Professional Documents
Culture Documents
net/publication/259913472
CITATIONS READS
7 1,789
2 authors:
All content following this page was uploaded by Robin Chhabra on 29 January 2014.
Published by:
http://www.sagepublications.com
Additional services and information for Concurrent Engineering can be found at:
Subscriptions: http://cer.sagepub.com/subscriptions
Reprints: http://www.sagepub.com/journalsReprints.nav
Permissions: http://www.sagepub.com/journalsPermissions.nav
What is This?
Abstract
This article details a holistic concurrent design framework, based on fuzzy logic, which is suitable for multidisciplinary
systems. The methodology attempts to enhance communication and collaboration between different disciplines through
introducing the universal notion of satisfaction and expressing the holistic behavior of multidisciplinary systems using the
notion of energy. Throughout the design process, it uses fuzzy logic to formalize subjective aspects of design including the
impact of the designer’s attitude, resulting in the simplification of the multi-objective constrained optimization process.
In the final phase, the methodology adjusts the designer’s subjective attitude based on a holistic system performance by
utilizing an energy-based model of multidisciplinary systems. The efficiency of the resulting design framework is illu-
strated by improving the design of a 5-degree-of-freedom industrial robot manipulator.
Keywords
concurrent design, multidisciplinary systems, mechatronics, robot manipulator, fuzzy logic
their interpretation of design goals. Hence, any effective (Dhingra et al., 1990; Dhingra and Rao, 1995; Otto and
multidisciplinary design formulation should provide a Antonsson, 1995). A notable example is the method of
communication means that can not only convey quali- imprecision (MoI), which takes into account the impre-
tative and subjective notions but also formalize them cision in design (Otto and Antonsson, 1995). This
rigorously (Bradley, 2010; Fruchter et al., 1996; Wang approach defines a set of designer’s preference for
et al., 1996). Although MDO methods attempt to take design variables and performance parameters to model
into account the interconnection between subsystems, a the imprecision in design. It determines and maximizes
majority of them do not employ a unified multidisci- the global performance under one of the two conserva-
plinary modeling algorithm (Basdogan, 2009). This tive or aggressive design trade-off strategies and uses
shortcoming usually increases the complexity of the fuzzy logic operators for trade-off in the design space.
optimization in MDO formulations and reduces the Fuzzy connectives are first briefly discussed in sec-
efficiency of the communication between disciplines. tion ‘‘Fuzzy connectives and fuzzy aggregation,’’ and
This article introduces the holistic concurrent design then, a step-by-step formulation of the HCD methodol-
(HCD) methodology that addresses the above-mentioned ogy is presented in section ‘‘HCD methodology.’’
issues based on the notions of satisfaction in the synthesis Section ‘‘Application to robot manipulators’’ discusses
and energy in the analysis of multidisciplinary systems. the application of the HCD methodology to robot
The methodology utilizes tools of fuzzy logic to systema- manipulators. Some concluding remarks are made in
tically define some subjective aspects, such as satisfaction, section ‘‘Conclusion.’’
customer’s preference, and designer’s attitude, which play
a vital role in a design process in addition to objective
aspects in the form of design attributes. In order to adjust Fuzzy connectives and fuzzy aggregation
the subjective notions, the methodology examines the set
Unlike the classic set theory where the membership of
of satisfactory design candidates against a performance
an element to a set is binary, in fuzzy set theory, the
supercriterion that is defined based on a holistic multidis-
membership of an element to a fuzzy set can be partial,
ciplinary model of the system. As a result, the HCD
that is, the membership degree of an element is a num-
formally reduces the multi-objective constrained optimi-
ber in the interval [0, 1]. Accordingly, the classic logical
zation problem to two single-objective unconstrained
connectives AND, OR, and NOT are also generalized
optimizations. Consequently, not only does the HCD
as functions of the membership degrees to perform
facilitate the communication between different disciplines
operations in fuzzy set theory. In fuzzy logic, AND
but it also results in a more practical solution for a multi-
and OR connectives have been interpreted through dif-
objective, multidisciplinary design problem. As a case
ferent classes of triangular norms (t-norm) and triangu-
study, the HCD methodology is then implemented to
lar conorms (t-conorm), respectively, such as Max-Min
develop a generic design framework for serial-link robot
Operators (Tmin, Smax), Algebraic Product and Sum
manipulators as notable multidisciplinary systems. The
(Tprod, Ssum), and Drastic Product and Sum (TW, SW).
efficacy of this framework is illustrated through improv-
Using the basic properties of these operators, it can be
ing the design of a 5-degree-of-freedom (DOF) industrial
shown that for any t-norm T and t-conorm S and for
robot manipulator.
all ai 2 ½0, 1(i = 1, . . . , n) (Yager and Filev, 1994)
A number of systematic synthesis approaches for
robotic systems have been suggested in the literature,
some of which attempt to solve a multi-objective con- TW (a1 , . . . , an ) T (a1 , . . . , an ) Tmin (a1 , . . . , an )
ð1Þ
strained optimization. For instance, evolutionary algo- Smax (a1 , . . . , an ) S(a1 , . . . , an ) SW (a1 , . . . , an )
rithms (Chocron, 2008), axiomatic design theory (Bi
et al., 2004; Li et al., 2011), and genetic algorithms (Bi To represent the range of operators in equation (1),
and Zhang, 2001; Coello et al., 1998) are employed to various types of parametric formulations have been
perform the multi-objective optimization in the design suggested in the literature. In particular, Emami et al.
of robotic systems. Recently, Rout and Mittal (2010) (1999) introduce a class of parametric operators for
utilized evolutionary optimization techniques, and Kim fuzzy reasoning whose parametric t-conorm operator is
et al. (2009) used a deconvolution method to design defined as
serial-link robot arms. In the field of engineering
design, a number of concurrent design methodologies S (p) (b1 , . . . , bn )
have been introduced, among them axiomatic design [ bp1 + (1 bp1 )½ ½bpn2 + + (1 bpn2 )
theory (Suh, 1998) tries to develop a hierarchical ½bpn1 + (1 bpn1 )bpn 1=p ð2Þ
approach to the design of engineering systems. In addi-
tion, some approaches attempt to include subjective where bi 2 ½0, 1 and p . 0, and the corresponding para-
notions in the design process using fuzzy logic tools metric t-norm operator is defined based on De Morgan
laws using standard complementation operator (NOT the design availabilities and design requirements. Then,
connective), that is, C(a) = 1 a 8a 2 ½0, 1, as using parametric fuzzy connectives, introduced in sec-
tion ‘‘Fuzzy connectives and fuzzy aggregation,’’ it
T (p) (a1 , . . . , an ) = 1 S (p) ð(1 a1 ), . . . , (1 an )Þ ð3Þ aggregates the satisfactions to obtain the overall satis-
faction. This will transform the multi-objective con-
Note that, (T(p), S(p)) approaches (Tmin, Smax) as strained optimization in equation (5) to a single-
p ! +‘, (Tprod, Ssum) as p ! 1, and (TW, SW) as objective unconstrained optimization problem whose
p ! 0. optimum set of inputs is locally pareto-optimal for
In fuzzy logic, the meaning of a connective can be equation (5). The solution to the single-objective opti-
neither pure OR (t-conorm) nor AND (t-norm), with mization depends on the choice of the aggregation
its complete lack of compensation. Such connectives parameters (corresponding to the parametric connec-
are called mean operators. As an example, a parametric tives) that model different designer’s attitude in aggre-
operator of this class, namely, generalized mean opera- gating the satisfactions, that is, different trade-off
tor, is introduced in Yager and Filev (1994) strategies in design. The closer the parametric t-norm
!1=a and the generalized mean operator are to Tmin, the
(a) 1X n
more conservative the design strategy is, and the farther
G (a1 , . . . , an ) [ aa ð4Þ they are from Tmin, the more aggressive the design strat-
n i=1 i
egy would be (Otto and Antonsson, 1991). However,
where a 2 R. It appears that this type of connective different designers may not have a consensus of opinion
monotonically varies between Tmin operator as a ! ‘ on the trade-off in design. Therefore, in the last phase
and Smax operator as a ! +‘. of the HCD, the designer’s attitude is adjusted through
enhancing a holistic system performance, called perfor-
mance supercriterion. Hence, the HCD methodology
HCD methodology breaks down the multi-objective constrained design
Formulation of design process optimization into two levels of single-objective uncon-
strained optimization and incorporates features of both
A design problem consists of two sets: design variables
human subjectivity and physical objectivity.
X [ fX1 , ... ,Xn g and design attributes A [ fA1 , ... ,AN g
such that any design solution can be identified by vec- Definition 1 (satisfaction).
tors X [ ½X1 , ..., Xn T 2 Rn and A [½A1 , ... ,AN T 2 RN ,
respectively. In this article, vectors are denoted by bold 1. A mapping xj : R ! ½0, 1 for the design variable Xj
letters. Design variables are to be assigned to satisfy is called satisfaction if for any two different values
the design requirements associated with the design Xj1 , Xj2 2 R one has ½xj (Xj1 ) . xj (Xj2 ) , ½Xj1 Xj2
attributes, subject to the design availabilities or ½xj (Xj1 ) = xj (Xj2 ) , ½Xj1 ’Xj2 . The symbols
D [D1 3 3 Dn , such that Dj R(j= 1, ... ,n). For and ’ denote strictly superior and as superior,
each design attribute Ai , there is a mapping Fi : Rn ! R respectively, which are interpreted based on the
that relates a design state X to the attribute, that is, design availabilities.
Ai =Fi (X)(i =1, ... ,N ). These functional mappings can 2. A mapping mAi : R ! ½0, 1 for the design attribute
be of any form, such as closed-form equations, heuristic Ai is called satisfaction if for any two different
rules, or sets of experimental or simulated data. A design states of the design variables X1 , X2 2 Rn one has
process can be modeled as a multi-objective optimiza- ½mAi s Fi (X1 ) . mAi s Fi (X2 ) , ½Fi (X1 ) Fi (X2 ) or
tion subject to a number of constraints on the design ½mAi s Fi (X1 ) = mAi s Fi (X2 ) , ½Fi (X1 )’Fi (X2 ),
variables and attributes due to the design availabilities where and ’ are interpreted based on the design
and design requirements specified by the customer requirements. The symbol ‘‘ s ’’ is the composition
operator. For brevity, in this article, the satisfac-
min ½F1 (X), . . . , FNW (X)T subject to tion for a design attribute is denoted by ai (X)[
X 2D ð5Þ mAi s Fi (X). The value of 1 for a satisfaction corre-
fFi (X) 2 Gi , Gi R, i = NW + 1, . . . , N g sponds to the ideal case, and 0 means the worst case
or the least satisfactory design variable or attribute.
where NW and NM [ N NW are the number of attri-
butes that should be optimized and the number of con- In the conceptual phase, design requirements are
straints, respectively. usually qualitative notions that imply the designer/cus-
Given a set of design variables and a set of design tomer’s criteria for design. These requirements are natu-
attributes, the HCD methodology first assigns satisfac- rally divided into demands and desires. Accordingly, in
tions to the values of design variables and attributes the HCD, the design attributes are divided into two
based on the designer/customer’s preference reflected in subsets.
Definition 2 (wish design attribute). A design attribute satisfactions corresponding to the must attributes and
is called wish if it refers to designer/customer’s desire, design variables using the p-parameterized class of t-
that is, its associated design requirement permits norm operators defined by equations (2) and (3).
room for compromise, and it should be satisfied as Therefore, the overall must satisfaction m(p)
M (X) is quan-
much as possible. These attributes form a set denoted tified by
as W [ fW1 , . . . , WNW g whose corresponding vector
½W1 , . . . , WNW T [ ½F1 (X), . . . , FNW (X)T should be
optimized. m(p) (p)
M (X) = T ðm1 (X), . . . , mNM (X), x1 (X1 ), . . . , xn (Xn )Þ p . 0
preference (satisfaction membership functions) and minimizing the supplied energy with respect to the atti-
designer’s attitude (aggregation parameters). Hence, in tude parameters, the best design can be achieved
this phase of design, the outcome must be checked
against a supercriterion that is defined based on a holis- SE(X ) = min SE(Xs (p, q, a)) ð14Þ
(p, q, a)
tic system performance. Indeed, such a supercriterion
adjusts the designer’s attitude based on the physical per- In the bond graph representation, the supplied energy
formance of the system. As the synergy in the concur- is the energy that is added to the system at the source
rent design of multidisciplinary systems necessitates, a elements that are distinguishable by Se and Sf with the
suitable supercriterion should take into account inter- bonds coming out of them. For a time interval,
connections between the subsystems and consider the SE(Xs(p, q, a)) can be calculated by integrating the sup-
system as a whole. plied power at all source elements (Chhabra and
Although multidisciplinary systems consist of vari- Emami, 2011).
ous subsystems in different physical domains, the uni-
versal concept of energy and energy exchange is Entropy. Based on the second law of thermodynamics,
common to all of their subsystems. Therefore, an after a slight perturbation of the supplied energy, an
energy-based model can deem all subsystems together energy system reaches its equilibrium state once the
with their interconnections and introduce generic entropy generation of the system approaches its maxi-
design criteria suitable for concurrent design. A suc- mum. While the system moves toward the equilibrium,
cessful attempt in this direction was introducing the its capability of performing effective work on the envi-
concept of bond graphs in the early 1960s (Paynter, ronment reduces continuously. The less the work loss
1961). Bond graphs are domain-independent graphical of a system, the higher its aptitude is to do effective
descriptions of dynamic behavior of physical systems. work. In the bond graph modeling, this work loss is
In this modeling strategy, all components are recog- equal to the irreversible heat exchange Qirr(teq(X),X) at
nized by the energy they supply or absorb (source or the dissipative elements, where teq is defined as follows
sink elements: Se, Sf), store or dissipate (storage ele- (Chhabra and Emami, 2011): given a unit step change
ments: I and C or dissipative elements: R), and reversi- of the supplied energy, the equilibrium time teq(X) is
bly or irreversibly transform (transformer elements: TF; the time instant after which the rate of change of dissi-
gyrator elements: GY; and distributing elements: 0 pative heat remains below a small threshold e, that is
(zero), 1 (one) junctions or irreversible transducer ele-
ments: RS). In Borutzky (2009) and Breedveld (2004), ∂Qirr
bond graphs are utilized to model multidisciplinary sys- teq (X) = Inf t0 : 8t . t0 (t; X)\e ð15Þ
∂t
tems, and in Chhabra and Emami (2011), bond graphs
are used to define three holistic design criteria for such The Qirr (teq (X), X) can also be considered as a holistic
systems, which are reviewed in sequel. performance criterion that is called entropy supercriter-
ion. Using this supercriterion, the best design can be
attained by
Energy. A multidisciplinary system is designed to per-
form a certain amount of work on its environment Qirr teq (X ), X = min Qirr teq ðXs (p, q, a)Þ, Xs (p, q, a)
(p, q, a)
while input energy is supplied to it. Based on the first
law of thermodynamics, the supplied energy SE(X) does ð16Þ
not completely convert into the effective work EW(X).
This criterion is usually used in the design of thermal
A portion of SE(X) is stored or dissipated in the system
systems (Bejan et al., 1996).
elements and transacted with the environment through
physical constraints or external fields. This cost energy
CE(X) in any system is the overhead energy for per- Agility. For multidisciplinary systems whose response
forming the effective work. Therefore, CE(X) is consid- time is a crucial factor, the rate of energy transmission
ered as a supercriterion, called energy supercriterion, through the system, or agility, can be a holistic measure
which should be minimized. Based on the principle of of design. Thus, the supercriterion is defined as the time
conservation of energy, for a predefined effective work that the system takes to reach a steady state after a unit
(i.e. EW is independent of X) step change of some or all input parameters. In the lan-
guage of bond graphs, a system is in the steady state
SE(X) = EW + CE(X) ð13Þ when the rate of change of introversive dynamic energy
K(t;X) is 0. The introversive dynamic energy is defined
which shows that minimizing SE is equivalent to mini- as the energy stored in the I elements of the system.
mizing the energy supercriterion. Therefore, by This energy is equivalent to the kinetic energy of
masses in mechanical systems or the energy stored in As a design supercriterion, when the response time
inductors in electrical systems (Chhabra and Emami, reaches its minimum value with respect to attitude para-
2011). Given a unit step change of input variables, the meters, the best design is attained in Cs, that is
response time, denoted by T(X), is the time instant after
which the rate of change of introversive dynamic T (X ) = min T ðXs (p, q, a)Þ ð18Þ
(p, q, a)
energy remains below a small threshold d, that is
The complete flowchart of the HCD methodology is
∂K presented in Figure 1.
T (X) = Inf t0 : 8t . t0 (t; X)\d ð17Þ
∂t
A supercriterion,
[ p0 , q0 , α 0 ] X0 D SE, Qirr, or T
Optimization
Change X Maximize
μ(p,q,α)(X) of the Overall
Satisfaction
NO
Change
[ p, q, α ] Converged
YES
Xs(p,q, α)
Optimization
of the
Calculate the selected Performance
supercriterion
SE(Xs), Qirr(Xs), or
Supercriterion
T(Xs)
Minimize
supercriterion
NO
Converged
YES
Record
* * * * * * * *
X , [ p q α ], μ ( X ), S ( X ) or T ( X ) or Qirr ( X )
Figure 3. The CRS CataLyst-5 manipulator, its schematic and link coordinate frames, and D-H parameters.
D-H: Denavit–Hartenberg.
li is the length of common normal between Zi21 and Zi along Xi; di is the distance from Xi21 to Xi measured along Zi21; ai is the
angle between Zi21 and Zi measured about Xi; ui is the angle between Xi21 and Xi measured about Zi21.
moment of inertia, and the position of the center of W1: the end-effector overall position error Etot(X). The
mass. From the control point of view, a PI position average of the end-effector position error over the set of
controller with velocity feedback and feedforward is Nt predefined end-effector trajectories at instant t is
considered for each joint. Hence, the control design
parameters for the ith joint consist of proportional Pi, 1 X Nt
integral Inti, velocity feedback Kvfb,I, and velocity feed- Eav (t; X) =
Nt m = 1
forward Kvff,i gains. Consequently, this design problem qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
deals with 40 design variables, in total. ðxm (t; X) xd, m (t)Þ2 + ðym (t; X) yd, m (t)Þ2 + ðzm (t; X) zd, m (t)Þ2
In the HCD methodology, design attributes are ð22Þ
divided into must and wish attributes, which are listed
below, for this case study. where (xd, m (t), yd, m (t), zd, m (t)) are the desired coordi-
nates of the end-effector in the mth predefined trajec-
tory at instant t and (xm (t; X), ym (t; X), zm (t; X)) are the
M1: design availabilities, that is, a set of inequalities for
actual coordinates of the end-effector following the mth
the design variables Xj’s
predefined trajectory at instant t. The time average of
Eav (t; X) for the interval [0, tf], where tf is the final simu-
Xjmin Xj Xjmax (j = 1, . . . , 40) ð19Þ lation time, is considered as the end-effector overall
position error, that is
M2: joint restrictions, that is, a set of inequalities for ðtf
the ith joint variable at instant t, ui (t; X) 1
Etot (X) = Eav (t; X)dt ð23Þ
tf
0
umin
i ui (t; X) umax
i (i = 1, . . . , 5) ð20Þ
W2: the robot manipulability Man(X)
M3: torque restrictions, that is, a set of inequalities for
the torque of joint i at instant t, ti (t; X) ðtf !
1 1 X Nt
m
Man(X) = cond(J0 (t; X)) dt ð24Þ
jt i (t; X)j t max ð21Þ tf Nt m = 1
i (i = 1, . . . , 5) 0
M4: the restriction on the farthest point of the end- where cond(Jm
0 (t; X)) is the condition number of the
effector reachable workspace, that is, Ri(X) Rimax . Jacobian matrix with respect to the base coordinate
μY μY
Y= di, li Y= ri
1 1
0 0
Ymax-5 Ymax Y 2 Ymax-5 Ymax Y
μY μY
Y= αi Y= θi
1 1
0 0
Ymin Ymin+10 0 Ymax-10 Ymax Y Ymin Ymin+5 0 Ymax-5 Ymax Y
μY μY
Y= Etot Y= Ri, Man, QL, |τi|, τtot
1 1
0 0
0.2Ymax Ymax Y 0.75Yma Ymax Y
x
frame at time t for the mth predefined trajectory (Bi Satisfaction assignment
and Zhang, 2001). Satisfactions are defined as fuzzy membership func-
tions over the universes of discourse of design variables
W3: the structural length index of the manipulator and attributes. The must attributes should often satisfy
QL(X) inequalities while wish attributes are optimized. A form
X5 of fuzzy membership functions that is utilized in this
(di + li ) case study is trapezoidal membership function (see
QL (X) = p
3
ffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð25Þ
i=1 Vol(X) Figure 4). This function is identified by its four corners
that are specified based on the design availabilities and
where Vol(X) is the workspace volume, which is com- requirements and the designer’s interpretation of
puted based on an algorithm presented in Ceccarelli inequality and optimization. The first and last corners
et al. (2005). of the trapezoid corresponding to a must satisfaction
are the lower and upper bounds of the inequality,
W4: the average of the overall required torque at time t respectively. The middle points are chosen such that
on the predefined trajectories ttot (t; X) the definition of the inequality is neither too fuzzy nor
too crisp. For a wish satisfaction that needs to be mini-
mized, the last corner is the maximum allowable value
1 X Nt X 5
of the attribute, and as the attribute decreases, the
t tot (t; X) = t m (t; X) ð26Þ
Nt m = 1 i = 1 i satisfaction approaches to 1. The middle point is
selected based on the designer’s interpretation of mini-
where t mi (t; X) is the required torque for the joint i at mum. All acceptable ranges of values corresponding to
time t in the mth predefined end-effector trajectory. the design variables and attributes are listed in Table 1.
ri (mm) li (mm)
i=1 i=2 i=3 i=4 i=5 i=1 i=2 i=3 i=4 i=5
Initial 65.6 27.9 24.2 10.0 10.0 0.0 255.2 254.0 0.0 0.0
Final 65.9 28.0 23.0 10.1 10.2 0.0 257.9 255.1 0.0 0.0
di (mm) ai (°)
i=1 i=2 i=3 i=4 i=5 i=1 i=2 i=3 i=4 i=5
Initial 254.0 0.0 0.0 0.0 0.0 290.4 0.0 0.0 289.3 0.0
Final 255.1 0.0 0.0 0.0 0.0 290.6 0.0 0.0 289.5 0.0
Pi Inti
i=1 i=2 i=3 i=4 i=5 i=1 i=2 i=3 i=4 i=5
Initial 20.48 22.26 13.00 12.00 10.05 0.100 0.100 0.150 0.200 0.101
Final 20.73 22.35 13.07 12.04 10.08 0.100 0.101 0.152 0.201 0.101
Kvfb,i Kvff,i
i=1 i=2 i=3 i=4 i=5 i=1 i=2 i=3 i=4 i=5
Initial 41.11 39.67 24.08 23.65 22.40 44.38 48.25 33.29 25.00 23.00
Final 40.55 39.68 24.12 23.71 22.52 45.04 48.39 33.37 25.07 23.08
[p, q, a] SE (J)
Initial [10.00, 1.50, 0.50] 8.2850
Final [9.56, 1.69, 0.50] 7.8049
Wish design attributes
Etot Man QL ttot(tk) (Nm)
k=1 k=2 k=3 k=4 k=5 k=6 k=7
Initial 2.1948 19.5192 1.3049 14.0631 12.1214 13.0851 12.1373 12.1434 13.1062 12.1474
Final 0.6757 18.7397 1.2982 13.3135 11.3882 12.3080 11.4063 11.4128 12.3297 11.4165
Wish satisfactions
mEtot mMan mQL mttot (tk )
k=1 k=2 k=3 k=4 k=5 k=6 k=7
Initial 0.000 0.738 0.747 0.591 1.000 0.828 1.000 1.000 0.823 1.000
Final 0.417 0.754 0.877 1.000 1.000 1.000 1.000 1.000 1.000 1.000
Overall must satisfaction (m(p)
M )
Overall satisfaction (m(p, q, a) )
Initial 0.418 0.278
Final 0.592 0.572
Calculating the design attributes and optimizing the system has already been optimized using the conven-
overall satisfaction tional design methodologies, it is shown in this section
that one can further enhance its performance using the
In the phase of overall satisfaction optimization, the
HCD methodology.
function fminsearch in the MATLABÒ optimization
toolbox is employed for performing the single-objective
optimization. This function uses a derivative-free search Performance supercriterion
algorithm based on simplex method that is suitable for In the phase of supercriterion optimization, the energy
handling discontinuity, sharp corners, and noise in the supercriterion, defined in subsection ‘‘Energy,’’ is mini-
objective function. At each optimization step, for the mized against the attitude parameters. In the design
design state X, the robot simulation is first run for dif- loop, this supercriterion is determined for each satisfac-
ferent end-effector trajectories. And, the must and wish tory design alternative using a bond graph model of a
attributes, defined in M1–M4 and W1–W4, are then 5-DOF serial-link manipulator including its joint mod-
computed and satisfactions are assigned based on ules and controllers, which is programmed in
Figure 4. Assuming small changes in the design vari- MATLAB Simulink. Since the bond graph model used
ables in the successive optimization steps, the positive- in this case study is identical to the one used in
and negative-differential wish attributes are specified. Chhabra and Emami (2011), the details of constructing
Then, the satisfactions are aggregated, as explained in and evaluating the model are omitted here.
section ‘‘Calculation of overall satisfaction,’’ to com- In this case study, energy flows to the system
pute the overall satisfaction. In the case study, the exist- through the constant voltage electric sources of the
ing design of an industrial manipulator, that is, CRS joint motors. Hence, the total energy consumption of
CataLyst-5, is used as the initial state. Although this the system as the supercriterion is calculated by
0 tf 1
ð All satisfactory design alternatives were checked
1 X Nt X 5
@V I m (t; Xs , p, q, a) dtA against a purely objective supercriterion, as part of the
SEðXs (p, q, a)Þ = i
Nt m = 1 i = 1 HCD methodology, to adjust the designer’s attitude in
i
the aggregation process. The energy supercriterion, intro-
ð27Þ
duced in subsection ‘‘Energy,’’ was used to finalize the
where Vi is the constant voltage and Iim (t; Xs , p, q, a) is design process. According to Table 1, the energy con-
the current at the ith electric source while the manipula- sumption has decreased by nearly 6%, which is consistent
tor is following the mth predefined trajectory that is with the change in the total input torque in the manipula-
evaluated by the bond graph simulation. Using a gradi- tor. Comparing the final attitude parameters with the ini-
ent-based, constrained nonlinear optimization algo- tial ones shows a 5% decrease in the must aggregation
rithm, called fmincon, the energy supercriterion is parameter p, which indicates that the designer was ini-
minimized over the attitude parameters. tially slightly conservative. Hence, instead of focusing on
the least satisfactory must attribute, the designer should
give more weight to the other must satisfactions as well.
Discussion of results In terms of wish satisfaction aggregation, the value of a
did not change significantly, that is, the designer was able
The initial and final design solutions of the 5-DOF to appropriately compromise between the two competi-
serial-link industrial manipulator, CRS CataLyst-5, are tive wish attribute subsets. On the other hand, parameter
presented in Table 1. Since the initial state was that of q has been adjusted by 13% increase, which means that
the existing system, whose design has already been the initial designer’s attitude was too aggressive. Thus,
refined conventionally, some of the design variables did the designer should not try to enhance all cooperative
not change from their initial values notably. However, wish attributes at once and should instead focus more on
for the dynamic parameters, the radius of the third link improving the minimum attribute.
has changed most notably by almost 5%. As for the
kinematic parameters, the lengths of the second and
third links have changed by nearly 1% and 20.5%, Conclusion
respectively. Considering these modifications, the
HCD as a concurrent design methodology for multidis-
masses of the first three links have been adjusted by
ciplinary systems was formalized. In addition to the
21.3%, 21.8%, and +9%, respectively. All control
objective criteria, the HCD methodology considers sub-
gains have been slightly modified by 0.3%21.5% to
jective notions of design in the form of satisfaction and
enhance the system performance.
attitude parameters, in the hope of enhancing the com-
An improvement in all wish attributes is noticeable
munication between different disciplines. Furthermore,
in Table 1, which indicates that the initial design state
it formally converts a multi-objective constrained opti-
was not a pareto-optimal solution for the design attri-
mization to a single-objective unconstrained problem,
butes described in M1–M4 and W1–W4. Hence, the
which makes it feasible to iterate on numerous design
HCD methodology was able to enhance the system per-
variables with different natures concurrently. In the
formance in terms of the designer/customer’s preference
HCD methodology, the ultimate goal of design is rede-
by effectively considering all design variables concur-
fined based on the qualitative notions of wish and must
rently and employing a holistic synthesis and analysis
satisfactions. The methodology also studies the effect
strategy. The most important wish design attribute is
of designer’s subjective attitude in the design process,
the end-effector overall position error Etot defined by
which can be adjusted based on the reality of system
equation (23). From Table 1, the final value of Etot is
performance expressed in terms of performance super-
almost 3.25 times smaller than its initial value. Table 1
criterion and determined by bond graphs. The applica-
shows 4% improvement for the manipulability attri-
tion of the HCD to robot manipulators was illustrated
bute. The structural length index of the manipulator as
through a case study involving the redesign of a 5-DOF
a wish design attribute has been slightly improved as industrial manipulator. It was shown that an existing
well, which shows that the final manipulator can cover design based on traditional methodologies can be fur-
a bigger workspace with less overall amount of mate- ther improved by considering the holistic notions of
rial. The average of the overall required torque for pre- satisfaction in the synthesis and energy in the analysis
defined trajectories is shown in Table 1 at seven and accordingly taking into account all design variables
different times, each of which is considered as a wish concurrently.
attribute. All of them have decreased by almost
6%27%. Furthermore, the overall must satisfaction
has also increased indicating that the final design is Declaration of conflicting interests
more fault-tolerant. The authors declare that there is no conflict of interest.
Author biographies
Robin Chhabra received the MASc degree in aerospace engineering from the University of
Toronto Institute for Aerospace Studies (UTIAS), Canada, in 2008. He is currently a PhD candi-
date at the Space Mechatronics Laboratory in UTIAS. His research area includes mathematical
modeling, control, and design of multidisciplinary systems, especially robotic systems.
M Reza Emami has a PhD degree in robotics and mechatronics from University of Toronto and
has worked in the industry as a project manager in 1997–2001. He is a professional engineer and
has been a faculty member at University of Toronto Institute for Aerospace Studies since 2001. He
is the Director of Space Mechatronics Group and Coordinator of the Aero-Design Undergraduate
Laboratories at University of Toronto. His research centers on concurrent engineering of mecha-
tronic systems and intelligent robot teams and their aerospace applications.