Proceedings of the ASME 2015 International Mechanical Engineering Congress and Exposition

IMECE2015
November 13-19, 2015, Houston, Texas

IMECE2015-52784

DESIGN OF ROBUST MECHATRONICS EMBEDDED SYSTEMS BY INTEGRATION

OF VIRTUAL SIMULATION AND MECHATRONICS PLATFORM

Devdas Shetty Naresh Poudel

School of Engineering and Applied Sciences School of Engineering and Applied Sciences
University of the District of Columbia University of the District of Columbia
Washington DC, 20008, USA Washington DC, 20008, USA
devdas.shetty@udc.edu naresh.poudel@udc.edu

Esther Ososanya
School of Engineering and Applied Sciences
University of the District of Columbia
Washington DC, 20008, USA
eososanya@udc.edu

ABSTRACT dynamic interactions between the machine components. Many

Increasing demands on the productivity of complex
systems, such as machine tools and their steadily growing
technological importance will require the application of new
methods in the product development process. This paper shows
that the analysis of the simulation results from the simulation
based mechatronic model of a complex system followed by a
procedure that allows a better understanding of the dynamic
behavior and interactions of the components. Mechatronics is a
design philosophy, which is an integrating approach to
engineering design. Through a mechanism of simulating
interdisciplinary ideas and techniques, mechatronics provides
ideal conditions to raise the synergy, thereby providing a
catalytic effect for the new solutions to technically complex
situations. This paper shows how the mechatronic products can
exhibit performance characteristics that were previously
difficult to achieve without the synergistic combination.
The paper further examines an approach used in modeling,
simulation and optimization of dynamic machine tools and
adopts it for general optimized design of mechatronics
instrumentation and portable products. By considering the
machine tool as a complete mechatronic system, which can be
broken down into subsystems, forms the fundamental basis for
the procedure. Starting from this point of view it is necessary to
establish appropriate simulation models, which are capable of
representing the relevant properties of the subsystems and the
real-world systems can be modeled by the mass-spring-damper
system and hence considering one such system, namely
Mechatronics Technology Demonstrator (MTD) is discussed
here. MTD is a portable low cost, technology demonstrator,
developed and refined by the authors. It is suitable for studying
the key elements of mechatronic systems including; mechanical
system dynamics, sensors, actuators, computer interfacing, and
application development. An important characteristic of
mechatronic devices and systems is their built-in intelligence
that results through a combination of precision, mechanical and
electrical engineering, and real time programming integrated to
the design process. The synergy can be generated by the right
combination of parameters, that is, the final product can be
better than just the sum of its parts. The paper highlights
design optimization of several mechatronic products using the
procedures derived by the use of mass spring damper based
mechatronic system. The paper shows step by step development
of a mechatronic product and the use of embedded software for
portability of hand held equipment.
A LabVIEW based platform was used as a control tool to
control the MTD, perform data acquisition, post-processing,
and optimization. In addition to the use of LabVIEW software,
the use of embedded control system has been proposed for real-
time control and optimization of the mass-spring-damper
system. Integrating embedded control system with the mass-

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 spring-damper system makes the MTD a multi-concepts
Mechatronics platform. This allows interface with external
sensors and actuators with closed-loop control and real-time
monitoring of the physical system. This teaches students the
skill set required for embedded control: design control
algorithms (model-based embedded control software
development, signal processing, communications), Computer
Software (real-time computation, multitasking, interrupts),
Computer hardware (interfacing, peripherals, memory
constraints), and System Performance Optimization. This
approach of deriving a mathematical model of system to be
controlled, developing simulation model of the system, and
using embedded control for rapid prototyping and optimization,
will practically speed product development and improve
productivity of complex systems.
INTRODUCTION
Mechatronics is a methodology used to achieve an
optimal design of an electromechanical product. As a design
philosophy, mechatronics serves as an integrating approach to
engineering design. A mechatronically-designed product relies
heavily on system and component modeling and simulation to
establish the optimal design tradeoffs between electronic and
mechanical disciplines when subject to specific cost and
performance constraints. The ideas and techniques developed
during the interdisciplinary simulation process provide the ideal
conditions to raise synergy and provide a catalytic effect for
discovering new and simpler solutions to traditionally complex
problems.
An important characteristic of a mechatronic system is its built-
in or embedded intelligence. This intelligence, a result of the
interdisciplinary simulation process, is implemented through
embedded software that orchestrates a combination of precision
mechanical and electrical components. There is a synergy in
the integration of mechanical, electrical, and computer systems
with information systems for the design and manufacture of
products and processes. The synergy can be generated by the
right combination of parameters, that is, the final product can be
better than just the sum of its parts. Mechatronic products
exhibit performance characteristics that were previously
difficult to achieve without this synergistic combination.
Electromechanical
Simulation and
Modeling Mechanical
Electrical
Mechatronics Automatic
Systems
Actuators
Systems
Control
Sensors
Optimization
Information Systems
Figure 1: Key Mechatronic Elements
The key elements of the mechatronics approach are presented in
Figure 1 (Shetty and Kolk, 1998). Mechatronics is the result of
applying information systems to physical systems. The physical
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system, the rightmost dotted block, consists of mechanical,
electrical, and computer (electronic) systems as well as
actuators, sensors, and real time interfacing. Sensors and
actuators are used to transduce energy from high power, usually
the mechanical side, to low power, the electrical and computer
or electronic side. The block labeled mechanical systems
frequently consists of more than just mechanical components
and may include fluid, pneumatic, thermal, acoustic, chemical,
and other disciplines as well.
New developments in sensing technologies have emerged in
response to the ever-increasing demand for solutions of specific
monitoring applications. They have produced faster, more
sensitive and precise measuring devices. Sensors are being
miniaturized and implemented in solid-state form so that several
sensors can be integrated and their functions combined.
Irrespective of the application; industrial control,
manufacturing, testing, or military, new developments in
sensing technology are constantly emerging.
Figure 2: Lockheed F22 fighter
The F-22 fighter, pictured in Figure 2, jointly developed by
Lockheed and Boeing, is an example of mechatronic technology
in action. The design metrics emphasize reliability,
maintainability, and performance. Multi-disciplinary
functionality such as the integrated flight-propulsion control
system and thrust-vectored engine nozzles, make point-and-
shoot maneuvers that defy conventional aerodynamic control
possible.
Starting with the basic system design phase and progressing
through the manufacturing phase, the mechatronic process
optimizes the system parameters at each phase to produce a
high quality multi-disciplinary integrated product in a short
Real Time Interfacing
cycle time. Mechatronics employs control systems to provide a
coherent framework for component interactions and their
Computer
D/A Systems analysis. Integration within a mechatronic system is performed
A/D
through the combination of hardware components and software,
including information processing. Hardware integration results
from designing the mechatronic system as an overall system,
which includes the sensors, actuators and embedded computer
as well. Software integration is based on control functions and
algorithms to be performed.
2 Copyright © 2015 by ASME
 Process
Hardware;
Software; Knowledge
Information Processing
Computers Actuators Process Sensors
Figure 3: General Scheme of Hardware and Software
Integration
Figure 3 illustrates how the hardware and software integration
takes place. It also illustrates how additional process
knowledge, as it becomes available, is utilized to improve the
system design.
The benefits of the mechatronic design approach are greater
productivity (shorter development cycles and faster time to
market), higher quality, and lower cost products. They also
provide additional influence through the acquisition of
knowledge information from the process. A mechatronic
product can achieve impressive results if it is effectively
integrated with the concurrent engineering management
strategy.
MECHATRONICS PLATFORM AS A TESTBED FOR
DESIGN VALIDATION OF PRODUCTS AND
MACHINING CENTERS
MECHATRONICS PLATFORM:
The Mechatronics Technology Demonstrator (MTD) is
a low cost technology demonstrator, developed and refined by
the authors. It is a mass – spring – damper system with an
electromagnetic force actuator and a non-contact position
sensor. It is built from low cost components available at most
electronic, hardware, and home supply stores. It is suitable for
studying the key elements of mechatronic systems including;
mechanical system dynamics, sensors, actuators, computer
interfacing, and application development.
The MTD can be constructed in two configurations, vertical
(Figure 4) and horizontal (Figure 5). The vertical
configuration offers greater motion control over shorter
distances while the horizontal configuration provides just the
opposite. The MTD is shown in Figure 4, and it consists of the
following four major components; (i) mechanical mass-spring-
damper assembly, (ii) displacement sensor, (iii) voice coil
actuator, (iv) voice coil power amplifier. In this case study, a
dynamic model of a mass-spring-damper system will be
developed, the behavior of the model with experimentally
obtained.
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Design Principles
The primary mass element in the system is the voice-
coil magnet. The magnet is suspended by four wires and “L”
brackets. They allow the mass to vibrate vertically with a very
small coefficient of friction.
Fig 4: Vertical MTD Configuration
Figure 5: Horizontal MDT Configuration
Regardless of the configuration, position of the mass in the
MTD is measured using a position sensing detector (PSD)
device. The PSD outputs a voltage proportional to the intensity
of the light cast upon it. The light source, a laser similar to the
type used for overhead presentations, is fastened to the base of
the MTD and aimed at a mirror attached to the mass. The laser
is adjusted until the reflected beam just hits the center of the
PSD when the mass is motionless and in its normal position. As
the mass moves around its normal position the reflection angle
changes which, in turn, changes the area (intensity) of the light
hitting the PSD and hence its voltage. Aside from the initial
“tuning” of the laser beam angle, the motion sensing method is
extremely accurate, non-contact, and extremely easy to
implement.
To provide force inputs to the mass for motion and/or active
damping a voice-coil/magnetic actuator is used. Basically a
small loudspeaker is used with the paper cone coated with
fiberglass resin to provide a firm mounting area. The magnet is
separated from the voice coil and attached directly to the mass.
The voice coil is attached to the base of the MTD. Application
of current to the coil results in either vertical or horizontal
motion of the magnet depending on the orientation of the
mounting. Alignment of the magnet inside the voice coil is
somewhat critical to reduce binding. The vertical configuration
offers additional benefit in this area. Figure 6 presents the
vertical configuration of the actuator.
 Figure 8 Physical Modeling
Figure 6: Voice coil/magnetic actuator – Vertical
Configuration Mass-Spring-Damper Mechanical Illustration for Physics Based
Model
Both the sensor and the voice coil actuator are connected to the From Newton’s Law of motion, we get
PC based visual modeling and real time simulation application
using a general purpose I/O card. The voltage output by the
PSD is ample for direct connection without the need for
amplification. The current used to drive the voice coil, Hence, the resulting transfer function of the model is,
however, does need amplification. The amplifier circuit used to
power the actuator is shown in Figure 7.
P o w e r S u p p ly ; + 6 v

C o il
Where, x = displacement of the mass.
S ig n a l fro m
C
f = force exerted on the mass.
d a ta I/ O B
b o a rd
3 .9 K R e s is to r D io d e E P o w e r T ra n s is to r 2 N 3 0 5 5
M = mass of the cart.
K = the equivalent spring constant.
B = the equivalent damping constant.

Experiment Options: The MTD can be used for several study

Figure 7: Actuator amplifier circuit options in mechatronics including modeling, simulation,
monitoring, and closed loop control. A brief description of two
The hardware components required for this case study are of the options follows.
presented in the following table:
Modeling and Simulation:
Table 1: Components of MTD Option 1
1 Position Sensitive Detector 1A: The physical model of the mass spring system is
(PSD) constructed using the block diagram. The model will provide
2 Laser Pointer prediction from a force input to the mass displacement (and
3 Power Transistor velocity). To verify the performance of the model, the
4 Power Supply experiment is conducted in parallel with actual data obtained
5 Braces and anchors along with a plot of comparison displacement outputs. Model
6 Laser Bracket parameters are adjusted until good performance correlation
7 Aluminum Sensor housing exists. An example of a block diagram model is shown in
Figure 8.
The physics based model for the mass-spring-damper system is
based on the mechanical illustration shown in Figure 8:

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 PROGRAMMING
 Using the Analog Input task defined in Measurement
and Automation, get two signals; Channel 1 and
Channel 2. The “Split Signals” function can be used to
extract the two signals from the single wire bundle.
 The actual movement of the mass is determined using
the following formula;

Displacement = (Channel 1 – Channel 2) x

Conversion Factor

 Establish the Analog Output using the task defined in

Figure 9: Physical system block diagram for MTD
1B: A Least Square model of the mass spring system is
developed using a step force input to the mass and recording the
resulting displacement. The parameters in the second order
model are computed using the least square method with gradient
adjustment. To verify the performance of the model, it is run in
parallel with additional data records.
Measurement and Automation explorer and a DAQmx
Write function.
 The actual run plot must contain the following values;
vertical movement of the mass, zero voltage level of
the mass and ten-voltage level of the mass (3/8 inches).
Front Panel

Option 2 - Control:
Closed loop control is used to provide additional electronic
damping to the MTD in order to smooth the time response.
Two control options are considered; rate feedback control
design and validation and on/off control design and evaluation.

2A: Design a model based control algorithm of the “rate

feedback” type to electronically increase the damping applied to
the mass. This will require installation and calibration of the
magnetic actuator and design of the rate feedback control
algorithm.
Block Diagram

Build Array

Figure 10: Mass displacement response with rate feedback

control
Build Array
2B: Design an on/off control which increases the damping
applied to the mass. This will require installation and
calibration of the magnetic actuator and design of the rate
feedback control algorithm. The algorithm will sense peak
points of mass acceleration, negate them and send the Figure 11: LabView front panel and Block Diagram for
information back to the actuator. MTD

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 CALIBRATION AND TESTING
Step1: Assembly: Verify that the mass oscillates freely when
displaced. Observe the oscillations for normal displacement
inputs. If there are problems, check the voice coil actuator and
magnet alignment

Step 2: Sensor Input and calibration: Check the alignment of

laser and PSD. With the mass at rest, the laser beam must hit the
center of PSD. Calibrate the input. At the center of psd the
resulting output voltage from the psd should be zero.
1. With the mass at rest, set the conversion factor
slider to a value of one. The resulting voltage from
the psd should be approximately zero.

2. Then actuate the coil to raise the mass to 3/8 inch.

Now adjust the conversion factor slider until the
resulting voltage from psd reads approximately
3/8 inch (0.375 in) Figure 14: Physics Based Model, Front Panel

EMBEDDED TOOLS FOR MECHATRONICS

PRODUCTS

(a) (b)
Figure 12: (a) Angle of reflection adjustment and (b)
Reflected laser beam at center of psd
3. The system is now calibrated and test runs can be
performed
Step 3: Run the actual test setup. Activate the coil to raise the
mass. Set the Output Voltage slider to 10V. Leave the mass
raised for about 10 seconds. Then release the mass by setting
the Output Voltage slider to zero. Repeat Step 3 with the 10-
second timer for raising the mass for 10 seconds.
MBED LCP1768
The LCP1768 is an ARM Cortex-M3 based
microcontroller for embedded applications requiring a high
level of integration and low power dissipation. The ARM
Cortex-M3 is a next generation core that offers system
enhancements such as modernized debug features and a higher
level of support block integration. The ARM Cortex-M3 CPU
incorporates a 3-stage pipeline and uses Harvard architecture
with separate local instruction and data buses as well as a third
bus for peripherals. The ARM Cortex-M3 CPU also includes an
internal pre-fetch unit that supports speculative branches.
The peripheral complement of the LPC1768 includes up to 512
KB of flash memory, up to 64 KB of data memory, Ethernet
MAC, a USB interface that can be configured as either host,
device, or OTG, 8 channel general purpose DMA controller, 4
UARTs, 2 CAN channels, 2 SSP controllers, SPI interface, 3
I2C interfaces, 2-input plus 2-output I2S interface, 8 channel
12-bit ADC, 10-bit DAC, motor control PWM, Quadrature
Encoder interface, 4 general purpose timers, 6-output general
purpose PWM, ultra-low power RTC with separate battery
supply, and up to 70 general purpose I/O pins.

Figure 13: Physics Based Model Test and Simulation Figure 15: LPC 1768 Cortex M3 Board

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 INTERFACE WITH LABVIEW
Figure 16: Functional Diagram of LCP1768
VisSim and LabView are all simulation tools that have
been developed over the years to support mechatronic products
design. LabView is also used for rapid prototyping and for
control of mechanical system that does not required real-time
operations. Incorporating embedded system allows real-time
and dynamic control of the mechanical system. The use of
embedded systems allows optimization of performance, and the
design of safe and reliable products. In particular, since in a
mechatronic system, the mechanical, electrical, and/or thermal
components of a product are connected through sensors and
actuators, using embedded controllers define the overall system
functionality and provide status of the control system and sensor
signals. VisSim and LabView use 1D model, in which icons to
which mathematical equations are connected represent
components, systems or subsystems. 0D models are also used
which describe systems with simple relations or tabular and
graphical representations.
Next, the MBED microcontroller is interfaced directly to the
MSD for dynamics control of the system. The MBED reads the
Position Sensor Displacement (PSD) of the Mass using the
MBED analog inputs and the AnalogIN MBED object. Using
the AnalogOut MBED object, the MBED analog output is
connected in a feedback control loop to provide the excitation
force for the damper. In the LabView control, the set of the
MSD constants and damper parameters is determined that can
meet the required performance. In the MBED control, feedback
loop dynamically control the MSD to provide required
performance, in response to excitation inputs. The excitation
input is the computed actuator force representing active shock
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absorber, which is fed into the suspension. The system has not
employed physical actuator because the magnetic coil
arrangement under excitation provides an actuator and/or shock
absorber behavior. The displacement of the Mass is measured
using Laser and PSD sensor.
The MBED is a valuable device, which can be used to
implement some simple control algorithms. Closed loop control
systems employ internal error analysis to achieve accurate
control of actuators, given continuous sensor input readings.
The system measures the displacement of the Mass, compares it
with the set point of zero at rest, and uses the error to move the
actuator to place the Mass in the rest position. The PSD
measures the effect of the action by tracking the displacement.
The MBED computes the difference between the zero set point
and actual position. No action is required when the desired set
point is achieved.
Compared to the LabView control, LabView uses calibrated
actuator settings or look-up table to achieve its desired action. It
could not measure time to response or mass velocity, or auto
detects misalignment of the laser, and so the control cannot be
accurately predicted. With the use of embedded system, the
system can detect inertial sensor reading or friction loading on
the mass, and signal corrective action. If laser is not at the set
point, additional sensors can be added to improve on the
measurement of the controlled variable and ensures that
accuracy is achieved. The closed loop control therefore has
advantages of improved accuracy of control variables and the
ability to automatically make continuous adjustment. In cases
where the actuator is non-linear in terms of performance or
instability, closed loop control built around fast microcontroller
is a necessity.
SIMULATION AND VALIDATION OF MACHINE
DYNAMICS
The mechatronics technology is studied and applied to
the investigation of machining centers for wide variety of
machining applications. The traditional design procedures
attempt to refine machining center performances through
iterative trials on prototypes, designing and modifying machine
tool architecture, auxiliary subsystems and components of the
feed drives with their static and dynamic performances. For
example, the whole system of Computer Machining Center
actuators, mechanical components, cutting process can be
modeled, simulated and validated through a series of simulation
runs. You can create a fully digitized model of the machining
centers and integrate simulated numerical functions and control
capabilities with the model of the kinematics of feed drives of
the mechanical structures.
The integration of virtual model and real time mechatronics
hardware makes it possible to study the interaction between the
dynamics of active and passive mechanical structures. A multi
body approach can be performed for a machining center. Each
 structural component of the machine is imported from a CAD
environment with proper dynamic behavior. The joint stiffness
between the mechanical components is simulated with linear
guides and roller bearings using spring elements. Using mass,
spring and damping elements one can simulate recirculating ball
screws, gearboxes.
[3] Gary Johnson, Richard Jennings, LabVIEW Graphical
Programming, McGraw Hill Professional, Jul 2006.
[4] Toulson, R. & Wilmshurst, T. (2012). Fast and Effective
Embedded Systems Design - Applying the ARM mbed,
Newnes, Oxford, ISBN: 9780080977683.

The Mechatronic Technology Demonstrator platform
implements a prototype of an active damper and active
suspension system. From the VisSim and LabView simulations
of the MSD system, the settings of the spring constant, the
optimal damper parameters or coefficients, were optimized for a
fixed mass and fixed load. These parameters were adjusted until
desired performance is achieved. Hardware-in-the-loop HIL
simulation, a model of the environment the mechatronic product
being designed will be used needs to be synthesized for a more
reliable product design. The virtual prototype of a machine tool
will be a computer simulation model using several mass spring
damping units that can be interlinked, presented, tested like a
real machine.
[5] K. Jeevan Kumar and N. Akshay (2014), “Multichannel
Data Acquisition And Control System Using Labview”,
International Journal of Embedded & VLSI System,
Volume 3, Issue 12 Dec 2014.
[6] Altinas, Y., Brecher, C., Weck, M and Witt, S., 2005
“Virtual Machine Tool”, Annals of CIRP, 53 (2), pp 619-
642
[7] Bedini, R., Tani, G., Fortunato, A, Gallorini, G and
Montega, C., “From Traditional to Virtual Design of
Machine Tools: A Long Way to Go.. 2006, IMECE 2006-
13526, IMECE, Chicago, November 5-10, 2006

CONCLUSION [8] M. Hamad, A. Kassem, R.A. Jabr, and C. Bechara,(2006),

The paper further examines an approach used in modeling, “A PIC-based microcontroller design laboratory”, Proc.
simulation and optimization of dynamic machine tools and IEEE Int. Workshop on Chip for Real-time Applications,
adopts it for general optimized design of mechatronics pp. 66-69.
instrumentation and portable products. Many real-world
systems can be modeled by the mass-spring-damper system and [9] “MBED rapid prototyping for microcontrollers”,
hence considering one such system, namely Mechatronics www.mbed.org
Technology Demonstrator platform is presented. The platform
is suitable for studying the key elements of mechatronic systems [10] “LabVIEWEmbedded Module for ARM
including; mechanical system dynamics, sensors, actuators, Microcontrollers”, www.ni.com/arm
computer interfacing, and application development. An
important characteristic of mechatronic devices and systems is
their built-in intelligence that results through a combination of
precision, mechanical and electrical engineering, and real time
programming integrated to the design process. By considering
the machine tool as a complete mechatronic system, which can
be broken down into subsystems, forms the fundamental basis
for the procedure. The paper highlights design optimization of a
mechatronic product using the procedures derived by the use of
mass spring damper based mechatronic system. In this way, the
designer can foresee the effects of his design ideas before
manufacturing a physical prototype with a good probability that
the optimization of virtual machining center will lead to real
good results.

REFERENCES

[1] Shetty, D and Kolk, R (2010) “Mechatronic System

Design”, 2nd edition Cengage Learning, Boston, USA.

[2] Schlemer, L and Alptekin, S (1998) “Team based product

Development in Mechatronics Design Class” ASME
Presentations, 1998-WA/DE-19.

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