Mexico_Automotive_Mechatronics_10-10-08.pdf

Automotive Mechatronics K. Craig 1


Automotive Mechatronics

Dr. Kevin Craig

Greenheck Chair in Engineering Design

& Professor of Mechanical Engineering

Marquette University


Mechatronics is the synergistic integration

of physical systems, electronics, controls,

and computers through the design process,

from the very start of the design process,

thus enabling complex decision making.

Integration is the key element in

mechatronic design as complexity has been

transferred from the mechanical domain to

the electronic and computer software

domains.

Mechatronics is an evolutionary design

development that demands horizontal

integration among the various engineering

disciplines as well as vertical integration

between design and manufacturing.

Mechatronics is the best practice for

synthesis by engineers driven by the needs

of industry and human beings.

What is Mechatronics?

Multidisciplinary Systems Engineering


Other Components

Communications

ComputationSoftware, Electronics

Operator

InterfaceHuman Factors

ActuationPower Modulation

Energy Conversion

Physical SystemMechanical, Fluid,

Thermal, Chemical,

Electrical, Mixed

InstrumentationEnergy Conversion

Signal Processing

Modern

Multidisciplinary

Engineering System:

A Mechatronic System

Simultaneous

Optimization

of all

System Components


Anti-Aliasing

FilterSensor

Plant /

ProcessActuator

A/D

Converter

D/A

Converter

Digital

Computer

Sampling

System

Digital Set Point

Sampled &

Quantized

Measurement

Sampled & Quantized

Control Signal

Sampling

Switch

Power Domain

Information Domain


Design&

Interactivity

OrganizationalBehavior

Technology(Feasibility)

Business(Viability)

Human Values(Usability, Desirability)

Realization&

Production

INNOVATION HAPPENS


Compelling Questions

Multidisciplinary engineering systems have as integral

parts electronics, computers, and controls. Performance,

reliability, low cost, robustness, and sustainability are

absolutely essential.

How can Engineering Educators best transform students to

become engineers poised to solve mankind’s problems of

the 21st century ?

How can a company transform itself to successfully design

multidisciplinary engineering systems ?


Mechatronics Educational Challenge

• Control Design and Implementation is still the domain of

the specialist.

• Controls and Electronics are still viewed as afterthought

add-ons.

• Very few practicing engineers perform any kind of

physical and mathematical modeling.

• Mathematics is a subject that is not viewed as enhancing

one’s engineering skills but as an obstacle to avoid.

• Very few engineers have the balance between analysis and

hardware essential for success in Mechatronics.


MechatronicsDesign,

Prototype, &

Deploy

Steady-State Yearly Activities

Mechatronics

Laboratory

IndustryU.S. and World

Universities

Industria

l Applica

tions –

Best P

ractice

s

Curr

iculu

m D

eve

lopm

ent – R

ese

arc

h A

ctiv

ities

What is the Best Way to Train

the 21st-Century

Multidisciplinary Systems Engineer?

Industrial Interaction

Shapes

Engineering Curricula

Across All Years


Marquette

Mechatronics

Workshop

Marquette

Mechatronics Laboratory

Rockwell

Automation

Procter

&

Gamble

Rockw

ell A

uto

matio

n T

ech

nolo

gyP

&G

Mech

atronic

Applic

atio

ns

P&G / Rockwell Automation Mechatronic Challenges


Marquette University August 18-20, 2008

P&G / Rockwell Automation Mechatronics Workshop


Engineering System Investigation Process

Physical

System

System

Measurement

Measurement

Analysis

Physical

Model

Mathematical

Model

Parameter

Identification

Mathematical

Analysis

Comparison:

Predicted vs.

Measured

Design

Changes

Is The

Comparison

Adequate ?

NO

YES

START HEREEngineering

System

Investigation

Process

The cornerstone

of modern

engineering

practice !


Physical & Mathematical Modeling

Less Real, Less Complex, More Easily Solved

Truth Model Design Model

More Real, More Complex, Less Easily Solved

Hierarchy Of Models

Always Ask: Why Am I Modeling?


Cein eout

iin iout

R

Cein eout

iR iout = 0

RiC

Physical System Physical Model

R C out

R C

R C

in out out

i i i

i i 0

i i

e e deC

R dt

in out

out

e e iR

dei C

dt

outout in

outout in

deRC e e

dt

dee Ke

dtK 1

RC

KCLComponent

Relations

Mathematical

Model


ControllerYPCR C

+

Power

ConverterPlant Sensor

Observer

Controller

Plant

Model

Sensor

Model

_

+

+ _

YO

CO

+

Σ

Σ Σ

Physical System

Modeled System

Observer

Modeling and Observers: Let’s Go Sensorless

Automotive Mechatronics K. Craig 19Design News Magazine


June 2008

ASME Magazine


Mechatronic System Design

• 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.


• 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.


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.


Mechatronic System DesignIntegration and Assessment Early in the Design Process

Fast Component

Mounter Placement

Module

MOTOR

CARRIAGE

FRAME

SPINDLE

TIMING BELT

PIPETTE

ELECTRONICS

J

k/2

xf

xe

mf

Tme

k/2


Flexible Actuator Suspension

– The figure represents a system consisting of a rotating

actuator with transmission that is contained in a flexible

linear suspension.

J

k/2

xf

xe

mf

Tme

k/2


– Linear movements of the end effector me are a

combination of movements due to actuator rotations

and suspension vibrations. i = xa / θ, 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 = θ) is of type AR. When

the position of the end effector is measured (y = xe), a

type RA transfer function is obtained.

J

k/2

xf

xe

mf

Tme

k/2

axi

Tu

i

2

e

r 2

e f e f

ar ar

e f f

J i m k

J m m i m m

k k

m m m

y ey x


2

2

ar

22

2

r

s1

1

sms1

ar r

2

1

ms

ar r

2

2

ar

22

2

r

s1

1

sms1

ar r

22

2

r

1 1

sms1

2

2

ar

22

2

r

s1

1

sms1

Type

AR

Type

D

Type

RA

Type

R

Type

N


– A physical interpretation of transfer function poles and

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 actuator suspension, the

anti-resonance can be looked upon as the resonance

frequency of the system in case the actuator is

blocked, i.e., constrained.


Engin

e

Managem

ent

Autom

atic

Transmission

EmissionsControl

Pow

ertrainSaf

ety

Chassis Tra

ction

Dynamic

Headlamps

Suppl

emen

tal

Res

train

t

Colli

sio

nP

repera

tion

Activ

e

Suspensio

n

Steering

Assist

CruiseControl

Slip

Regulation

Ant

ilock

Bra

king

Sta

bili

tyC

ontr

ol

Automotive

Mechatronics


Spring 2007

Approach

Automotive Engineering Fundamentals + Latest Mechatronic Advances +

Mechatronic Fundamentals + Latest Computer Tools

Course Topics

• Introduction to Automotive Mechatronics

• Engine Systems and Electronic Controls

• Transmissions and Electronic Controls

• Steering and Suspension Systems

• Breaking, Traction, & Stability Control Systems

• Automotive Safety Systems

• Electric and Hybrid Vehicles

• Automotive Sensors and Actuators

• LabVIEW + ADAMS

Automotive Mechatronics Course

Automotive

Fundamentals

Mechatronics

Fundamentals

MotivationEnvironmental, economic, &

consumer forces

Automotive

Mechatronics

Industrial CAE ToolsLabVIEW, ADAMS


Automotive

Mechatronics


• The Automobile – A Comprehensive Mechatronic

System

– Today, mechatronic features have become the product

differentiator in these traditionally mechanical systems.

– This is further accelerated by:

• Higher performance-price ratio in electronics

• Market demand for innovative products with smart

features

• Drive to reduce cost of manufacturing of existing

products through redesign incorporating mechatronics

elements

– The use of electronics in automobiles is increasing at a

staggering rate.


– Examples of new applications of mechatronic systems in the

automotive world include:

• semi-autonomous to fully-autonomous automobiles

• safety enhancements

• emission reduction

• intelligent cruise control

• brake-by-wire systems eliminating the hydraulics

– Mechatronic systems will contribute to meet the challenges

in emission control and engine efficiency.

– Clearly, an automobile with up to 60 microcontrollers and

100 electric motors, about 200 pounds of wiring, a

multitude of sensors, and thousands of lines of software

code can hardly be classified as a strictly mechanical

system.


• Expanding Automotive Electronic Systems

– Cost of electronics in luxury vehicles can amount to 23%

of the total manufacturing cost.

– More than 80% of all automotive innovation now stems

from electronics.

– High-end vehicles today may have more than 4

kilometers of wiring compared to 45 meters in vehicles

manufactured in 1955.

– In 1969, Apollo 11 employed a little more than 150

Kbytes of onboard memory to go to the moon and back.

30 years later, a family car might use 500 Kbytes to keep

the CD player from skipping tracks.

– The resulting demands on power and design have led to

innovations in electronic networks for cars.


– Researchers have focused on developing electronic systems

that safely and efficiently replace entire mechanical and

hydraulic applications.

– Highly reliable and fault-tolerant electronic control systems,

X-by-wire systems, do not depend on conventional

mechanical or hydraulic mechanisms. They make vehicles

lighter, cheaper, safer, and more fuel-efficient.

– Increasing power demands have prompted the development

of 42-V automotive systems.

– X-by-wire systems feature dynamic interaction among

system elements.

– Replacing rigid mechanical components with dynamically-

configurable electronic elements triggers a system-wide

level of integration.


• Challenges of Automotive Mechatronic System

Design

– For typical mechatronic systems, there has been a dramatic

increase of complexity during the past few years (doubling

every 2-3 years) almost comparable to complexity increase

in microelectronics.

– System complexity can be measured by different

parameters, e.g., number of components and their level of

interaction, code size of software.

Challenge

Mastering the future

increase of mechatronic

system complexity


Only wires (green) may relay

signals from a car’s steering

wheel to its front wheels in a

front-wheel steer-by-wire

system. And an electrically

actuated motor, not a

mechanical link with the

steering wheel, turns the front

wheels.

Steer-By-Wire Enhances Car Wheel Control


Sensors That Can Make Cars Safer


A prototype “fusion

processor” depends on

optical and radar sensors to

move a car automatically at

the varying speeds of traffic.

A camera and radar report on

the width, distance, and

speed of objects ahead, and

the processor combines the

data, feeding it to a unit that

controls the car.

Next Generation

of

Cruise Control


Dynamic Driving Control Systems


Active and Passive

Safety Systems


Mechatronics Module: Smart Actuator


Automotive Microcontroller Volume Demand


Automotive Microcontroller Applications


Bose Suspension System


Mercedes-Benz

Active Body Control


Mercedes-Benz

Front Suspension


Active vs. Passive Suspension


The Camless Dream Meets Reality

Current Future

Auto Fundamentals 2005

Valeo


Engine Systems & Electronic Controls

• May 2005 – Industry experts say “Don’t expect to see the

internal-combustion engine evaporate as a viable power

source anytime soon.” There are still many more

improvements remaining.

• As computer-modeling capability improves, there is a

better understanding of the IC engine and how to improve

it, e.g., variable valve timing, combustion development,

and fuel-injection systems.

• There will be significant improvements in fuel economy,

emissions, and performance.


• Technologies related to the engine itself – not so much

technologies within the engine itself – have dramatically

accelerated.

• Controls, with computing power and speed, and sensors,

capable and durable, are enabling technologies!

• Goal of manufacturers: build engines with high levels of

fuel economy, power, and torque, along with low

emissions levels – and to do so at very high volumes –

better than ever in terms of reliability and durability.

• Advanced technologies will focus on “variable

everything.” Adding on-demand and variable controls to

almost any system can improve fuel economy and lower

parasitic losses.


• The last two decades have seen the ever-increasing usage

of electronics and microcontrollers in response to the need

to meet regulations and customer demands for high fuel

economy, low emissions, best possible engine

performance, and ride comfort.

• This has also lead to the development of new engine

control methods with new sensors and new actuators.

• Devices have gone from purely mechanical to electro-

mechanical with electronic control, e.g., carburetors and

injection systems.

• New actuators have been added, e.g., exhaust gas

recirculation (EGR), camshaft positioning, and variable

geometry turbochargers (VTG).


• Today’s combustion engines are completely microcomputer

controlled with:

– many actuators (e.g., electrical, electro-mechanical, electro-

hydraulic, electro-pneumatic influencing spark timing, fuel-

injector pulse widths, EGR valves)

– many measured output variables (e.g., pressures,

temperatures, engine rotational speed, air mass flow,

camshaft position, exhaust gas oxygen-concentration)

– taking into account different operating phases (e.g., start-up,

warming-up, idling, normal operation, overrun, shut down.)

• The microprocessor-based control has grown up to a rather

complicated control unit with 50-120 look-up tables, relating

about 15 measured inputs and about 30 manipulated variables as

outputs.


• Because many output variables (e.g., torque and emission

concentrations) are mostly not available as measurements (too

costly or short life time), a majority of control functions is

feedforward.

• Increasing computational capabilities using floating point

processors will allow advanced estimation techniques for non-

measurable qualities like engine torque or exhaust gas properties

and precise feedforward and feedback control over large ranges

and with small tolerances.

• New electronically controlled actuators and new sensors entail

additional control functions for new engine technologies (e.g.,

VTG turbo chargers, dynamic manifold pressure, variable valve

timing (VVT) of inlet valves, combustion-pressure-based engine

control).


Electromagnet

Infrared LEDPhototransistor

Levitated Ball

Magnetic Levitation

System

Electromagnetic Valve Actuator

For a Camless Automotive Engine


Electromagnet

Infrared LED

Phototransistor

Levitated Ball

Magnetic Levitation System A Genuine Mechatronic System


Thank You

? Questions ?

Mexico_Automotive_Mechatronics_10-10-08.pdf

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