EMEg5241: Design of Electro-Mechanical

Systems
(Design of Mechatronic Systems)

Instructor : Tayachew Fikire

MSc In Mechatronics Engineering

2 November 2022
Corse outline 01 Introduction to
Mechatronics
o Definitions ,key elements and real world
applications
o History of Product design
- Traditional design approach
- Mechatronic design approach

02 Modeling & control of

Mechatronic systems
o Modeling process s for mechatronic systems
- First principle -Method
- System identification
o Control of mechatronic system
Introduction to micro-
03 mechatronic systems
o Design and Manufacturing of Micro mechatronic
system
0

Course
overview
 Overview of the Course

☞ Course objective
The course enables to integrate knowledge gained from several courses
(i.e. Electronics, control systems, measurement systems ,mechanics
,programming ..) to design comprehensive mechatronic systems.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Overview of the Course

☞ Course outcomes:
 Synthesize the knowledge and skills gained from several course and design and
create mechatronic systems/products.
 Apply proper design process to design mechatronic systems.
 Analyze dynamic behaviors & performances of mechatronic components
through modeling & simulation.
 Work collaboratively on a team to successfully complete a design project and
develop presentation, report writing and problem solving skills.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

01

Advising and
Introduction to
Monitoring
Mechatronics
 Introduction to Mechatronics

☞ Definition and Key elements ☞ Why Mechatronics?

 Mechatronics is a synergy of several  Limitation of classical Engineering
disciplines.
disciplines to deal with multi-domain
complex systems.
 An increasing global demand for a new
breed of Engineering discipline able to
deal with complex mechatronic systems
/problems .
 Now a days most global
industries/companies are deploying
complex mechatronic processes.
Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1
 Introduction to Mechatronics

☞ Components

CONTROLLER ACTUATORS
SENSORS

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Introduction to Mechatronics

☞ Mechatronic system components • Actuators: produce motion or

cause some action.
• Sensors: detect the state of the
system parameters, inputs, and
outputs
• Digital devices: control the system.
• Conditioning and interfacing
circuits: provide connections
between the control circuits and the
input/output devices
• Graphical displays: provide visual
feedback to users.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Introduction to Mechatronics

☞ Typical Mechatronic systems example:

Copying
Machine

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Introduction to Mechatronics

☞ Real world applications

Manufacturing applications Transportation applications

- CNC machines

Segway

Smart robotic applications Systems Uses

Big Dog •Tilt and pressure sensors
•Microcontroller
•Motors
•Onboard power source.

•Robot with rough-terrain mobility that could carry

equipment to remote location.
•Developed by DARPA
 Introduction to Mechatronics

☞ Real world applications

• Smart robotic applications

Space exploration applications

Vacuum Floors
Robot that can travel to other planets and take
measurements automatically.

Robots can vacuum floors and

clean gutters so you don't
have to.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Introduction to Mechatronics

☞ Real world applications

• Medical applications
Prosthetics
•Arms, Legs, and other body parts
can be replaced with
electromechanical ones.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Introduction to Mechatronics

☞ Real world applications

• Medical applications

Pace Maker

•Used by patients with slow or erratic

heart rates.
•The pacemaker will set a normal heart
rate when it sees an irregular heart
rhythm.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Introduction to Mechatronics

☞ Real world applications

Defense applications

Unmanned Aerial Vehicle

•Advanced technology is making

our soldiers safer.
•Some planes can now be flown
remotely.
 Introduction to Mechatronics
☞ Real world applications
• Sanitation applications Paper Towel Dispenser

Soap Dispenser

•Motion sensors
•Control circuitry
•Electromechanical actuators
•Independent power source
Advantages
•Reduces spread of germs by making
device hands free
•Reduces wasted materials by
controlling how much is dispensed
Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1
  History of Product design
 Traditional (sequential )
design approach
 Mechatronic design
approach
03
 System Interfacing

History of
product design
History of product design
 Traditional design process

Resulting system
First Mechanical Parts are designed
(skeleton )  Design steps are performed sequentially.
 System is partitioned into individual homogenous
subsystems.
Electrical systems  Homogenous subsystems are designed by specialist.
(Muscles ,Actuators)  The subsystems operate independently with limited
interactions.
 The developed system is only a result of application
Electronic systems
of existing solutions and technologies.
(Sensors ,Nervous system)
 R & D of new technologies and/or solutions is not
needed if the traditional methodology is used.
 If the final product is not satisfactory the whole
Control systems design processes is repeated .
(brain)  Time & financially consuming process .
 Each design steps add extra constraints for the next
step.
Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1
 Mechatronic design process
The traditional design approach can not fulfill the following
demands
Resulting system
More functions Life cycle design /Life cycle factors
(i.e. from conception to retirement )

Higher efficiency and reliability

Reliability
Electrical systems
(Muscles
Lower ,Actuators)
demands on energy,
Maintainability : modular in design, on
board diagnostics ,prognostics

Minimal size and weight,

Upgradeability: Future compatibility with
current designs.

Lower cost & shorter Disposability : Recycling and disposal of

development & design time the product after its service ends.
 Mechatronic design process

Resulting system
Life cycle design /Life cycle factors
(i.e. from conception to retirement )

Electrical systems
(Muscles ,Actuators)

Lower cost & shorter

development & design time

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic design process

System design
Resulting system
 cycle
Life Mechanical, hydraulic,
design /Life cycle pneumatic,
factors electrical,
Analysis and design of partitioned (i.e.Sensors and actuators
from conception to retirement )
system  Automatic control and information processing
 Interfacing with human operator(HMI)
Electrical systems
(Muscles ,Actuators)

Task distribution between mechanical ,

 Simplification of mechanical/ electrical design
electrical/ electronic/ & software design  Replacement of simple mechanical & electrical
systems with software based control.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic design process
 Modeling: Deriving set of ODE ,PDE or DAE equations
Component design
Resulting that represent real dynamic behavior of the system using
system
physical
Life cycle laws
design or cycle
/Life technique of system identification.
factors
Modeling & simulation
 from
(i.e. Simulation : Solving
conception of the developed
to retirement ) mathematical
model.
 Used for analysis of dynamic behavior individual
component .
Electrical systems
(Muscles ,Actuators)

 Hard ware in the loop simulation/real time interfacing:

Prototyping
Fusing & synchronizing real parts with simulated
components of the system in real time.

 Mechanical design
 Electronic design
Development of components  Control design
 Software design
Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1
 Mechatronic design process

Component design
Resulting system
Component testing Life cycle design
Testing /Life cycle
performance of factors
components
(i.e. from conception
 Component to retirement
interface testing )

System Integration

Hardware integration  Spatial integration of components .

 Signal interfacing .

 Integration of software functions with hardware

Software integration
components.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic design process

Component design
Resulting system
Component testing Life cycle design
Testing /Life cycle
performance of factors
components
(i.e. from conception
 Component to retirement
interface testing )

System Integration

Hardware integration  Spatial integration of components .

 Signal interfacing .

 Integration of software functions with hardware

Software integration
components.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic design process
 Testing of all functions of components .
 Testing of integrated system .
Resulting system
 Verification – testing that the product meets its
System testing Life cycle design /Life cycle factors
specifications .
(i.e. from conception to retirement )
 Validation – field testing (testing if the final product is
appropriate for its purpose with regard to the
requirements.

Hardware integration

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Modularization & hierarchy
 Complex mechatronic systems are usually made by synergetic integration of different
mechatronic module. Resulting system
System testing Life cycle design /Life cycle factors
 Mechatronic module or Basic Module :(i.e.
elements of system
from conception or components
to retirement ) connected to
groups, jointly executing a certain function.
 It is not recommended to make the integration at one level but it is necessary to separate the
configuration according to the principle of hierarchization because the modules contain and
Hardware integration
constitute different functions.
 A higher-level system is made if more basic modules are connected together by its functional
mechatronic structure and mechanic supporting structure.
 Modularization & hierarchy

Automobile: has several mechatronic Resulting system

modules integrated together.
System testing Life cycle design /Life cycle factors
(i.e. from conception to retirement )

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing

Actuation system
Resulting system
System testing Life cycle design /Life cycle factors
(i.e. from conception to retirement )

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing

Sensor Resulting system

 Examples
Life cycle design /Life cycle factors
 Position, velocity & acceleration sensors
(i.e. from conception to retirement )
Sensor capture real time information  Pressure ,force ,strain, torque sensor
about the internal state of the physical
system or the environment .

 Filtering : noise removing

Signal conditioning  Amplification : amplifying low level sensor signals to
make maximum voltage range of the conditioned signal
equal to the maximum input range of the ADC. Or increase
• Modification of a signal to make it the resolution and reduce noise.
more useful or appropriate.
 Isolation : isolating sensor signal from other signals
• Modifies a signal into a form that is
suitable for input into ADC  Multiplexing (time & frequency multiplexing): measuring
several signals with a single measuring device
 Linearization: Some sensors have a nonlinear response to
changes in the phenomena being measured.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Signal conditioning  Analogue passive filters :(composed of
(Filtering ) Resulting systeminductors & capacitors).
resistors,
System testing Life cycle designactive
Analogue /Life cycle
filtersfactors
: composed of OPAMPS
 Filtering is attenuation of certain (i.e. from conception
,resistors, to retirement )
& capacitors).
frequencies from a signal.  Digital filters: can be software or hardware
 This processes can remove noise from based.
a signal.  Low pass ,high pass, band pass, band stop
filters.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
 Opamps: are used to amplify /attenuate sensor
signals .
Signal conditioning  Inverting
Resulting system,non inverting & difference opamps.
System testing)
(Amplification Life cycle design /Life cycle factors
(i.e. from conception to retirement )
 The most common type of conditioning is
amplification. Inverting
 The signal should be amplified so that the amplifier
maximum voltage range of the conditioned
signal equals the maximum input range of
the ADC.

Non-inverting
Difference amplifier
amplifier

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Conversion process involves:
Signal conversion  Sampling : Sampling the continuous signal using
(ADC ) Resulting system& Hold amplifier (SHA).
Sample
Lifecycle design
Storing /Life
this cycle factors
voltage, and, before the next sample is
(i.e. from conception to retirement )
 It is necessary to use an taken.
analog-to-digital converter  Quantization : rounding of the sampled values to the
(ADC) to transform an analog nearest quantization level.
voltage into a binary number.  Binary codding :First change quantized values to
corresponding decimal values and perform binary
codding (i.e. change decimal value into binary
Physical number)
signals

Digital n-D
Physical Sensors Sampling Quantization signal
process

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Signal Conversion
Analogue Input Range: Input range of values the ADC can accept from a sensor
Resulting system
(eg.0-10Volt) Life cycle design /Life cycle factors
(i.e. from conception to retirement )
ADC number of bits(n): The number of bits the ADC generates while converting analogue values into
binary.
Number of discrete values or quantization levels of ADC : 2^n.

 Example: If the ADC has an input range from (0 -10 volt) Among these infinite numbers the ADC can
generate 2^n equidistant discrete values as an output.

 ADC resolution: Maximum input range value/ 2^n.

 Sampled value=resolution *decimal value.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Signal Conversion/ADC
Examples (8 bit ADC with input range from (0-12v) Digitized Sine wave with 3 bit ADC ,input range
Resulting system
( 0-10v)
Life cycle design /Life cycle factors
(i.e. from conception to retirement )

• The error that results from the quantization

process is called the quantization error.
• The quantization error can be as large as
one-half the quantization level spacing or
the resolution.
quantization error=1/2*resolution of ADC

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Signal Conversion/DAC

Staircase Smooth
Life cycle design /Life cycle factors
analogue
(i.e. from conception to retirement )
analogue
Binary Quantized
Binary signal signal
values values Hold LPF
Decoder interpolator

Binary Decoder: maps binary values into quantized values.

Hold Interpolator: turns quantized values into staircase analogue signal.

Low pass reconstruction filter: smooth the staircase analogue signal.

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Actuation System
Actuation system : Play a primary role in mechatronic systems.
 ThisLife
stage is concerned
cycle withcycle
design /Life converting
factorsthe control signal (low
Components of actuation power)(i.e.
intofrom conceptionsignal
an appropriate to retirement )
that delivers the required input
System power to the energy conversion unit.
 In electrical drives, such an element will consist of a power electronic
Power Modulation & circuit, providing the appropriate high power switching to the
Amplification stage electrical drive.
 In hydraulically powered drive, this stage will include appropriate
valves (and hydraulic fluid supply), in order to convert the control
signal to an appropriate hydraulic fluid flow and pressure to the
hydraulic actuator.

 This stage represents the physical actuator, i.e. the component that
Energy converting stage converts energy and produces work, acting on the controlled process
/Actuator or environment accordingly. Eg. Electric motor or hydraulic cylinder

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Actuation System

Life cycle design /Life cycle factors

(i.e. from conception to retirement )

Power Modulation &

Amplification stage

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1

 Mechatronic system interfacing
Actuation System

Life cycle design /Life cycle factors

Coupling System (i.e. from conception to retirement )

Power Modulation &

 Rack and pinion
Acts as the
Amplification interface
stage  Gear drive
between the actuator and
 Belt drive
the physical system
 Lead screw and nut,
 Piston and linkages
 Pulley system
 Chain

Tayachew Fikire – AASTU Design of Mechatronic Systems – Chapter 1