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Mechatronics 20 (2010) 827–841

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Mechatronics
journal homepage: www.elsevier.com/locate/mechatronics

Mechatronics – More questions than answers


David Bradley
School of Computing & Engineering Systems, University of Abertay Dundee, Bell Street, Dundee DD1 1HG, UK

a b s t r a c t

Since the introduction of mechatronics as an integrated and integrating approach to the design, develop-
ment and operation of complex systems, there have been significant developments in technology, and in
particular in processing power, which have changed the nature of a wide range of products and systems
from domestic appliances and consumer goods to manufacturing systems and vehicles. In addition, the
development and implementation of strategies such as those associated with concurrent engineering
and the introduction of intelligent tools to support the design of complex products and systems has also
changed the way in which such systems are conceived, implemented and manufactured.
The aim of the paper is not however to attempt to address or answer specific questions as to the nature
of mechatronics and its current and future standing as an approach to engineering design and develop-
ment, but to initiate, provoke and stimulate debate and discussion on a range of mechatronics related
issues, without necessarily attempting to provide answers or suggest new methods or approaches, relat-
ing to the future potential of and directions for mechatronics. In this respect therefore, while containing
an element of review, the paper is intended as a discussion document structured around the author’s per-
sonal experience and perspective of mechatronics issues.
Inherent to this questioning of the ways in which mechatronics may develop are the various attempts
that have taken place over the years to provide a definition of mechatronics, either in the form of text or
logo and whether these efforts have of themselves been a source of confusion as to both content and
direction within mechatronics? In which case, might it be preferable for mechatronics practitioners to
operate within their own particular context than to attempt to conform to a specific and overarching def-
inition?
Finally, it must also be made clear that in writing this paper that complete agreement with the reader
as to the particular questions raised and comments made is neither sought nor intended.
Ó 2010 Elsevier Ltd. All rights reserved.

1. Introduction Thus while the paper incorporates a review element in respect


of certain aspects of mechatronics, it is not aimed at providing a
Over many years of involvement with mechatronics it has be- detailed analysis of a specific aspect of mechatronics or of propos-
come increasingly challenging at a personal level to reconcile the ing new and novel structures for the discipline but at posing ques-
various different and differing arguments as to what it is that de- tions relating to its future role and development. It should
fines, constitutes and differentiates mechatronics with respect to therefore be considered as a discussion paper presenting a partic-
related engineering disciplines such as systems engineering, con- ular, and personal, viewpoint, in this case that of the author.
trol engineering, design engineering and manufacturing systems In developing the discussion it is necessary to consider the ways
as well as identifying its continuing role in education [1]. The in which mechatronics is perceived. Various attempts have taken
aim in writing this paper is not however to attempt to answer place over the years since its introduction to provide a ‘concrete’
the general questions of ‘what is mechatronics?’ or ‘how might definition of mechatronics, either in the form of text or logo. As
mechatronics be defined?’, but to raise these and other questions, an illustration of this activity, one web site [2] lists over 20 defini-
without necessarily providing answers, with the intent of provok- tions of mechatronics, each of which places a slightly different
ing debate and discussion as to the future potential of and direc- emphasis on the central theme of the integration of the core disci-
tions for mechatronics as an engineering discipline. For instance, plines of electronics, mechanical engineering and information
is there, or indeed could there be, a single overarching structure technology1. Similarly, a search for mechatronics logos suggests that
for mechatronics, or are there several interrelated and interlinked many academic and other institutions engaged in aspects of mecha-
structures, each emphasising a specific aspect of the whole? tronics have attempted, at various degrees and levels of complexity,

1
E-mail address: d.bradley@abertay.ac.uk Or Computing, Information Systems and other variants.

0957-4158/$ - see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mechatronics.2010.07.011
828 D. Bradley / Mechatronics 20 (2010) 827–841

to produce something which reflects both the nature of the institu- Table 2
tion and its mechatronics context. Some milestones in mechatronics.

Could it however be argued that an such attempt to provide any 1940 Isaac Asimov published the first of his robot stories and develops the
form of expression of mechatronics, whether textually or graphi- ‘Three Laws of Robotics’
cally, may of itself be a source of confusion and that it may there- 1948 Transistor is developed at Bell Laboratories by John Bardeen, Walter H.
Brattain and William B. Shockley
fore be better for mechatronics practitioners to operate within 1952 A prototype Numerically Controlled machine is demonstrated at
their own particular context than to attempt to conform to a spe- Massachusetts Institute of Technology
cific and overarching definition? 1958 Texas introduces the first commercial integrated circuit
In order to place the subsequent discussion into context, the pa- 1959 Planet Corporation introduces the first commercial robot based on
limit switches and cams
per begins by providing an overview of the introduction of mech-
Richard Feynman delivers the lecture There’s Plenty of Room at the
atronics, its initial concepts and the ways in which it has Bottom at Caltech [2]
developed. By its very nature and breadth, Table 1 provides an 1961 A Unimate robot is installed by Ford to service a die-casting machine
indication of the topics that have been and are associated with The part programming language APT (Automatically Programmed
mechatronics, any of which could have been chosen to illustrate Tooling) is released
1963 The American Machine Company introduces the Versatran robot
the arguments within the paper, this means that a choice has 1965 Gordon Moore proposes that the size of integrated circuits will double
had to be made, in this case that of engineering design. It must also approximately every 2 years
be acknowledged that in writing this paper it will be inevitable Digital Equipment Corporation introduces the PDP-8 computer
that issues which individual readers consider important will have 1968 Burroughs produces the first computers to use integrated circuits
1969 The term mechatronics is proposed by Tetsuro Mori to describe the
been omitted and apparently ignored. No apology is made for this
integration of electronics with mechanical engineering
other than those of limitations of space and the background, views 1970 Digital Equipment Corporation introduces the PDP-11 computer
and opinions of the author, and complete agreement with the read- 1972 8-bit microprocessors introduced
er is neither sought nor intended. 1974 ASEA introduce the all electric drive IRb6 robot
The T3 robot Tomorrow Tool, better known as the T3 robot, is
introduced by Cincinnati Milicron
2. The growth of mechatronics 1978 The PUMA (Programmable Universal Machine for Assembly) is
introduced by Unimation
16-bit microprocessors introduced
The first commercial and industrial use of the term ‘mechatron- 1979 The SCARA (Selective Compliance Arm for Robotic Assembly) arm is
ics’ is generally credited to Tetsuro Mori in 1969 [3–5], though it developed at Yamanshi University in Japan
may well have been used informally several years earlier by Profes- 1980 Intel introduces the first 32-bit microprocessor
sor Takashi Kenjo [6]. Since its introduction, it has generally been 1981 IBM introduces a personal computer with an industry standard disc
operating system (DOS)
argued that mechatronics represents a significant, and initially dif-
1982 IBM introduces the RS-1 assembly robot
ferent, approach to the design, development and implementation 1984 Sumitomo demonstrates an organ playing robot developed at Waseda
of a wide range of inherently complex products and systems. While University in Japan
that may have been the case when the concept was originally pro- 1988 Institute for Defense Analysis Report R-338 on concurrent engineering
posed, can this view be sustained 40 years later [7]? is published
1990 The World Wide Web is set up by Tim Berners-Lee at the European
Consider the very much abbreviated timeline of Table 2 as to Particle Physics Laboratory in Switzerland
what might be considered mechatronic oriented developments. 1993 Intel introduce the Pentium processor
This list must however also be placed in the context of earlier 1997 Pathfinder mission lands the Sojourner vehicle on Mars
developments and not taken as implying that systems and techni- 1998 Honda introduces the P3 humanoid robot
1999 Sony introduces the AIBO robot dog
cal integration began with mechatronics. Consideration of the ear-
2000 AMD released the Athlon 1 GHz
lier years of the 20th century provides many examples of such Honda introduces the ASIMO humanoid robot
integration ranging from the naval gunnery control systems based 2001 First autonomous flight over the Pacific by the Global Hawk unmanned
around integrated optics and mechanical analogue computers [8] aerial vehicle
to aircraft flight control and inertial navigation systems [9]. In 2004 Rovers Spirit and Opportunity land on Mars
2005 DARPA Grand Challenge, five teams completed the off-road course
manufacturing, the introduction and development of mass produc- with Stanford University’s Stanley the winner
tion systems integrated with developments in machine tool tech- 2006 Intel introduces the Core 2 processor
nology also supported the underlying concepts of systems Sony releases the Playstation 3
integration generally felt to be integral to mechatronics. In addi- Nintendo releases The Wii
2007 TOMY introduces the i-sobot humanoid robot
tion, mechatronics has developed to encompass issues such as bio-
Apple launches the iPhone
mechatronics, focused on issues such as the analysis of human
motion, interfacing with the nervous system and ways in which

to use muscle tissue as actuators [10–12] and micromechatronics,


Table 1 generally associated with MEMS2 technologies [13,14].
Some mechatronics applications areas. What may however be considered to be of particular signifi-
Automation and robotics Machine vision cance to the development of mechatronics from the 1960s on is
Automotive engineering Mechatronics systems that at about the time that the concept was first being mooted,
Computer aided and integrated Medical systems computers such as the PDP-8 and PDP-11 were beginning to im-
manufacturing systems pact upon the industrial and process control markets. Though ini-
Computer Numerically Controlled machines Packaging
Consumer products Sensing and control systems
tially limited in power and scope, at least in current terms, such
Diagnostic, reliability, and control system Servo-mechanics computers nevertheless provided a whole series of lessons that
techniques have stood future systems designers and integrators in good stead.
Engineering design Structural dynamic systems Consider for instance the development of avionics where in the
Engineering and manufacturing systems Systems engineering
1960s aircraft designers and manufacturers began to conceive of
Expert systems Transportation and vehicular
systems
Industrial goods
2
Micro Electro-Mechanical Systems.
D. Bradley / Mechatronics 20 (2010) 827–841 829

the translation of the complex analogue flight control and engine available [15]. It is also perhaps salutary in this context to recog-
management systems into their digital equivalents, initially in nise that the Apollo Primary Navigation and Guidance System
the form of electronic logic and then by means of microprocessor (PNGS) computer, essentially a digital fly-by-wire unit, developed
based systems and their subsequent developments, and were for the Moon landing programme from 1969 to 1972 had the spec-
thinking in those terms even before the necessary devices became ifications and functions as set out in Table 3 and Fig. 1 [16].
However, at the start of the 21st century, computing technolo-
Table 3
gies have matured and developed to the point where processing
Apollo Primary Navigation and Guidance System (PNGS) computer specifications. power is available at near zero cost to the system developer. Sys-
tem costs are then to a very large degree those associated with
Developed by MIT instrumentation laboratory
Manufacturer Raytheon
achieving integration and developing the software required to
Processor Discrete IC RTL based meet user perceptions in what continues to be a rapidly developing
Frequency 2.048 MHz market place.
Memory 16-bit words, 2048 words RAM (magnetic core memory), While technology was evolving, so to was the concept of engi-
36,864 words ROM (core rope memorya)
neering design changing from the static and linear strictures asso-
Ports DSKY, IMU, Hand Controller, Rendezvous Radar (CM),
Landing Radar (LM), Telemetry Receiver, Engine Command, ciated with the established concepts of sequential development,
Reaction Control System and all the problems associated with this, to the introduction of
Power 70 W the concepts of concurrent engineering with its implied parallelism
Weight 70.1 lb (31.8 kg) as illustrated by Fig. 2 [17,18].
Dimensions 24  12.5  6.5 in. (61  32  17 cm)
Thus whilst the original concept of mechatronics as concen-
a
The core rope memory consisted of a series he ferrite cores operating as trans- trated on the integration of electronics with mechanical engineer-
formers. The signal from a word line wire passing through a core was coupled to the ing and software, is it now the case that the emphasis needs to shift
bit line wire and interpreted as a binary ‘‘one” while a word line wire that bypassed
to one which encompasses a more holistic view of system design
the core was not coupled to the bit line wire and was read as a ‘‘zero”. Up to 64
wires could be passed through a single core. Software written by NASA program- and development?
mers was ‘woven’ into the cores to create the ‘rope’. [86]. This shift, as suggested in part by Fig. 3, would effectively place
mechatronics within a network of engineering functions and issues
ranging from aesthetics to marketing. In reviewing this network it
is however also important to recognise and understand that mech-
Display & atronics, and indeed engineering design in general, is not solely
Radar DSKY
Range concerned with or about technology but relies on people, and in
Keyboard particular on the interactions between individuals, to make it
Direction
Velocity Engine work.
Commands Is it therefore the case that mechatronics can no longer, as
might have originally have been the case, be considered purely
Navigation as being associated with the integration of specific technologies
Star Tracking
Computer Attitude but as a systems oriented approach to the design, development
Inertial Platform
Controls and implementation of complex systems which takes as its founda-
tion the transfer of functionality from the physical domain to the
Manual information domain? This view is reflected in the comment by
Control Millbank that [19]:
Data
Signals Telemetry
Display ‘By definition then, mechatronics is not a subject, science or tech-
nology per se – it is instead to be regarded as a philosophy – a fun-
Fig. 1. Apollo Primary Navigation and Guidance System (PNGS) computer damental way of looking at and doing things, and by its very nature
functions. requires a unified approach to its delivery.’

Quality

Design for
testability

Conceptual
design Service &
Support
Requirements Design for
Definition Manufacture Embodiment Manufacture Product

Marketing Manufacturing
processes
Industrial
design

Interface
design

Fig. 2. Concurrent engineering work flow.


830 D. Bradley / Mechatronics 20 (2010) 827–841

Politics

Sociology
Psychology

Economics

Engineering Engineering Engineering


Science Production
Science Design Technology

Industrial
Design

Artistic Design

Art

Fig. 3. Mechatronics and engineering design issues.

100% 100%
INNOVATORS EARLY PRAGMATISTS SCEPTICS INNOVATORS EARLY PRAGMATISTS SCEPTICS
ADOPTERS ADOPTERS
Relative percentage of

Market penetration
customers

MAIN MARKET MAIN MARKET

Time Time
(a) Adoption (b) Market penetration
Fig. 4. Profiles of technology adoption and market penetration.

The strength of such an approach may then be that it supports translate that motion into an on screen response by means of a
the understanding of the nature of the embedded complexity by Bluetooth communications link. At another level a modern car will
ensuring that the different engineering, and other, disciplines are integrate multiple systems ranging from engine management to
considered together from the start of the design process. driver and passenger comfort controls and potentially even auton-
That such a parallelism is important may be seen from the fact omous navigation [22,23].
that products typically generate the most revenue early in their life These developments are supported by the increasing availabil-
cycle, particularly if the product offers new features not present in ity of ‘smart components’ such as the SunSPOT3 system from Sun
its competitor’s products. As the product matures and competitors Microsystems [24], which in turn facilitate the construction of larger
enter the market, profit erosion will begin to occur as the compe- systems utilising the embedded processing power of their distrib-
tition for available customers increases. It is therefore important uted elements. The increasing availability of system elements such
that products are designed and produced on time and that produc- as SunSPOTs and RFID tags is resulting in increasingly complex sys-
tion rates are rapidly ramped up to mature levels. Any delays in the tems in which the ability to analyse and interpret the data then be-
release of the product to the market will translate into lost sales comes the major source of added value. Thus while historically
that will not be recovered over the life of the product. mechatronics has been associated with system products such as
As indicated by Fig. 4, a key element of the market profile is the vehicles and manufacturing technologies such as robots, these same
need to convince the pragmatists that the system is of value to mechatronic concepts are now appearing in applications such as
them once the innovators and early adopters have opened up the healthcare.
market [20,21]. The introduction of a mechatronic approach to So, does mechatronics remain something that could, or indeed
technology integration allied to a concurrent engineering develop- should, continue to be considered as separate and distinct from
ment strategy has historically resulted in products which are other approaches to engineering and engineering design, or has it
inherently more capable, and hence more attractive to the prag- some 40 or more years after the term was proposed, become
matic users, than their predecessors at reducing real costs. embedded within mainstream engineering? Or is it the case that
In recent years, products and systems of all types from domestic both contentions are to some degree correct?
appliances to vehicles have become increasingly complex. This Consider first the validity or otherwise of treating mechatronics
complexity may often be defined in turn by the combination of lo- as a separate and distinct approach to engineering design. Given
cal and distributed processing power with mechanical design and the increasing complexity of systems, and of the integration of
is driven by the increased availability of processing power based technologies that this implies, there is a need to ensure and man-
not only around microprocessors but of devices such as Application age the communication between the domain specialists whilst
Specific Integrated Circuits (ASICS) and Field Programmable Gate ensuring that there is awareness of the need to transfer functional-
Arrays (FPGAs) allied to enhanced communications strategies and
protocols. Thus at one level, a system such as the Wii games con-
sole utilises three-axis accelerometers to record motion and to 3
Sun Small Programmable Object Technology.
D. Bradley / Mechatronics 20 (2010) 827–841 831

ity and complexity between domains [25]. By its nature, mecha- need to design the test processes along with the system rather than
tronics has implied such an integration across disciplines, and separately as had often historically been the case.
hence an awareness of mechatronic approaches and outcomes by Other examples of the holistic approach to design that may now
a design team is likely to be supportive of the appropriate identifi- be considered as common are the use of a ‘Third Age Suit’ by Ford
cation of the range and variety of solutions associated with these. A engineers [32,33] to allow younger members of the design team
similar case can also be made in relation to the teaching of mech- to evaluate the physical layout of a vehicle from the perspective
atronics within undergraduate and postgraduate engineering pro- of someone with reduced joint flexibility, vision and dexterity
grammes as a means of generating a breadth of awareness not and the establishment by Volvo of an all female design team to re-
necessarily associated with more conventional, and single disci- view concept vehicles [34]. Whilst neither of these examples is
pline, engineering courses and programmes [26–29]. explicitly associated with design integration or mechatronics, they
However, as the majority of engineering systems are now inher- are illustrative of the parallelism now found in most design teams.
ently integrated and interdisciplinary in nature, an effective case In this context therefore, should mechatronics now be considered
could perhaps also be made that the engineering design process as being an element of the mainstream design process rather than
has itself adapted to accommodate the need to manage technical a separate and independent design strategy?
and other integration at all levels within that process. This is illus- Following on from the above, should it be considered that the
trated here by comparing the design model proposed by French issues previously associated with the design of mechatronic sys-
[30] and shown in Fig. 5 with the V-Model [31] of Fig. 6, the later tems are now essentially those associated with the design of all
initially being for software development but increasingly used to types and forms of complex, integrated systems?
describe system development.
As can be seen from Fig. 5, while French’s model incorporates
3. Successes and failures
elements of feedback, it follows an essentially linear representa-
tion of the design process with minimum embedded parallelism.
The danger in considering mechatronics from the standpoint of
In contrast, the V-Model attempts to combine the sequential ele-
the various developments presented in the previous section is that
ments with appropriate evaluation, for instance by stressing the
it may come to be perceived as a continuous and continuing suc-
cess story. That is indeed far from being the case, and any review
of literature will reveal the various flaws in any such argument.
Whilst it is not the aim of this paper to go into the detailed reasons
Need as to why failures occur, it is possible to explore, albeit briefly, the
reasons behind some of these failures within a mechatronic, and
indeed a more general systems context.

Analysis of 3.1. A misunderstanding of the relationships between system


Problem technologies, and particularly software

Engineering disciplines such as mechanical design and control


engineering have often followed an essentially separate path
Statement whilst acknowledging a commonality of approach in certain areas.
of Problem This has led on occasion to control systems being deployed at a rel-
atively late stage in the development process to accommodate
deficiencies in the mechanical design of a system, rather than their
having been considered as a part of that system from the first
Conceptual instantiation.
Design This problem was perhaps exaggerated or exacerbated when
Feedback

the view developed in some quarters that ‘it is all software now’,
and that as changes to the software were considered as relatively
easy, changing the system was in turn easy. This then led to further
Selected
complications as the demands on software by other parts of the
Schemes system were continually changing as ‘it was simple to make the
change there’! In fact, both these approaches led to delays and
errors.
As an illustration of this type of failure, consider the case of a
flight F22 Raptors transferring from Hawaii to Okinawa in 1997
Embodiment
of Schemes which when they crossed the International Date Line lost all navi-
gation aids. The problem was traced to a coding error which re-
sulted in an infinite loop as a consequence of the unexpected
date change. In the words of Donald Shepperd, a former head of
Detailing
the US Air National Guard, ‘‘Reliance on electronics has changed
the flight-test process. It used to be tails falling off, now it’s typos that
ground a fighter.” [35,36].

Working 3.2. Problem complexity and communications


Drawings
As systems become increasingly complex, it is difficult, and of-
ten indeed impossible, for any single individual to manage all the
Fig. 5. French’s design model. levels of detail required. This leads to a necessary partitioning of
832 D. Bradley / Mechatronics 20 (2010) 827–841

Requirements
Service
Analysis

Requirements Certified
Test Planning
Documents System

Specificatiion Certification

Verified
Specification Test Planning
System

High-Level
System Test
Design

Design Integrated
Test Planning
Specification System

Detailed System
Design Integration

Module Test Tested


Design Planning Modules

Development
Phase Construction/
Module Test
Coding

Output from
Phase

Modules

Fig. 6. The V-model.

function to levels at which an individual can operate. This in turn broader awareness of the overall context within which the mech-
implies that there is an understanding at the level of the ‘domain atronics approach is being deployed is therefore likely to be detri-
experts’ both of their specific task and of the nature of that task mental both to outcomes, and to an outsiders view of the nature of
within the wider context of the overall system. Failure to achieve mechatronics.
this understanding can then have a significant impact on the out-
comes of the design process.
Thus, the Mars Climate Orbiter (MCO) was lost in 1999 when a 4. Design issues in mechatronics (and elsewhere)
failure in communications between the group responsible for nav-
igation, who customarily used Newton-seconds to express thrust, As was suggested in the introduction, the breadth of mecha-
and that responsible for the propulsion system, who in contrast tronics and the range of engineering domains with which it is asso-
used pound-seconds to express thrust, resulted in the MCO being ciated requires that within the context of the paper a specific area
100 km too close to Mars when it attempted to enter orbit [37]. must be chosen in order to develop the discussion. As was indi-
A further issue associated with system complexity is that of cated earlier engineering design was chosen for this purpose as it
fault detection and diagnosis. While it would normally be the case is believed that it presents the most complex challenges and argu-
that individual sub-systems and sub-assemblies are tested in their ments relating to the future role and contribution of mechatronics.
own right, this is often achieved through the use of synthetic data Similar arguments could however be developed for any of the in-
to represent the remainder of the system. A ‘hardware-in-the-loop’ stances identified in Table 1, and it must also be acknowledged
simulation being an example of this. However, when the sub- that this table is not complete or comprehensive. Some of the is-
assemblies are connected to form the complete system, their indi- sues presented in the following sections, as for instance the impor-
vidual interactions can result in faults and abnormal behaviours tance of establishing robust communications across a design team,
which are extremely difficult to detect. have already been introduced and the intent here is to give more
detailed consideration to specific points.
3.3. An overemphasis on core disciplines
4.1. The engineering design process
The name mechatronics by implication and usage has, as re-
ferred to earlier, become associated with the three core disciplines As technologies expand they provide additional capacity, capa-
of electronics, mechanical engineering and information technology bility and functionality to the designer, leading to a requirement
or computing. This can result in a lack of focus on issues such as for new and novel tools to support design thinking and integration
aesthetics or manufacturing technology which may ultimately at all stages in the design process and the effective integration of
determine the success of the product or system. Any lack of a such tools with more function oriented design tools, as for instance
D. Bradley / Mechatronics 20 (2010) 827–841 833

those associated with detailed mechanical design and analysis. Product Data Product support
Such tools aim not to simply manage the details of the design pro- Management manuals
cess, but to underpin the associated thinking by helping users with Automatic generation of
2D drawings (if wanted)
the identification of alternative solutions. This is particularly
Shopfloor
important as the various aspects and stages of the design process assembly aids
become more tightly linked, as for instance through the need to 3D
3D Thinking Computer Aided
evaluate the manufacturing process through the employment of
Engineering
Design for Manufacture and Assembly tools and methods at the
conceptual stages of design. Assembly
Figs. 7 and 8 and Table 4 illustrate some of these relationships checking
Integration with
within the context of the overall design flow. Together, these show diagnostic control and
Performance
that as the design progresses, so the tools progressively add detail checking - FEA
feedback systems
to the information passed down from the earlier stages of that Computer Aided
process. Manufacturing
Integration
In looking at this linkage, it perhaps needs to be considered that
the development of engineering design understanding is, almost by Fig. 8. 3D-CAE and business integration [84].
necessity, retrospective in that it looks at what has been done to
obtain an effective solution, and then analyses and interprets this
to arrive at best practice which can then be deployed in future de-  Mechanical Engineers think in terms of physical forms and
sign activities. There is also within engineering design a balance, as motions.
well as a conflict, between the theoreticians, who seek to under-  Electrical Engineers think in terms of signals and circuits.
stand the processes by which a successful and effective design is  Software Engineers think in terms of logic and syntax.
achieved, and the pragmatists, who are primarily concerned with
achieving effective solutions in response to identified need. As sug- However, such a simplistic division based on technology, while
gested by Fig. 9, the balance between these two different aspects of perhaps initially having some justification, has been superseded in
the design process, supported by the effective use of appropriate many, but certainly not all, instances by approaches structured, as
tools to enhance communication and understanding, perhaps has already been suggested, around methods such as concurrent
should be considered as a symbiotic process based around effective engineering which recognise such differences and put in place
information exchange. mechanisms to deal with them. Such approaches also place an
Within the context of mechatronics, such linkages can be found emphasis on ensuring effective communication not only within
in a variety of application domains ranging from manufacturing to the design team but also with prospective specifiers and users [38].
vehicle systems and domestic products, further illustrating the There however remains the need to provide effective tools to
diversity of application of the mechatronics concept. support the ability to work with, and hence to communicate, ab-
stract concepts as part of the design process. This perhaps implies
a need to provide means of ensuring an understanding across spe-
4.2. Communication cialisms through a combination of ontological forms, both linguis-
tic and symbolic, together with relevant syntactical and semantic
Referring to Fig. 10, it has often previously been suggested that: structures to support a common meaning.

Project Ideas Concept


Evaluation Detailing
Definition Generation Development

General
Project Management Continuing role throughout project
Tools
i.e. Microsoft Office

Visualisation Increasing sophistication and detail


i.e. Photoshop, Illustrator,
etc.
Interchange
Simulation
Distillation of technical i.e. MatLAB/Simulink,
information into form Dimola, 20Sim Increasing sophistication and detail of models
understandable by all
stakeholders
Interchange
CAD Tools
Develop understanding and i.e. AutoCAD, ProEngineer,
allow expression of ideas in etc. Increasing detail
appropriate forms and
language
Interchange
Analysis
i.e. Finite Element,
Workflow, etc Increasing detail

Specialist

Fig. 7. Design support tools.


834 D. Bradley / Mechatronics 20 (2010) 827–841

Table 4
Activities in the product development process.

Market Product development stages


Specification Concept design Detail design Manufacture
Tasks
Market analysis Develop Product Definition Generate, select and embody Detail concept Optimise design for
Statement (PDS) concept manufacture
Input
Legislation, reports, competitive products, Market analysis results PDS document Layout drawing Detailed drawing
statistics, market data
Tools/approaches
User behaviour capture tools Objectives tree Brainstorming Performance Simulation and computer
specification methods analysis
– Parametric analysis Competitive benchmarking Sketching and rendering
– Needs analysis Comparative analysis – Decision tools
– Matrix analysis Word processors – Weighted objectives tree 3D modelling Laboratory experiments
Spreadsheets – QFD Finite Element Design for manufacture
modelling
– Morphological chart Engineering analysis Process planning
2D draughting Process simulation
Information
User observations Performance of competing ‘Standard’ functions (i.e. Standard part Available manufacturing
products common mechanisms) catalogues processes and facilities
Market surveys Material databases
Forecasts and trends User specifications
Comparative analysis Manufacturer’s on- Comparative costs
line catalogues
Details on competing products Discussion
Patent database
Output
Market analysis results PDS document Layout drawing Detailed drawing Production plan

Theoretician Pragmatist
Reviews design process and Emphasis on problem solving
outcomes Selects, uses and refines
Identifies methods and methods
generates procedures Generates solutions
Establishes good practice Establishes practice
Refines theories

Fig. 9. Approaches to design.

access to relevant information, principles, exemplars and context


all support the creation of robust design concepts by acting as
stimuli for discussion [44].

4.3. Artificial intelligence and mechatronics design

Despite the availability of a wide range of tools to support de-


sign thinking as was suggested earlier by Fig. 7, the basic problem
of managing communications between domain specialists remains
in place. There is a specific need to support specialists from one do-
main in the early identification of potential solutions from other
domains in a way that then enables the relevant domain expert
to provide effective input. One approach to achieving this has been
through the use of a case-based reasoning approach [45,46] in
Fig. 10. Communications issues. which the system guides the user towards either existing solutions,
the cases, or to the generation of outline solutions which can then
be taken to the domain expert for refinement.
Consider also the design environment of Fig. 11 in which func-
Referring specifically to concept design, this is generally under- tional decomposition tools are used to support the mapping of the
taken in a collaborative setting founded on and based around dis- decomposed system onto the relevant hardware. For instance, take
cussion [39–42]. Although exposure to previous solutions can in the filter hierarchy of Fig. 12. The top level of this hierarchy con-
some instances result in a fixation on a particular approach [43], tains information common to all filters while the progressive lower
D. Bradley / Mechatronics 20 (2010) 827–841 835

ing environment such as that shown in Fig. 15 in which a factory


Design
Information
wide system, a manufacturing cell and an individual machine tool
or robot are represented. This environment may then be redrawn
in the form of the structured graph of Fig. 16 in which each level
Design Environment
is represented by a series of nodes linked by a communications
Functional Functional Implementation network. Structurally therefore, each level in the system represents
Simulation Decomposition Libraries an individual mechatronic system, with higher levels in the system
being formed from the integration of a number of lower level
systems.
Mapping to
Costing & This hierarchical structure also reflects the nature of the tasks
Simulation Hardware &
Documentation involved at each of the individual levels within the overall system.
Software
At the lowest, or device, level the emphasis is implicitly on achiev-
ing specific levels of functionality and performance. Progressing
upwards through the system, the emphasis shifts from the perfor-
mance of the individual devices, to the integration of a number of
Hardware Software Electronic Enclosure
Development Development Development Design such devices as part of a larger system. Thus there is a move away
from the detailed design and operation of these devices to the
Fig. 11. Structuring the design environment [85].
management of the information infrastructures required to
achieve overall system functionality and performance.
Such shifts are also associated with changes in the operational
levels then contain more detailed information specific to the retrie- time frame which may range from milliseconds at the lowest, or
val category. The bottom level is then the instantiation of the spe- machine, level to hours, days or weeks at the highest, human, lev-
cific filter. Each instance thus inherits information from the top els. These time shifts are also associated with changes in the nature
level ‘‘filter” along with features from the associated subclasses. of the associated information. Consider the situation of Fig. 17
This structure can be decomposed as shown in Fig. 13, estab- which illustrates the flow of procedural, the WHAT, and process
lishing the major high-level processes and their relationships. Fur- data, the HOW. Each of the layers in this system represents an inte-
ther decomposition then allows the detail of the individual grated process such as a the strategic or factory level, a manufac-
processes to be defined. The associated data dictionaries contain turing cell, an individual machine tool or robot or an individual
three elements; a Name field which specifies the flow or group of actuator or sensor. There is then a requirement for the manage-
flows to which the entry corresponds, the Form field which identi- ment of the procedural information as it flows up and down the
fies, where appropriate, the variable to be used as the information system to match the information needs at each of the process lev-
carrier for the flow and a description of the flow, provided for the els. In this model, human interaction with the system decreases
benefit of the designer and intended as purely descriptive. The user from top to bottom, the highest levels being those associated with
can then define the design requirements and application criteria strategic decision making and the lowest with the operation of
for the filter when the system will then return the best-fit cases individual devices or components.
as in Fig. 14. In the context of such systems, whether they be factories, air-
craft, vehicles, or indeed any systems based device, product or pro-
4.4. Mechatronics and systems engineering cess, is it perhaps therefore the case that the lower levels of the
hierarchy are those where the mechatronics approach has had a
A feature of many mechatronic systems is that the design per- major impact, while at the higher levels it is systems integration,
spective is inherently scalable. Consider for instance a manufactur- and hence systems engineering, that is more important?

Filter

Lowpass Highpass Band-Pass Band-Stop

Passive Active Digital

Butterworth Chebyshev1 Chebyshev2 Elliptic FIR IIR

Equiripple Least-squares Window Butterworth Chebyshev1 Chebyshev2 Elliptic

Chebyshev Kaiser Bartlett Blackman Hamming Hann Triangular

Fig. 12. Filter hierarchy, Butterworth block is shaded.


836 D. Bradley / Mechatronics 20 (2010) 827–841

lay User Fil


d is p te r
_a
h ._ pp
e/ te c F il
._ d
isp
p t te r
_ ty n pu _a la y
te r ._i pp
F il e ch ._ i
e/t np
_ ty p ut
te r
Select F il
Link_to_app. Select
type/tech App .
1.1 1.2
Link_to_type/
tech.
Ne
w_
ty p
e_t

New_app._to select
Ty

Ne
os
e le
pe

w_
c t( 1
/

)
te

ty
pe
ch

_t
._

o
inf

se
or

le
m

ct
at

(2
ion

)
S im u
Design late d
_ de s
User_inputs(1) ign Find
Design tools
a filter To ol_req
design
User uest
1.4
1.3
User
Design_display

De
De

s
puts

ig
De
st
st
lay

n
sig

ue

_s
ue

sig
ria_in

disp
n_

el
eq

req

ns

ec
_r
inf

fit

tio
n_

_lis
h
_
orm

n_

Design_match
rc
Crite

eria

n
s ig
a

t
sig
Se
ati

De
est

Crit

De
on
requ

User
Optimise Complete
Tool_

the design designs


1.5
Updated_
design
Simulated_design Modify
Design tools the design
1.6
Tool_request

Frequency_ New_
range frequency

User

Fig. 13. First Level Decomposition of the Filter Design System.

Fig. 14. Search results.


D. Bradley / Mechatronics 20 (2010) 827–841 837

5. Mechatronics education
Factory-wide Network
Since its inception, mechatronics has, in a variety of forms and
formats, established itself internationally as a discipline within
engineering science education and there are increasing numbers
of courses worldwide carrying a mechatronics label. Such courses
cannot necessarily be considered as having significant commonal-
Manufacturing Cell ity in either approach or content other than at a basic level as they
each tend to reflect the local and national interests where the
course is being developed and implemented. Within that context,
is the very flexibility and adaptability of the mechatronics concept
working to its advantage in terms of course structures, whilst add-
ing to the diversity of perception as to what, in the widest sense,
mechatronics represents?
Actuators Sensors Whatever the context, in the development of mechatronics edu-
cation, the concern in course design has always been that achieving
Robot or Machine Tool an appropriate balance between the provision of the necessary
depth of understanding of the core technologies and disciplines
Fig. 15. A simplified manufacturing hierarchy.
with the ability to develop solutions which integrate those tech-
nologies. This may be compared to a subject based approach to
engineering science education where the emphasis is on ensuring
Factory-Wide Network
a depth of understanding within the subject area.
Each node represents a
manufacturing ce with the Is it therefore then the case that the education of a mechatron-
interconnection provided by the ics engineer should place an emphasis on the ability to work across
factory wide network
and between individual areas of technology? This is not however
to suggest that a mechatronics educated engineer is not required
have to have a depth of knowledge in specific specialist areas,
Manufacturing Cell rather that such depth is balanced by an understanding and appre-
Each node represents an individual ciation of the contributions of other areas of technology as is sug-
machine tool, robot or handling
systemn with interconnection gested by Fig. 18.
provided by the local network
Should therefore the achievement of a balanced programme of
mechatronics education be based around ensuring that individuals
are provided with sufficient depth in at least one area of technol-
ogy in order to allow them to make an effective contribution to
that area, whilst ensuring the breadth of understanding necessary
Machine Tool or Robot to give them credibility with respect to other subject specialists?
Each node represents an Consequently, is the key challenge facing mechatronics course
actuator, sensor or controller
with interconnection provided by
designers then that of ensuring that there is an appropriate balance
the machine network between depth and breadth within the course as well as providing
opportunities to enable students to practice integration?
Though mechatronics emphasises integration, it may also be
Fig. 16. Manufacturing hierarchy. perceived as encompassing a number of themes such as design,
manufacturing or automation. In relation to course development,
the choice of theme is generally dictated by a number of factors
including:
Human based

Engineering
systems

System

Overlap Mechatronics
Engineer
Procedural Information
- the WHAT

Depth

Depth

Data Translation &


Interpretation between
Process Layer Process Layers
Mechatronics
Machine based
systems

Subject Area Subject Area


Process Information
- the HOW (a) Specialist education (b) Mechatronics education
Fig. 18. Balance of technical expertise for specialist and mechatronics educated
Fig. 17. Information flows. engineers. (a) Specialist education, and (b) mechatronics education.
838 D. Bradley / Mechatronics 20 (2010) 827–841

 The backgrounds and interests of the staff involved in teaching Such a shift in perspective will in turn cause present consider-
the course. ations of Design for Manufacture and Assembly, which are often
 Industrial requirements, both locally and nationally. in conflict with the requirements of design for disassembly or
 Student perceptions and interests. maintenance, to be brought into question. Consider for instance
 Availability of resources, particularly human and financial. the use of snap connectors for joining components. These are easy
 Research activity. to assemble but can make access problematic without the destruc-
tion of the item in question.
While it is unlikely that any one of these considerations will
dominate course development to the exclusion of others, any one 6.1. Mechatronics and a sustainable future
of these factors may well be the defining influence for a particular
programme or course. In the 1987 report of the Brundtland Commission, Our Common
For instance, resource implications will often mean that teach- Future, sustainable development was defined as [49]:
ing of specialist material will require that mechatronic engineers
‘Development that meets the needs of the present without compro-
are incorporated as part of a larger group of subject specialists
mising the ability of future generations to meet their own needs’.4
for this purpose, with the courses then being structured to meet
the needs of the subject specialists rather than the mechatronics This requirement to embbed sustainability within future sys-
students. Also, the increasing modularisation of programmes can tems in emphasised by the ratification in 2007 of the United Na-
tend to mitigate against the ability to introduce the necessary inte- tions and ICLEI5 TBL standard for urban and community
grating material, particularly where modules are seen as having to accounting. Similar UN standards apply to natural capital and human
be complete and entire within themselves. capital measurement to assist in measurements required by TBL
In light of the above challenges, how might the designers of a [50–53].
mechatronics course respond? What is clear is that they are faced Given the significance of these developments, is it implicit that
with a number of questions including: mechatronics must change and adapt itself to encompass issues of
sustainability within its conceptual remit? Assuming that this is
 Should a theme be chosen or should it emerge as a result of the the case, what then are the implications for the design, develop-
local expertise and enthusiasms? ment and implementation of future mechatronic systems?
 How are the integration aspects of mechatronics to be intro-
duced and managed? 6.2. Developments in mechatronic applications
 How are external requirements, as for instance the Bologna
Agreement in Europe [47,48], to be managed? Some of the potential areas where mechatronics could poten-
 What is the local market for graduates and is the proposed tially have a major impact in relation to future applications are
course going to meet those requirements? suggested in the following sections.

As a consequence of the above, has mechatronics suffered from 6.2.1. Manufacturing


an identity crisis both within the academic community and else- Mechatronics is often associated with robotics and factory sys-
where, and is this likely to continue to be the case given the diver- tems. However, systems that move, machine and assemble are per-
sity of approaches and emphasis that are found within the haps only classifiable as such by the degree to which they
community? incorporate adaptability and agility within their operation? As
Yet there is no doubt that there is a need for graduate engineers manufacturing systems have evolved to incorporate increasing
with the particular integration skills that are provided by a mech- numbers of semi and near autonomous elements, mechatronic sys-
atronic education. tems have played a role in applications such as assembly, machin-
The key challenge facing mechatronics course designers there- ing, inspection, dangerous material handling and disassembly.
fore remains that of achieving an effective balance between the With the introduction of ‘manufacture on demand’ strategies,
requirement for detailed knowledge and engendering the ability buyers seek increased opportunities for customisation. This has
to act in an integrating role in a wide range of engineering environ- necessitated an agility of operation, often involving autonomously
ments. The achievement of this balance is further subject to a reconfigurable machine tools [54] and dynamic decision making
whole range of pressures ranging from the rapid advance of tech- [55] as an integral part of the process, enabling manufacturing
nology to external factors impacting on course management and groupings to be created [56] in response to demand. As a conse-
design such as the moves to implement sustainable systems or in- quence, manufacturing cells increasingly provide a variety of job
crease student mobility. The underlying precepts presented here functions on a part-by-part basis. The resulting organisational
are however likely to remain as a constant for course designers and operational complexity has in turn been supported by the
and developers. introduction of strategies such as game theory [57] and self-orga-
nisation [58,59].
Other areas of production where mechatronic systems can be
6. Challenges considered to have impacted is with respect to those environments
where it is either unsafe or inconvenient for humans to work. This
It is clear that engineering design and its mechatronic compo- includes the movement of materials [60], the handling of toxic and
nent will need to continue to adapt to meet and respond to a range radioactive materials and maintenance in heavily polluted envi-
of challenges in areas such as energy systems, transport, health ronments [61].
care, medicine and manufacturing. Indeed, could it be argued that There is also an increasing move, driven in part by legislation on
the achievement of sustainable systems in all of these, and other, waste disposal and management as well as on recycling, to in-
areas will depend on the ability to integrate a mechatronic ap- crease the emphasis on design for disassembly and component re-
proach to system design and development with corresponding
developments in areas such as materials technology which will im- 4
Formerly the World Commission on Environment and Development and chaired
pact not only on new product concepts, but also on the way they by the then Prime Minister of Norway, Gro Harlem Brundtland.
are made? 5
ICLEI – Local Governments for Sustainability.
D. Bradley / Mechatronics 20 (2010) 827–841 839

use. Is this perhaps also an area where mechatronics will have a 6.3. Potential for technological impact
growing, and significant, role to play?
Developments in technology are going to continue to drive
changes within the design process and to impact upon the design
6.2.2. Transport
process. For instance, the development of low cost network sensors
Is this a key area where mechatronics is likely to significantly
creates opportunities to develop new approaches to information
impact on and influence design, development and operation? For
collection and management and the increasing availability of
instance:
MEMS devices is likely to force a radical rethink of the approach
to many areas of application, supporting the integration of mea-
6.2.2.1. Rail. The further development of tilting trains, active sus- surement and data processing throughout the system.
pensions, driven and steered wheelsets and traction and braking Many of these system components will incorporate significant
control are all likely to feature to some degree in future train sys- processing power in their own right, opening up the opportunity
tems along with enhanced drive technologies and controller strat- to create not only a distributed sensor network, but of using those
egies [62]. Other potential areas of development include high- same sensors as part of a distributed and parallel processing array.
speed trains and the use of maglev technologies [63,64]. It is not therefore inconceivable to envision a system such as a
vehicle relying on such a distributed array to manage all its on-
6.2.2.2. Road transport. The move towards hybrid vehicles and the board functions, with the added benefit of multiple redundancy
use of fuel cell technology [65] as well as an increasing range of in case of a failure of component part.
on-board systems for driver assistance, safety and security and Developments in materials and actuators are also going to im-
vehicle and engine management. An example of such thinking is pact on the approach to the design of a wide range of systems.
the Siemens eCorner ‘smart wheels’ concept. This uses a hub motor For instance, neural interface chips such as those being developed
located inside the wheel rim together with an electronic wedge at the University of Utah and elsewhere could support the design,
brake whose pads are driven by electric motors. An active suspen- development and implementation of a new range of prosthesis by
sion and electronic steering replace conventional hydraulic sys- allowing a level of connectivity between the original nerve bundle
tems, supporting advanced drive-by-wire concepts [66]. and the prosthetic to be re-established. This brings with it the
prospect of providing neural feedback on the position and behav-
iour of the prosthetic limb, perhaps even restoring an element of
6.2.2.3. Aircraft. Aircraft, the growth of air transport and the impact proprioception and kinesthesia to limb movement.
on the environment is undoubtedly one of the most contentious
areas in which mechatronics is likely to play a role. Issues include
the design of aircraft that are quieter and more fuel efficiency and 7. Discussion
with a lower environmental impact than present aircraft [67–70].
In the introduction it was stated that the key aim of the paper
6.2.3. Energy technologies was to raise questions as to the current and future direction and
The deployment and use of alternative energy sources such as status of mechatronics as an engineering discipline, or perhaps a
wind and wave power [71,72], the introduction micro combined design philosophy structured around integration. Or indeed if
heat and power (microCHP) systems [73] heat pumps and fuel cells some other direction or directions of development are likely or
as well as new generations of appliances and energy management appropriate. In this context, it is perhaps possible to reduce the dis-
options within the home are all going to be influenced by mecha- cussion of the previous sections to the key question ‘‘Does mecha-
tronic approaches to their design operation and control. tronics still remain significantly different when compared to other
approaches to system integration?”
While it is the intent of the author that each reader formulates
6.2.4. Health
their own response to this and the other questions and issues
Instances here include the development of enhanced and intel-
raised, there are a number of comments that might perhaps be
ligent prostheses for both the upper and lower limbs [74–77], the
made in support of the discussion that it is hoped to engender.
introduction of systems to support the rehabilitation of a range of
For instance, while it is possibly the case that mechatronics has
medical and clinical conditions [78,79], the provision of new surgi-
to a significant degree been integrated with and incorporated with-
cal methods and techniques involving the deployment of robotic
in mainstream engineering design methods and strategies, is this
systems and telecare, telemedicine and telehealth strategies based
because other areas of engineering design have learnt about inte-
on the introduction and deployment of enhanced sensors, net-
gration from mechatronics as part of the natural transfer that takes
working and data analysis [80]. In each of these and related areas,
between design practice and design theory and vice versa?
is the deployment of a mechatronic approach is likely to be key in
Further, when mechatronics was first suggested, was it repre-
achieving robust, reliable and effective systems?
sentative of a wider shift in thinking about systems and integration
with in the overall engineering design process that was taking
6.2.5. Materials place around that time, as expressed by the emergence of the pre-
The choice of materials is becoming increasingly important in cepts of concurrent engineering? When combined with such new
relation to the design and operation of systems of all types, as for and different ways of thinking about the management and organi-
instance in the increased use of composite materials in vehicles sation of the design process, and supported by an evolving techni-
such as cars and aircraft as well as in consumer products. The pro- cal capability, this has led over the last 40 years to the
vision of new types of materials has itself made it possible to de- development and implementation of a wide range and variety of
velop these products in a way which supports the general products and systems which have technical integration at their
mechatronic concepts of integration at the systems level [81–83]. core. Having thus initially been driven by a realisation that changes
This includes technologies such as smart fabrics which can incor- in technology required a shift in thinking about product design and
porate a sensing function for health related issues such as monitor- development, does mechatronics still retain that ability to bring to-
ing people working in hazardous environments such as those gether the best from a wide range of domains, and not exclusively
involving high ambient temperatures. technical domains, to create further systems?
840 D. Bradley / Mechatronics 20 (2010) 827–841

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