ED5080: Mechatronics System Design
Nilesh J. Vasa (Email: njvasa@iitm.ac.in)
Introduction, Actuator types (mechanical, pneumatic, hydraulic, electric),
Control and examples, Different types of electrical actuators and control,
Programmable logic controllers
Srikanthan Sridharan (Email: srikanthan@iitm.ac.in)
Pulse Width Modulation (PWM) control, Mathematical modeling (Transfer
functions and Bond graphs), Response of dynamic systems, System
integration (Embedded systems, hardware design)
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Notes for this course have been prepared from a
variety of resources and are intended for
educational purposes only
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Electric Vehicle Components
Electrically powered loads - Power windows, power seats, and power door locks etc.
make use of small DC motors
Auxiliary battery recharged with DC-DC converter, from the HV battery pack
Ongoing research to adopt 42-volt electrical system standard (requires redesign and
manufacture of new components)
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An electric vehicle power and drive system
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Control of DC motors
• Vary armature voltage
• Vary flux (field voltage -> field current) – not possible with
permanent magnet machines
Can be accomplished through PWM
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Drive for motors
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Pulse Width Modulation - Principle
On-Off switching pattern within a
switching period changes average value of
waveform
The Duty Cycle is a measure of the time
the PWM signal is in its “high” state (or
on-time of the signal)
Motor ‘relatively’ unaffected by high-
frequency switching
Vavg D VH 1 D VL
On Time
Duty Cycle 100%
Period
Features of PWM
Control power flow (voltage/current
regulation)
High efficiency
High frequency switching (electronic)
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Realization of PWM
Analog methods Digital methods
Uses operational amplifiers Uses digital controllers
(analog computers) (inbuilt timers)
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Bipolar voltage control through PWM
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Unipolar drive circuit Bipolar drive circuit
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DC motor control
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Problem
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Example response of 2nd order system
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Model and Simulation of Mechatronic Systems
Model
• a physical, mathematical, or logical representation of a system
entity, phenomenon, or process.
Simulation
• Implementation of a model to understand behavior over time
• Useful for testing, analysis or training where real-world systems or
concepts can be represented by a model.
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Integrated approach in System Design
Pure Mechanical System Identification of Functional
System Requirements
Addition of Sensors, actuators, Electronics Mechanical Software .
microelectronics, control function
System Design
Integration of Components (hardware
integration) Simulation and Analysis
System Redesign
Design, Analysis, Simulation
Product
Redesign of Mechanical System
Conventional Approach Integrated Approach
Mechatronic System Design and Implementation
• How to identify critical design parameters?
• How to predict the behaviour?
• How to sense the status?
• How to select the motors/sensors/controllers
• How to make it behave the way we want?
• How to ensure trouble free operation even in the presence of
disturbances?
All these without even having a physical prototype
Create a model of the whole system and simulate the system behaviour !
Modelling of systems
Modelling
• Process of generating a model as a conceptual representation of some
phenomenon.
• Typically, refers only to some aspects of the phenomenon, and two
models of the same phenomenon may be essentially different
•Ability to explain past observations
•Ability to predict future observations
•Ability to control events
•Cost of use, especially in combination with other models
•Enabling estimation of the degree of confidence in the model
•Simplicity
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Surgical Robot
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Project carried out in Robotics lab (Courtesy: Prof. Asokan)
Teleoperation of Tracked Vehicles
Model and Experimental Comparison
• Mathematical model for motor, controller and actuating mechanisms developed
• Simulation studies carried out
• Experimental setup made and experimental verifications carried out
Project carried out in Robotics lab (Courtesy: Prof. Asokan)
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For information only
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Integrated Model: Combined Motion Dynamics
Inputs: Outputs:
• Throttle (%), • Time derivatives of Longitudinal, Lateral and
• Brake (%) and Yaw displacement
• Steering (%).
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For information only
Experimental verification Comparison of simulation
with no-load and experimental result with load
Plot of Rotor position output (55o)
Plot of motor speed
Plot of rotor position output (30o)
For information only 24
Integrated Model Results Comparison: Longitudinal Dynamics
Throttle Input Gear Change Brake Input
Longitudinal Displacement
For information only
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Electrical Power Assisted Steering
Need theta vs Torque
(Study response time…)
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Modelling techniques
• Mathematical modelling
– A mathematical model is an abstract model that uses mathematical
language to describe the behavior of a system.
• Physical system modelling
– Bond graph method (Physical elements instead of equations)
• Graphical Modelling
– Visual representation of information, data, or knowledge (empirical…)
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Mathematical Modelling and Simulation
Physical System
Engineering Model
Differential Equations
Block Diagrams
Simulation Language
Output
Classical approach for modeling of physical system 28
Single DOF (mechanical) System (2nd order)
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Electrical System (2nd order)
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Electrical Analogy (Force-voltage)
Develop the mathematical model for the dynamics of the system and draw
the corresponding electrical circuit
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Modelling of DC Servomotor
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Solenoid controlled valve
Electrical Power Assisted Steering
System dynamics
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