Mechatronics Design Process

Introduction
• Traditional elctromechanical part  increases
reliability & performance in mechanical parts
• Control part  increases further & corrects
errors
• Traditional approach  sequential type
• E.g. 1994 Standish group survey of software
dependent projects
– 31% cancellation rate
– 222% time overrun
– 16% all project completed within time & budget
– Maintenance cost 200% of initial development cost of
delivered software
 Mechatronics approach
• Concurrent engineering
• Computer based interdisciplinary interaction between a
number of engineering disciplines
• Helps to combine , analyse and test those data
• Also looks “life cycle design”
– Delivery : time , cost , medium
– Reliability : failure rate , material ,tolerance
– Maintainability :
– Serviceability : on board diagnostics , prognostics
– Upgradeability :
– Disposability : Recycling and disposal of hazardous materials
 Design process
• 3 steps  modeling & simulation , Prototyping
and deployment
• Modular type of design  can be reconfigured
in design or throughout the life span.
•
 Information for future modules/upgrades
Modeling / simulation Prototyping Deployment / life cycle

Recognition of Deployment of
Hardware in the
need Embedded
loop simulation
software
Conceptual
design & Design Life cycle
functional spec. optimization optimization
1st principle
mathematical
modeling

Sensor actuator
selection

Detailed
mathematical
modeling
Mechatronics Design Process
Control system
design

Design
optimization
 Contd..
• Conceptual design: takes statement of problem
and generate solution. Greatest demand for
designers and scope for striking improvements.
• Engineering science , practical knowledge ,
production methods and commercial aspects
brought together
• 1st principle: captures some of the fundamental
behavior of subsystem
• Detailed model : Extension of previous one gives
more function & accuracy
 Contd..
• Modeling: block diagram or visual interface for
creating intuitively understandable behavioral
models
• Code generator : produce high level source code
form block diagram. C is widely used
• Real time interface :
• Analysis : Frequency domain , time domain
design
• Embedded processor interface : resides in final
product and provides communication between it
and Computer aided prototyping environment
 Contd..
• Prototyping : Non computer system of model
is replaced with actual hardware
– Sensors & actuator provide interface
• Distinct function of Mechatronics system
configuration:
Control : algorithm in software form
Computer : embedded computer
Sensors
Actuators
Process : product hardware
Protocol : Bus based distributed control application
 Mechatronic Application
• Autonomous production cells with image based object
recognition
• Monitoring and control of welding process
• Mechatronics systems with offline programming that
automatically a robot receiving CAD data
• FMS  off and online programming
• Biorobotics
• Endoscopic and orthopedic surgery
• Magnetically levitated vehicle
• Robotics in nuclear inspection and space applications