MFE 3102
Design of Mechatronic Systems
Mechatronic System Design
Dr Conrad Pace
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.1
The Design Process for Mechatronic
Systems The Integration Aspect within the Design Process
System Definition
Integrated engineering
Requirements Engineering Specification
System General Design
Domain specific
engineering
Mechanical and
electrical engineering
Electronic
engineering
Information and
control engineering
Operating
engineering
Process Design (Part
that performs work)
Electronic
hardware design
Information processing
and software design
Human machine
interface (HMI) design
Integration of components
(hardware)
Integrated engineering
Integration of information
processing (software)
System Integration (hardware and software)
System testing
Integrated Mechanical
and electronic system
Manufacturing
MFE3102 Design of Mechatronic Systems Mechatronic System
C. Pace
Page 2.2
The Design Process for Mechatronic
Systems
Requirements Engineering Specification
Definition of the general functions
Definition of general constraints
Reliability and safety requirements
Development and manufacturing requirements
Partitioning into manageable modules
Specification of the Modules
Functions
Performance
Constraints and limitations
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.3
The Design Process for Mechatronic
Systems Defining System Requirements
System
Requirements
OPERATIONAL
FUNCTIONAL
Define major system
purpose why is the
system required.
NON-FUNCTIONAL
Specify what the system
has to do
Bounding
Define constraints and
influences on system
functions
Defining
Define System interaction Define System
internal actions
with environment at
system boundary
Performance
How a particular function
must be performed
MFE3102 Design of Mechatronic Systems
C. Pace
System
Constraints on whole
system
Implementation
How should the
system be built
Page 2.4
The Design Process for Mechatronic
Systems
System Design
Detailed Analysis and Design of partitioned system
Mechanical, hydraulic, pneumatic, electrical, etc..
Sensors and actuators
Automatic control and information processing
Interfacing with human operator=
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.5
The Design Process for Mechatronic
Systems
System Design
Task distribution between mechanical and electrical/
electronic/ software design
Simplification of mechanical/ electrical design
Replacement of simple linearised mechanical/ electrical systems
with non-linear software based control
Realisation of Functions
Power Conveyance (Energy Transfer Component of System)
Information Processing (Information Component of System)
Domain Interfaces (Sensors and Actuators)
Realisation of Synergies (possible integration effects)
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.6
The Design Process for Mechatronic
Systems
Component Design
Modelling and Simulation - Analysis of individual
component behaviour
Dynamic Requirements for components
Performance measures for software based control
Development of components
Mechanical Design
Electronic Design
Control Design
Software Design
Component Testing
Testing performance of components
Component interface testing
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.7
The Design Process for Mechatronic
Systems
System Integration
Hardware Integration
Spatial integration of components
Signal interfacing
Creation of Synergetic Effects
Interface influences amongst components
Software Integration
Integration of software functions with hardware
components
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.8
The Design Process for Mechatronic
Systems
System Testing
Testing of all functions of components
Testing of integrated system
Verification testing that the product meets its
specifications
Validation field testing (testing if the final product
is appropriate for its purpose with regard to the
requirements)
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.9
A V Development Scheme for
Mechatronic Systems
Degree of maturity
Production
Validation
Requirements
Field Testing
Verification
Specifications
System Testing
System Design
System
Design
System Integration
(software)
Modelling and Simulation
Component design (domain specific)
Prototypes
System
Integration
System Integration
(hardware)
Component testing
Mechatronics
Components
MFE3102 Design of Mechatronic
Systems
C. Pace
Page 2.10
A Common System Specification
A Communication Problem between areas of
Specialisation the need for a common specification
the design of the mechanical elements
of the system is primarily concerned with
spatial relationships and interactions
the design of the electronic component
of the system is primarily concerned with
signal processing and the interconnection
of discrete components and devices
the design and engineering of the
associated software is primarily
concerned with the development of data
and information processing algorithms.
MFE3102 Design of Mechatronic Systems
C. Pace
?
Page 2.11
A Common System Specification
System Representational Models
Models that are not technology specific and that allow the specification
of general system characteristics
The representation allows a proper System breakdown which allows
focused analysis on the individual system components.
Typical Examples
Information and Dataflow Diagrams
Power and Energy Flow Diagrams
State and Transition Diagrams
Sequence Diagrams
Morphological Charts
Function Means Tree
Hierarchical Diagram Constructs
Timing Diagrams
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.12
A Common System Specification
Information and Dataflow Models
Model flow of information and data through the system
Originated from Software systems engineering. However can be
extended to multi-domain systems
Allow appropriate division of systems into subsystems, aiding analysis
management
Process
B
Process
A
Process
D
Dataflow 2
Dataflow 1
Process
C
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.13
A Common System Specification
Power and Energy Flow Models
Bond graph models model the flow of energy and power
Energy and power are parameters that are domain
independent
Not used for modelling information flow
Sf:i
R:r1
MFE3102 Design of Mechatronic Systems
C. Pace
Gy:x
x= 1/k
R:d
I:M
Page 2.14
A Common System Specification
State Transition Diagrams
Model individual system states and conditions pertaining to the
specified states
Model the transition conditions between states
State B
Transition
Condition AB
State A
Transition
Condition BC
Transition
Condition CB
State C
Transition
Condition AC
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.15
A Common System Specification
Sequence Diagrams
Model the order of a sequence of operations and associated action
transition logic
Action A
Transition 1
Action B
Transition 2
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.16
A Common System Specification
Morphological Charts
Spatial Modelling of potential solutions of system elements
Provides a qualitative means of evaluating element spatial
integration
Function-Means Trees
Breaks down complex operations into basic functions that
constitute operation
Can illustrate individual functional requirements and
related solutions
Hierarchical Diagram Constructs
Techniques that provide a means of modelling individual
operations at various operational levels with appropriate
links and relations being defined
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.17
A Common System Specification
Timing Diagrams
Modelling of timing constraints of sequential/ transition
operations
Used to investigate relationships amongst time dependent
operations.
P2
P1
P3
t1
MFE3102 Design of Mechatronic Systems
C. Pace
t2
Page 2.18
A Common System Specification An
Example
Suppose we want to design an intelligent washing machine. Such a
washing machine should satisfy the following requirements;
A standard size
Can take a standard wash load
Should determine the load make-up
Should identify the fabric type
Should determine the best wash cycle given the load make-up and fabric
Should detect mixed loads
Inform the user of any decisions taken on the wash cycle selected
Cost within 15% of the existing machine prices
Should have a distinctive style
Should use domestic water and currently available detergents
Should work with a standard electric supply
Should operate at appropriate temperatures and wash cycles
The user can check the wash cycle and override the machine decision
Should rinse and spin-dry the clothing as appropriate to the load and type.
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.19
Analysing System Functionality
A Structured Analysis Approach
Objectives
Sufficiently abstract to capture both physical and
information characteristics
Include human and non-technical forms of interaction
Presenting information in a clear and simply fashion
Use of Representational Diagrams
Information Hiding
Abstraction
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.20
10
Analysing System Functionality
Structured Analysis
Dataflow Diagram (DFD)
Depicts system activities/ processes and interactions
Dataflow
Process
Terminator
Datafile
Terminator
Datafile
Dataflow
Process
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.21
Analysing System Functionality
Structured Analysis
Data
DataDictionary
Dictionary(DD)
(DD)
Defines
Definesdataflows
dataflowsininDFDs
DFDs
IS
EQUIVALENT
IS EQUIVALENTTO
TO
AND
AND
EITHER-OR
EITHER-OR
ITERATIONS
ITERATIONSOF
OF
OPTIONAL
OPTIONAL
Process
ProcessSpecification
Specification(PS)
(PS)
Specifies
Specifiesprimitive
primitiveprocesses
processesininthe
thelowest
lowestlevel
level
DFDs
DFDs
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.22
11
Structured Analysis
Term. A
Top Level Context Diagram
Definition of system operation
Term. B
System
Operation
Level 0 Diagram
Breakdown of Context
Diagram single Process
Proc.
1
Level 1 Diagram
Breakdown of Level 0
processes (ex. Proc. 1)
Proc.
1.1
Proc.
2
Proc.
3
Proc.
1.2
Proc.
1.3
Proc.
1.4
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.23
Structured Analysis
DATAFLOW
DIAGRAM
PROCESS
SPECIFICATION
P
Dataflow
Datafile
P
.
DATA
DICTIONARY
Datafile .
Dataflow
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.24
12
Washing Machine Example
CONTEXT DIAGRAM
Installers
Domestic
Services
INSTALLATION_SERVICE
SERVICES
WASTE
MACHINE_OUTPUTS
Wash
Clothes
Intelligently
MAINTENANCE_SERVICE
User
USER_INPUTS
Service
Providers
FAULT_CODES
SERVICE_REQUEST
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.25
Washing Machine Example
LEVEL 0 DIAGRAM
DIAGRAM 0 Wash Clothes Intelligently
SERVICES
INSTALLATION_SERVICE
MAINTENANCE_SERVICE
Install
Washing
Machine
1
Maintain
Washing
Machine
3
Use
Washing
Machine
2
MACHINE_OUTPUTS
MFE3102 Design of Mechatronic
Systems
USER_INPUTS
C. Pace
FAULT_CODES
WASTE
Page 2.26
13
Washing Machine Example
LEVEL 1 DIAGRAM
DETERGENT_CONDITIONER
DIAGRAM 2 Use Washing Machine
LOADED_CLOTHES
MAINS_POWER
Load
Dirty Clothes
2.1
WATER_SUPPLIES
Determine
Load
2.2
Wash
Clothes
2.4
MAINS_POWER
DIRTY_CLOTHES
WASTE_WATER
W_C_FAULT
LOAD_MAKE_UP
WASHED_CLOTHES
D_L_FAULT
Determine
Best Wash
Cycle
2.3
SELECTED_WASH_CYCLE
Unload
Clean
Clothes
2.6
BEST_WASH_CYCLE
D_B_W_C_FAULT
USER_INFORMATION
USER_COMMANDS
MFE3102 Design of Mechatronic Systems
C. Pace
Communicate
with User
2.5
MAINS_POWER
CLEAN_CLOTHES
FAULT_CODES
Page 2.27
References
Mechatronics Handbook , Robert H. Bishop (Ed.) , CRC
Press, 2002
Mechatronics Systems Design with Applications, Course
book, Kevin C. Craig, Fred P. Stolfi, the American Society of
Mechanical Engineers (ASME), the Institute of Electrical and
Electronic Engineers, USA (IEEE), 1993
Mechatronics, Dan Necsulescu, Prentice Hall, 2002
MFE3102 Design of Mechatronic Systems
C. Pace
Page 2.28
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