ED5080: Mechatronics System Design

Nilesh J. Vasa (Email: njvasa@iitm.ac.in)

Introduction, Actuator types (mechanical, pneumatic, hydraulic, electric),

Control and examples, Different types of electrical actuators and control,
Programmable logic controllers

Srikanthan Sridharan (Email: srikanthan@iitm.ac.in)

Pulse Width Modulation (PWM) control, Mathematical modeling (Transfer
functions and Bond graphs), Response of dynamic systems, System
integration (Embedded systems, hardware design)

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Notes for this course have been prepared from a
variety of resources and are intended for
educational purposes only

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 Electric Vehicle Components

 Electrically powered loads - Power windows, power seats, and power door locks etc.
make use of small DC motors

 Auxiliary battery recharged with DC-DC converter, from the HV battery pack

 Ongoing research to adopt 42-volt electrical system standard (requires redesign and
manufacture of new components)
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An electric vehicle power and drive system

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 Control of DC motors

• Vary armature voltage

• Vary flux (field voltage -> field current) – not possible with
permanent magnet machines

Can be accomplished through PWM

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Drive for motors

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 Pulse Width Modulation - Principle
 On-Off switching pattern within a
switching period changes average value of
waveform

 The Duty Cycle is a measure of the time

the PWM signal is in its “high” state (or
on-time of the signal)

 Motor ‘relatively’ unaffected by high-

frequency switching

Vavg  D  VH  1  D  VL

On Time
Duty Cycle   100%
Period
 Features of PWM

 Control power flow (voltage/current

regulation)

 High efficiency

 High frequency switching (electronic)

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 Realization of PWM

Analog methods Digital methods

Uses operational amplifiers Uses digital controllers

(analog computers) (inbuilt timers)

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Bipolar voltage control through PWM

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Unipolar drive circuit Bipolar drive circuit

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DC motor control

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Problem

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Example response of 2nd order system

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 Model and Simulation of Mechatronic Systems

Model
• a physical, mathematical, or logical representation of a system
entity, phenomenon, or process.

Simulation
• Implementation of a model to understand behavior over time
• Useful for testing, analysis or training where real-world systems or
concepts can be represented by a model.

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 Integrated approach in System Design

Pure Mechanical System Identification of Functional

System Requirements

Addition of Sensors, actuators, Electronics Mechanical Software .

microelectronics, control function

System Design

Integration of Components (hardware

integration) Simulation and Analysis

System Redesign

Design, Analysis, Simulation

Product

Redesign of Mechanical System

Conventional Approach Integrated Approach

Mechatronic System Design and Implementation
• How to identify critical design parameters?
• How to predict the behaviour?
• How to sense the status?
• How to select the motors/sensors/controllers
• How to make it behave the way we want?
• How to ensure trouble free operation even in the presence of
disturbances?

All these without even having a physical prototype

Create a model of the whole system and simulate the system behaviour !
 Modelling of systems

Modelling
• Process of generating a model as a conceptual representation of some
phenomenon.

• Typically, refers only to some aspects of the phenomenon, and two

models of the same phenomenon may be essentially different

•Ability to explain past observations

•Ability to predict future observations
•Ability to control events
•Cost of use, especially in combination with other models
•Enabling estimation of the degree of confidence in the model
•Simplicity

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 Surgical Robot

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Project carried out in Robotics lab (Courtesy: Prof. Asokan)
 Teleoperation of Tracked Vehicles
Model and Experimental Comparison

• Mathematical model for motor, controller and actuating mechanisms developed

• Simulation studies carried out
• Experimental setup made and experimental verifications carried out

Project carried out in Robotics lab (Courtesy: Prof. Asokan)

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For information only
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Integrated Model: Combined Motion Dynamics

Inputs: Outputs:
• Throttle (%), • Time derivatives of Longitudinal, Lateral and
• Brake (%) and Yaw displacement
• Steering (%).

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For information only
Experimental verification Comparison of simulation
with no-load and experimental result with load

Plot of Rotor position output (55o)

Plot of motor speed

Plot of rotor position output (30o)

For information only 24

Integrated Model Results Comparison: Longitudinal Dynamics

Throttle Input Gear Change Brake Input

Longitudinal Displacement

For information only

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Electrical Power Assisted Steering

Need theta vs Torque

(Study response time…)

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 Modelling techniques

• Mathematical modelling
– A mathematical model is an abstract model that uses mathematical
language to describe the behavior of a system.

• Physical system modelling

– Bond graph method (Physical elements instead of equations)

• Graphical Modelling
– Visual representation of information, data, or knowledge (empirical…)

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 Mathematical Modelling and Simulation

Physical System

Engineering Model

Differential Equations

Block Diagrams

Simulation Language

Output

Classical approach for modeling of physical system 28

Single DOF (mechanical) System (2nd order)

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Electrical System (2nd order)

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Electrical Analogy (Force-voltage)
Develop the mathematical model for the dynamics of the system and draw
the corresponding electrical circuit
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Modelling of DC Servomotor
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Solenoid controlled valve
Electrical Power Assisted Steering
System dynamics

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