Mechatronic System Design

Mechatronic System Design
K. Craig
K. Craig
K. Craig

Mechatronic system design deals with the integrated and optimal design of a physical system, including sensors, actuators, and electronic components, and its embedded digital control system. Every controlled physical system is not a mechatronic system as controls can be just an add-on in a sequential design process. A real mechatronics approach requires that an optimal choice be made with respect to the realization of the design specifications in the different domains. Mechatronic system design requires optimization of the system as a whole.
Mechatronic System Design K. Craig 4
In the initial conceptual design phase it has to be decided which problems should be solved mechanically and which problems electronically. In this stage decisions about the dominant mechanical properties have to be made, yielding a simple model that can be used for controller design. Also a rough idea about the necessary sensors, actuators, and interfaces has to be available at this stage. When the different partial designs are worked out in some detail, information about these designs can be used for evaluation of the complete system and be exchanged for a more realistic and detailed design of the different parts. Good mechatronic system designs are based on a real systems approach no after-thought add-ons allowed. Simultaneous optimization of all system components is required.
In a mechatronic system, the mechanical part has to perform certain motions and the electronic part (including an embedded computer system) adds intelligence to the systems. In the mechanical part of the system power plays a major role. In the electronic part information processing is the main issue. Sensors convert the mechanical motions into electrical signals where only the information content is important or even into pure information in the form of numbers (if necessary through an A/D converter). Power amplifiers convert signals into modulated power. In most cases the power supply is electrical, but other sources such as hydraulic and pneumatic power supplies are possible as well.
Integrated Modeling, Design, & Control Implementation

During the design of mechatronic systems it is important that changes in the physical system and the controller be evaluated simultaneously. Although a proper controller enables building a cheaper physical system, a badly designed physical system will never be able to give good performance by adding a sophisticated controller. Therefore, it is important that during an early stage of the design a proper choice be made with respect to the physical system properties needed to achieve a good performance of the controlled system.
On the other hand, knowledge about the abilities of the controller to compensate for physical system imperfections may enable that a cheaper physical system be built. This requires that in an early stage of the design a simple model is available that reveals the performance limiting factors of the system. It is important that the modeling of physical systems is done in a way that the dominant physical parameters are preserved in the model and that the controller design can be done simultaneously.
K. Craig

Integration and Assessment Early in the Design Process
Fast Component Mounter Placement Module
K. Craig
Introduction
During conceptual design of controlled electromechanical motion systems, one has to obtain feasible technical design specifications for the: path generator the control system the electromechanical plant with appropriate sensor locations And this must be done in an integrated way! Lets investigate how this might be done for the task of positioning an end effector at a certain location within a limited period.
During the conceptual design, the aim is not to complete a final design, but rather to identify the performance limiting factors of the design proposals and to choose satisfactory specifications for these factors. Experience has shown that the following factors dominantly determine system performance: Task specification: motion distance, motion time, required positional accuracy after motion time Path Generator: smoothness of the path Controller: proportional and differential gains Plant: total mass to be moved, lowest eigenfrequency, location of the position and velocity sensors
The dominant plant factors motivate the use of simple 4thorder models which take only the rigid-body mode and the lowest mode of vibration into account. These models have the following characteristics: Simple and of low order Have a small number of parameters Completely describe the performance-limiting factor Are a good basis to provide reliable estimates of the dominant dynamic behavior and the attainable closedloop bandwidth A Mechatronic Approach to Design allows for the assessment of the influence of these design factors on the system performance. Lets first begin by classifying plant dynamics.
Basic Open-Loop Transfer Function Types

Consider the plant transfer function P(s) from the input force u to a measured position y. The mechanical damping in the plant is neglected, as damping does not in general dominate the dynamics of a mechanism and it unnecessarily complicates the mathematics. The influence of friction is also not explicitly considered, as mechanical friction is difficult to estimate and highly nonlinear; it should be preferable to minimize it by proper mechanical design. In any way, it would be impossible to anticipate friction characteristics of a plant during the conceptual design stage.
The denominator polynomial of P(s) is always the same for a particular dynamic system, but the numerator polynomial depends on the locations of the actuator and the position sensor. The zero pair of the transfer function P(s) moves along the imaginary axis for different locations of the sensor. This is called migration of zeros and can be used to characterize five different types of plant transfer functions at an abstract level. We will consider the location of the complex conjugate zero pair in the s plane with respect to the complex conjugate pole pair. We will refer to these pairs as the anti-resonance frequency ar and the resonance frequency r of a plant transfer function.
Basic Plant Transfer Function Types
s2 +1 2 1 ar ms 2 s 2 +1 2 r
1 ms 2
s2 +1 2 1 ar ms 2 s 2 +1 2 r
1 1 ms 2 s 2 +1 2 r
s2 1 2 1 ar ms 2 s 2 +1 2 r
ar < r
ar = r
ar > r
Type AR
Type D
Type RA
Type R
Type N
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In the previous diagram: Type AR: anti-resonance resonance Type D: double integrator Type RA: resonance anti-resonance Type R: resonance Type N: non-minimum phase These basic transfer functions describe the dynamic behavior of four classes of electromechanical motion systems. These classes are characterized by the mechanical subsystem that contains the dominant stiffness. They are typically obtained after simplification and reduction of more extensive plant models.
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Classes of Electromechanical Motion Systems

Flexible Mechanism
Dominant stiffness is located in the mechanism. X2 m1s 2 + K m t = m1 + m 2 G 2 (s ) = (s ) = 2 AR F m t s ( m es 2 + K ) m1m 2 me = X1 K m1 + m 2 R G1 ( s ) = (s ) = 2 2 F m t s ( m es + K ) K ar = m1
K r = me
actuator
end effector
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Flexible Frame
Dominant stiffness is located in the supporting frame. The mass of the frame is m2 at position x2. The mass m1 is a rigid body containing the mass of the actuator and end effector. Its position x1 is the position to be controlled. This position can be measured with respect to the frame or with respect to the ground, resulting in different types of transfer functions.
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The transfer function from the input force F to the position measurement with respect to the frame (y = x1 x2) is of type AR, while it is type D when the position measurement is with respect to the ground (y = x1). X1 1 (s ) = 2 F m1s K ar = m1 + m 2 K r = m2
( m1 + m 2 ) s 2 + K X1 X 2 (s ) = 2 F m1s ( m 2s 2 + K )
Flexible Actuator Suspension

The figure represents a system consisting of a rotating actuator with transmission that is contained in a flexible linear suspension.
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Linear movements of the end effector me are a combination of movements due to actuator rotations and suspension vibrations. i = xa / , where xa is the end-effector translation due only to actuator rotation. The transfer function from the input force (u = T/i) to the position of the actuator (y = ) is of type AR. When the position of the end effector is measured (y = xe), a type RA transfer function is obtained.
r = ar = J ( me + mf ) + i 2 me mf k me + mf ar = k mf
(J + i m )k
2 e
xa i= T u= i
y=
y = xe
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A physical interpretation of transfer function zeros for simple control systems with mechanical flexibilities is as follows. The poles of the transfer function are the resonances of a flexible structure, while the zeros are the resonances of a constrained substructure. In the case of the flexible mechanism, flexible frame, and flexible actuator suspension, the antiresonance can be looked upon as the resonance frequency of the system in case the actuator is blocked, i.e., constrained.
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Flexible Guidance
Due to an input force (u = F) the mass m will move in the x direction. Additionally, F will excite a rocking mode around the center of mass due to flexibilities K.
2Kb 2 ar = J + ma f a x 2Kb 2 r = J
The type of transfer function from the input force (u = F) to the measured position (y = x) depends on geometrical properties: the distances af and ax. Five situations can be distinguished: When F and x are on the same side of the center of mass (ax > 0 and af > 0 or ax < 0 and af < 0) we obtain a type AR transfer function because ar < r. When either F or x are exactly located at the center of mass (ax = 0 or af = 0) we obtain a type D transfer function, as ar = r. Note that ax = 0 or af = 0 are two different situations, where the plant is unobservable and uncontrollable, respectively.
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When F and x are on different sides of the center of mass (ax > 0 and af < 0 or ax < 0 and af > 0) we obtain a type RA transfer function, under the condition that J + maxaf > 0. When F and x are on different sides of the center of mass and J + maxaf 0, we obtain a R type transfer function, as ar is located at infinity. When F and x are on different sides of the center of mass and J + maxaf < 0, we obtain a N type transfer function, as ar is complex.
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Specifications for this Electromechanical Device

Fast Component Mounter Placement Module
Maximum error e0 = 100 m Motion time tm = 250 ms Motion distance hm = 0.15 m Settling time ts = 30 ms Maximum acceleration amax = 10 m/s2 Maximum velocity vmax = 1 m/s Goal: Satisfy design requirements in a short design cycle using only plant knowledge available at the conceptual design stage
Simple Model
Parameter Values Motor mass (J/i2) = mm = 6.53 kg Frame stiffness k = 4.3E6 N/m Frame mass mf = 16.5 kg End-effector mass me = 2.3 kg
xa i= T u= i
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Block Diagram Representation
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Linear Graph Representation
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Bond Graph Representation
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Performance Assessment Procedure

Class of Electromechanical Motion System
Flexible Actuator Suspension
Concept
Location of Position and Velocity Sensor Concept AR: position and velocity measurement at the actuator Concept RA: position and velocity measurement at the end effector Concept AR-RA: position measurement at the end effector and velocity measurement at the actuator Consider concept AR with only a position sensor on the motor axis. 2 ar Frequency Ratio = r Mechatronic System Design K. Craig
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Consider Three Alternative Situations

Assume that the reference path and the desired performance, in terms of maximal position error e0, are fixed. Based on this, calculate the minimal required anti-resonance frequency of the plant. Assume that the reference path and the anti-resonance frequency are fixed. Based on this, calculate the maximum position error e0. Assume that the desired performance and the antiresonance frequency are fixed. Produce a characteristic reference path.
Determine the control system for the particular problem setting.

Summary
The aim of conceptual design is to obtain a feasible design for the path generator, control system, and electromechanical plant with appropriate sensor locations in an integrated way. Electromechanical motion systems are classified by four types using standard 4th-order plant transfer functions. Dimensionless quantities are used to characterize closed-loop behavior (i.e., reference path generator, controller, and plant) and standard closed-loop transfer functions are defined. Standard solutions are determined for these standard problems and an assessment method is developed.
Conclusions
Using minimal plant knowledge, the assessment method provides the designer with relevant knowledge about the design process, early in the design process. The assessment method can quickly provide insight into the design problem and feasible goals and required design efforts can be estimated at an early stage.
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Mechatronic System Design

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