Introduction to Mechatronics

Mech-1540

Stefan B. Williams
Research Fellow of Mechatronic Engineering

Stefan Williams

1540 Introduction To Mechatronics 1

Schedule of Events
Week

Date

Content

Assignment Notes

13/3

Introduction

20/3

Design Process

Q 1 of Assign. 1

27/3

Actuators

Q 2 of Assign 1

3/4

Sensors

Q 3 of Assign 1

10/4

Assignment 1 Design Exercise

Due 11/4

17/4

Computer Hardware

Q 1 of Assign 2

MID SEMESTER BREAK

Q 2 of Assign 2

1/5

Computer Software and Design Tools

Q 3 of Assign 2

8/5

System Modelling and Control

Q 4 of Assign 2

15/5

Assignment 2 - Control and Modelling

Due 16/5

10

22/5

Active Sensor Systems (Graham Brooker)

11

29/5

Case Study : Formula SAE

12

5/6

Case Study : Unmanned Air/Land/Sea Vehicles

13

12/6

Major Assignment

14

19/6

Spare

Stefan Williams

Due 13/6

1540 Introduction To Mechatronics 2

What is Engineering Design?

Engineering Design is the systematic,
intelligent generation and evaluation of
specifications for products whose form and
function achieve stated objectives and satisfy
specified constraints
The purpose of design is to derive from a set
of specifications a description of a product
sufficient for its realization

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1540 Introduction To Mechatronics 3

Why is Engineering Design important?

It provides us with
A methodology to be followed in the search for a
solution to a recognized problem
A set of requirements that characterize a
successful solution to the problem
A means of managing increasingly complex,
technological problems by breaking the task of
finding a solution into smaller sub-system design
problems

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1540 Introduction To Mechatronics 4

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 5

The Product lifecycle

Concept
Exploration

System
Definition

Engineering
Development

Operation &
Maintenance

System
Qualification
Deployment

Production

Disposal

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1540 Introduction To Mechatronics 6

Design models : The Waterfall

Requirements

Design

Implementation

Testing

Integration
Operation and
Maintenance
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1540 Introduction To Mechatronics 7

Design models : The Spiral

Determine goals,
alternatives,
constraints

Alternatives,
constraints

Risk analysis

Alternatives,
constraints

Risk analysis

Alternatives,
constraints

Risk analysis

Problem
Identification
Requirements,
lifecycle Plan

Development Plan
Integration & Test Plan

Risk analysis
Reqts

Concept of
operation

Stefan Williams

Initial
design

Detailed
Design

Validated reqts
Validated design

Plan
Implementation Plan

Evaluate
alternatives and
risks

Acceptance test

Develop
and test

1540 Introduction To Mechatronics 8

Design Models: The System V

Concept
Definition

Operational
Evaluation

Contract Boundary
System
Design

First Sub-system Tier

Verification

Design
Design
Design
Design

Integrate
Integrate
Integrate
Integrate
Implement
Implement
Implement
Implement
Design

Tier n

Stefan Williams

System
Integration

Integrate

Implement

1540 Introduction To Mechatronics 9

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 10

Problem Identification
Identify problem to be solved
talk to the customer
acquire domain knowledge
expertise to be brought to bear

Clarify the problem domain

identify the problem boundaries
develop design parameters that allow comparative
judgement of competing designs

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1540 Introduction To Mechatronics 11

Problem Identification
Understanding

operational concept
system context
major states and modes of the system
identify other unstated needs

Discussion of potential solutions

proposal of various solution concepts

brain storming
lateral thinking
interaction with customer

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1540 Introduction To Mechatronics 12

Problem Identification
Design constraints must be identified
Restrictions or limitations on a behaviour or a
value or some other aspect of a designed objects
performance

Requirement analysis
allows us to verify that we have reached a solution
a description of the requirements that characterise
a solution
the criteria to be used to verify that the
requirements have been met
produces an understanding of the nature and
scope of the remaining activities
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1540 Introduction To Mechatronics 13

Sources of Requirements
Customer Requirements
Contract documents and standards
Operational Concept Descriptions (OCD) etc.

Derived Requirements
To correct ambiguity or incomplete requirements
Implied or transformed from higher-level
requirements

Allocated Requirements
Divided or allocated to multiple lower level
requirements
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1540 Introduction To Mechatronics 14

Planning and Project Management

Management is the process of achieving
organizational goals by engaging in the four
major goals of planning, organizing, leading
and controlling
Involves planning major and minor
milestones of design process
Time line and allocation of available
resources to complete the job
Project scope, spending and schedule must
be estimated and tracked during the
remainder of the design process
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1540 Introduction To Mechatronics 15

Time Lines

Mar 2003

ID

Task Name

Start

End

3/16

Problem Identification

17/03/2003

21/03/2003

5d

Systems Dessign

21/03/2003

17/04/2003

20d

System Specification

21/03/2003

3/04/2003

10d

System Modelling

28/03/2003

17/04/2003

15d

18/04/2003

15/05/2003

20d

Implementation

Apr 2003

May 2003

Jun 2003

Duration

Component Selection

18/04/2003

24/04/2003

5d

Component Testing

25/04/2003

15/05/2003

15d

System Integration

16/05/2003

29/05/2003

10d

System Verification

30/05/2003

5/06/2003

5d

3/23

3/30

4/6

4/13

4/20

4/27

5/4

5/11 5/18

5/25

6/1

6/8

6/15

6/22

An example of a Gantt Chart a graphical representation of the time line and

interrelationship between tasks

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1540 Introduction To Mechatronics 16

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 17

Characteristics of a System
A complex set of interrelated elements
working together to fulfill some designated
need
must be functional and able to respond to that
need

Sub-systems can be equipment, materials,

software, people, and other systems
A system is contained within some form of
hierarchy
Sub-systems are not necessarily technologybased
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1540 Introduction To Mechatronics 18

Systems Engineering
The design of the whole as distinct from the design
of the parts
A structured way of handling complexity
Defines the interfaces between major components of
the system
The best way to maximise probability of a successful
outcome
But it is not.
A silver bullet
A cookbook approach to success
An excuse to stop thinking
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1540 Introduction To Mechatronics 19

Why do we Need Systems Engineering ?

Simplification of Complex Systems
Control Design Process
Flow down of System Requirements to
Component Level
Facilitate Progressive Testing (flow up)
Production and cost approximately 90% of
the cost of production determined during
design phase
ENSURE FINAL PRODUCT MEETS
REQUIREMENTS
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1540 Introduction To Mechatronics 20

The Systems Engineering as

Front End
nt
ro
eF
Th

Operational
Evaluation

d
En

Concept
Definition

Tier 0

Tier 1

ion
sit
po
m
co
De

Tier 2

Stefan Williams

System
Design

System
Integration

Design
Design
Design
Design

Integrate
Integrate
Integrate
Integrate
Implement
Implement
Implement
Implement

on
i
t
ra
g
e
Int

1540 Introduction To Mechatronics 21

System Specifications
Specifications are precise descriptions of the
properties of the object being designed
Design specifications articulate in a numerical or
measurable way what a design is supposed to do and
provide the basis for evaluating that design
Prescriptive specifications specify values of attributes that
designed object must meet to be successful
Procedural specifications identify procedures or methods
to be used in calculating attributes
Performance specifications characterise the desired
behaviour or performance of the system

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1540 Introduction To Mechatronics 22

Interface Specifications
Specifications are also required for the
internal components of the system
The interface between components must be
specified to enable the problem to be broken
up into manageable sub problems
Interface specifications should be formalized
in sufficient detail to minimize ambiguity and
the need to reformulate interfaces in the
future

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1540 Introduction To Mechatronics 23

Modular Design
Desirable attributes of modular system
components,
Low Coupling
High Cohesion
Well defined interfaces between components

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1540 Introduction To Mechatronics 24

Modular Design
Definition,
Coupling - a measure of the relative
interdependence between subsystems.
Simple connectivity among subsystems results in a
system that is easier to understand and less prone to a
ripple effect when errors or changes occur in another
part of the system.

Cohesion - a measure of the relative functional

strength of a subsystem.
A cohesive subsystem performs a task with little
interaction with other parts of the system.

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1540 Introduction To Mechatronics 25

Modular Design

In summary, develop subsystems with,

single-minded function.
an aversion to excessive interaction with other
subsystems.

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1540 Introduction To Mechatronics 26

Systems Modelling
Modelling of
overall response of the system
individual components of the system

Models allow us to predict the system

behaviour

Will it meet our design constraints?

Will the system be stable?
What components are required for the system?
What are the characteristics of those components?

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1540 Introduction To Mechatronics 27

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 28

Component Selection
Selection of appropriate components to meet
design constraints and fulfil system design
Identification of commercial off-the-shelf
(COTS) and specialised components
Verification that components meet the
models formulated during systems design

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1540 Introduction To Mechatronics 29

Design of Components
l
l

The design of a Component is not affected by the

size or complexity of the System it is used in.
The design of a component is driven by three
requirements:

Physical
-Size
-Shape
-Weight
-CG
-Inertia

Stefan Williams

l
l
l

Form
Fit
Function

What it does &

How it does it
-Performance
-Environment

Interfacing
-Mechanical Interfacing (fixing)
-Electrical Interfacing
-Communication / Data Interfacing
- Effect of function

1540 Introduction To Mechatronics 30

Exercise - Design of Components

Consider 2 components from vastly different systems:
System 1. An electronic automatic garage door.
Component: Actuator to open and close the door.
System 2. A Ship Based Theatre Air Defence System
Component: Actuator to move the missile control fins

Q1. What information is required to design or select an

appropriate actuator for each case?
Q2. How do you determine that information?

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1540 Introduction To Mechatronics 31

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 32

The Implementation Leg

Requirements
Analysis

System
Verification

Verification
Criteria

Functional Analysis/
Allocation

Synthesis

Integrate

Correct

ign
Des

Verification
Criteria

Functional Analysis/
Functional
Analysis/
Allocation
Allocation

Sub-system
Verification

Synthesis
Synthesis

Integrate

Correct

Requirements
Requirements
Analysis
Requirements
Analysis
Requirements
Analysis
Analysis

Functional Analysis/
Functional
Analysis/
Allocation
Functional
Analysis/
Allocation
Functional
Analysis/
Allocation
Allocation

Synthesis
Synthesis
Synthesis
Synthesis

Verification
Criteria

Unit
Verification

Integrate

Correct

Imp
lem
ent

Requirements
Requirements
Analysis
Analysis

Component Implementation

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1540 Introduction To Mechatronics 33

System Integration
Integration of the individual components to
form the system
Verification of individual sub systems
typically undertaken during this stage
Do the system components meet the
specifications?
Do the interface specifications accurately
capture the final system configuration?

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1540 Introduction To Mechatronics 34

Definitions
Integration: The merger or combining of two or more
lower level elements into a functioning or unified
higher level element with the logical and physical
interfaces satisfied.
Verification: Confirmation by examination and
provision of objective evidence that the specified
requirements to which an end product is built, coded
or assembled have been fulfilled.
Validation: Confirmation by examination and
provision of objective evidence that the specified
intended use of an end product or aggregation of end
products is accomplished in an intended usage
environment.
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1540 Introduction To Mechatronics 35

Design for Integration

Multiple levels of integration and verification
Each level corresponds to the design
hierarchy
The interfaces between all components must
be defined
The interfaces between the system and
external systems must be defined
Engineering models and prototypes can
assist the design and implementation
process
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1540 Introduction To Mechatronics 36

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 37

System Verification
Verification of the system performance
Does the system meet our requirements?
If the system or some component of the
system does not meet the specification, why
not? Can it be rectified?

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1540 Introduction To Mechatronics 38

Design and Product

Verification
Design verification ensures that the design
meets the requirements if manufactured
correctly
Full functional and performance verification
Detects non-conformance between the product
and its specification

Product verification ensures that the system

has been manufactured correctly
Inspection
Production controls
Acceptance testing
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1540 Introduction To Mechatronics 39

Integration and Verification

Problems
Plans must cover what to do if integration
problems or verification failures occur
Corrected at the next level down or design
where necessary
Dealing with COTS

Undocumented features
Not developed for the environment
Defined behaviour and interfaces
Support

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1540 Introduction To Mechatronics 40

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 41

Iteration
For any subsystems that do not meet the
design requirements, some iteration may be
required
Iteration can occur at any stage in the design
the earlier the better
Changes to design will have a cascading
effect on remainder of system design
Proper and thorough systems design should
minimize the need for change
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1540 Introduction To Mechatronics 42

The Design Process

Problem Identification
Systems Design
System Specification
Systems Modelling

Implementation
Component Selection
Component Testing

Stefan Williams

System Integration
System Verification
Iteration
Operation and Maintenance
1540 Introduction To Mechatronics 43

Installation and Validation

Installation into the operational environment
Interfaces to external systems may require
simulation
Uncontrolled environment - validate in
phases
May involve user training
Validation of user manuals
May be used to verify operational
requirements such as availability
Must be well planned
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1540 Introduction To Mechatronics 44

Operation and Maintenance

Once the design has been validated, the
product must be produced, sold and
maintained
A good design should lead to a product that
is easy to operate and maintain

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1540 Introduction To Mechatronics 45