account very early in the design of such systems:
Measurement Technology
Actuation Technology
Microprocessor based control Technology

C. Pace
Page 1.31
Mechatronic System Design

Mechatronic System Design Considerations
C.Information flow will play a fundamental role in
any Mechatronic system design
Understanding the nature of information to be handled
will be critical in determining how the enabling
technologies are to be applied.

C. Pace
Page 1.32
16

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MFE 3102

Design of Mechatronic Systems

Introduction to Mechatronic System Design

MFE3102 Design of Mechatronic Systems

How would we start approaching such a problem?

MFE3102 Design of Mechatronic Systems

A Design Problem Solution

UNDERSTANDING THE PROBLEM

MFE3102 Design of Mechatronic Systems

A Basic Model for a basic Suspension

A Basic Model for a basic Suspension

MFE3102 Design of Mechatronic Systems

A Basic Model for a Basic Suspension

MFE3102 Design of Mechatronic Systems

A Basic Model for a Basic Suspension

MFE3102 Design of Mechatronic Systems

A Basic Model for a Basic Suspension

Understanding the Problem The

What is the objective?

Rate of variation of x0(t)

MFE3102 Design of Mechatronic Systems

Converting the basic Physical to a

MFE3102 Design of Mechatronic Systems

Converting the basic Physical to a

MFE3102 Design of Mechatronic Systems

Interpreting the Mathematical Model

MFE3102 Design of Mechatronic Systems

Understanding System Behaviour

The objective now is to

Understanding System Behaviour

How will x0(t) vary?

MFE3102 Design of Mechatronic Systems

Understanding System Behaviour

Therefore Objective = determine values of

What results would be expected?

Developing a system with better

MFE3102 Design of Mechatronic Systems

Developing a system with better

Developing a System with better

MFE3102 Design of Mechatronic Systems

A Typical Solution for the Suspension

MFE3102 Design of Mechatronic Systems

Developing a System with better

MFE3102 Design of Mechatronic Systems

Developing a System with better

Defining Controller behaviour requirements

Defining interface requirements amongst elements in

MFE3102 Design of Mechatronic Systems

Developing a System with better

Evaluate the integration of the various sub-systems so as

MFE3102 Design of Mechatronic Systems

What is being gained by the integration

Enhanced System Transparency

MFE3102 Design of Mechatronic Systems

MFE3102 Design of Mechatronic Systems

A Generalised Mechatronic System

Enabling Technologies and Building

MFE3102 Design of Mechatronic Systems