IFAC

0
Copyright 0 IFAC Mechatronic Systems,
California, USA, 2002
c: [>

Publications
www.elsevier.comllocatelifac

VDI 1206 - A NEW GUIDELINE FOR THE DESIGN

OF MECHATRONIC SYSTEMS

Prof. Dr.-Ing. J. Gausemeler, Dr.-Ing. S. Moehringer

Heinz Nixdorf Institute

University of Paderborn, Fuerstenallee 11, D - 33102 Paderborn, Gennany
Tel.: ++49-5251-606267, Fax: ++49-5251-606268
{gausemeierlmoehr}@hni.uni-paderborn.de

Abstract: Mechatronics - the synergetic integration of different engineering domains such

as mechanics, electronics and infonnation technology can create new products and
stimulate innovative solutions. In order to yield this potential, experts from the involved
domains need a cross-domain methodology for the systematic design of mechatronic
systems. Inspite of the wide spectrum of research activities and industrial developments
in the mechatronic field it seems to be difficult for the design engineer in practice - in
particular for the still unexperienced one - to select the suitable procedures, methods and
tools for his design task. Therefore a committee of the German Association of Engineers
(VDI) is working out a new VDI-guideline. The VDI 2206 guideline "Design
methodology for mechatronic systems" intends to structure the variety of findings and to
make them accessible to the practician in a concise and understandable way. This
contribution presents the draft of the VDI 2206 guideline. Copyright © 2002 [FAC

Keywords: Design methodology, design process, mechatronic systems, system design,

system integration

1. INTRODUcrION in the vehicle prove the potential ofmechatronics.

The global competition is characterised by high
innovation dynamic, shortened development and
product life-cycles, and increasing customer
requirements on perfonnance, quality and price of
future products. Product innovations contribute in a
decisive manner to assert oneself in this global
competition. Mechatronics - a buzzy word from
mechanics and electronics - represents a success
potential for the design of future products: Thanks to
the close interaction of mechanical engineering,
electronics and information technology new principle
solutions become possible which can both improve the
cost-value ratio of known products considerably, and
stimulate new products. Success stories such as the
progression from the record player to the portable CD-
player, from the manual gear to the adaptive automatic
transmission and quotidian product innovations as the
auto-focus camera or the controlled catalytic converter
Mechatronics offers success potentials, makes
however special requirements to the design process:
Mechatronic systems are characterized by high
complexity due to the cross-linkage of different
engineering domains. The complexity is caused by the
great number of connected elements which are
realized furthennore in different engineering domains
(heterogeneity). This is already to be considered in the
early phase of design since the interactions of
mechanical, electronic and information processing
components influence the behavior and the shape of
the mechatronic overall system.
The design is mostly worked out in the respective
domains themselves on the basis of established,
specific design methods which are characterized by
their own ways of thinking, nomenclatures and
experiences. The integration of heterogeneous
components to mechatronic systems requires cross-
domain communication and cooperation between the

785
involved disciplines in order to gain a common idea
of the future product and to design an entirely
optimized solution.
With the progression of information technology a
great number of computer-aided tools supporting the
design has been established. These tools are however
not adequately integrable. On the one hand they allow
an early modelling and simulation of mechatronic
systems, but on the other they lead to changed working
methods and new topics such as integration and
interface concepts. The design ofmechatronic systems
across different departments and enterprises is to be
supported by suited forms of organizational co-
operation.
Facing the wide spectrum of the research activities and
industrial developments in the mechatronic field it
seems to be difficult for the design engineer in
practice - in particular for the still unexperienced one
- to select the suitable procedures, methods and tools
for his task and application. Therefore the German
Association of Engineers (VD!) assigned the mandate
to Professor Gausemeier to establish a committee
responsbible for a new VD! -guideline" Design metho-
dology for mechatronic systems". The committee was
constituted in September 2000 .
This contribution presents the draft of the VD! 2206
guideline "Design methodology for mechatronic
systems". The "green print" of the guideline is
scheduled for the third quarter 2002 (VD! 2206, 2002).
2. SURVEY OF THE MAIN TOPICS
OF THE VD! 2206 GUIDELINE
2.1 Objective
access them to the prachclan in a concise and
understandable way. By means of examples the
transfer of findings into successful products is
illustrated.
2.2 Target group
In the first place the guideline addresses to design
engineers of mechatronic systems in practice. It is
supposed to provide the basic elements for the design
of mechatronic systems and to stimulate a cross-
domain and integrative view overcoming the single
engineering discipline.
2.3 Position 10 relatedVDI guidelines
\.
The new guideline will complement the VD! 2221
(VD! 2221, 1993) and VD! 2422 (VD! 2422, 1994)
guidelines. In analogy to the VDI 2221 which deals
with universally valid, line-independent bases for the
methodical design, the VDI 2206 describes the
methodology for the design of mechatronic systems.
The mechatronic approaches of the VD! 2422 will be
enlarged to a universal and cross-domain guide.
2.4 Contenl structure
In chapter 2 the bases of mechatronic systems are
treated. These include a common understanding of the
term mechatronics and methods to structure
mechatronic systems (figure I). The potential benefit
of mechatronics is clarified and the specifics for the
design of mechatronic systems are sketched.

The aim of the guideline is to support the cross-

domain design of mechatronic systems in a
systematic way. Procedures, methods and tools for the
early phase of design are explained with a special
focus on the system design. The result of the system
design is the reliable concept of a mechatronic
system, that is, its prineipally defined and verificated 1
resp . validated 2 solution. According to the design task
and the risk consideration different grades of
validation are neeessary: The validation of the design
can be done with the help of a virtual prototype, a
partly real or a completely real prototype.
The guideline refers with preference to mechatronic
systems which consist of discrete mechanical and
eleetronie components in symbiosis with information
...... il'iorrnalion flOw
technology.
The guideline is supposed to structure the variety of
suspension strut ""SE"":-::'ba--s""'C""e"'.,m""e-n7't_ _ _ _.J -=Q mallrialUow
findings which have been developed through research
and industrial applications in the last years and to
Figure I. Example of the structuring ofmechatronic
systems (Liickel et aI., 2000).
I. Verification: examination whether a realized design corresponds
with the specified requirements. The key message of the guideline, the design
2. Validation: examination whether a realized design is suitable for methodology, is explained in chapter 3. It consists of
its operation purpose and/or achieves the wanted performance a tripartite procedure model (micro-level, macro-level,
(fulfillment of possibly not specified requirements).

786
process modules), the methods of modelling and
model analysis, supporting computer-aided tools and
selected aspects ofthe organization.
The application and practical handling of the design
methodology is illustrated in chapter 4 by means of
four examples with different focusses: The first
example "From the mechanic to the mechatronic
brake" shows, how thanks to the synergetic interaction
of mechatronics, existing product features can be
improved and new functions can be created. Within
the second example "Design of the drive unit of a
varnishing line" the phases system design and initial
modelling are in the foreground. The third example
"Design of an active suspension-inclination-module"
focusses on the modelling, the structuring of
mechatronic systems, the controller design and the
system verification/validation in a hardware-in-the-
loop environment. Finally the special demands of the
spatial integration are described by " Design of
integrated multi-coordinate drives" in the fourth
example.
The literature (chapter 5) and a glossary of the most
important terms (chapter 6) complete the guideline.
In the following an extract of the design methodology
with the focus on the system design is presented in
detail.
3. DESIGN METHODOLOGY
Both the experiences of the industrial practice and the
results of the empirical design research of the last
years are illustrating that there is no "optimal form of
tbe design process the design engineer can follow
according to a fixed flowchart" (Diimer, 1994). In
order to take this finding into account for the
development of mechatronic systems, a more flexible
procedure model is suggested within this guideline. It
is based onto three main elements:
- the general cycle of problem solving on the micro-
level,
- the V-shaped model on the macro-level and
predefined process modules for repeating
operation steps during the design of mechatronic
systems.
3.1 The cycle ofproblem solving on the micro-level
The presented cycle of problem solving on the micro-
level (cf. figure 2) comes from systems engineering
and is used as well in a modified way in other
disciplines as for example business management or
software engineering. Its basic validity for the
planning and realization of effective problem solution
behavior was confirmed again from the point of view
of psychology (Kranach et aI., 1986).
The cycle of problem solving comprises the following
steps:
Situation analysis and/or take-over of target: A
basic cycle starts either with the situation analysis or
787
procHdlng In accordance procHding in accordance
with the actual condlUon with the tllrget condition
Impuls.
• firming up
0100101;00
variant&.
deciolon
plilnnilg
of further lumilg
proc •• dilg
Figure 2. Cycle of problem solving on the micro-level
(Daenzer and Huber, 1994).
the take over ofthe target (figure 2): An externally pre-
set target can be taken over by the acting group and/or
the individual; the situation analysis will follow
(proceeding according to target condition). In the
second case a first unclear situation will be analysed
and the target will be formulated respectively
(proceeding according to actual condition).
Analysis and synthesis: It is the aim to search for
solutions for the given problem and to elaborate
alternative solution variants. This process represents
in practice a permanent interaction of synthesis and
analysis steps which the design engineers carry out -
partly conscious, partly unconscious as well. During
the solution search additional aspects of the problem
can be recognized that might require a return to the
situation analysis and target formulation or the
consideration of supplementary criteria.
Analysis and evaluation: The solution variants are
subject of a detailed evaluation phase. If certain
solution ideas differ too strongly concerning their
degree of concretion to be compared appropriately, a
return to the phase of solution search should be
considered. The evaluation of the solution variants is
done on the basis of the evaluation criteria defined
within the target formulation and solution search. The
result consists of a proposition for one or several
solution alternatives.
Decision: It must be found out whether the previous
process of the problem solution has led to a
satisfactory result. If that is not the case, one must
return to the situation analysis and target formulation.
Otherwise one, maybe also several solution
alternatives are chosen and represent the basis for the
further planning.
Planning of the further proceeding resp. learning:
The further procedure leads in many cases more or less
continuously to further cycles of problem solutions
and thus to an efficient, situation-adapted process.
Beside the operational evaluation of the action result
the process execution should be analysed critically as
well. By comprehending the positive and negative vermC8tlonNald adon
impacts on the process execution and the result
knowledge for coming design tasks can be generated.
In this way future design processes will be improved
systematically.

3.2 V-shaped model on the macro-level

The V-shaped model is well-established in the domain

of software engineering (Brohle and Droschl, 1993)
and has been adapted to mechatronic needs. It
describes the generic procedure for the design of
mechatronic systems which has to be specified
according to the individual design task (figure 3).
Requirements: Starting point is an individual design
task. The task has been clarified/defined and described
with the help of requirements. These requirements
represent at the same time the measure for the
evaluation of the later product.
System design: The object is to define a cross-domain
solution concept which describes the essential
physical and logical characteristics of the future
product. The overall function of a system will be
divided into sub-functions. Suitable working princi-
ples and/or solution elements are assigned to these
sub-functions and the fulfilling of the functions re-
< degree of maturity
.
Figure 3. V-shaped model on'the macro-level
A complex mechatronic product will normally not be
finished within one macro-cycle . Rather several
passes are necessary (figure 4).
During a first cycle, for example, the system will be
specified functionally, first working principles I and/or
solution elements 2 are selected and specified roughly
and at the same time checked for consistency in the
system context. First laboratory samples are the result.
These results are worked out in detail within a second
cycle (detailled specification of the structures,
behavior and shape simulation) in order to generate
early prototypes.
degree of matlXlty

garding the overall system context is evaluated.

Domain-specific design : The solution concept which
has been developed conjointly by the involved
domains will be worked out in detail mostly separately
in the concerned domains. Elaborate design and
calculations are necessary in order to guarantee the
functional performance, in particular that with critical ':-'-;

functions. ,/ ,/
: :
System integration: The results from the specific
domains are integrated to an overall system in order to
analyse the interrelations.
Verification/validation: The design progress has to
be checked continuously by means of the specified
solution concept and the requirements . It is to be
assured that the actual system characteristics match
with those wanted.
Figure 4. Proceeding with several passes (macro-
Modelling and model analysis: The described phases
cycles) and increasing product maturity
are flanked by the modelling and analysis of the
system characteristics with the aid of models and
Depending on design progress, type and complexity of
computer-aided tools for simulation.
the design task, further macro-cycles can be necessary
Product: The product is the result of a macro-cycle
sucessfully passed through. It does not exclusively
mean the finished, really existing manufactured item, I . Working principle: relation between physical effect and geome·
but the ongoing concretion of the future product tric/material characteristics; shows the principle of a solution to
fulfil! a sub· function, e.g. bimetal as a control element (Pahl and
(product maturity). Degrees of maturity are, for Beitz, 1996).
example, concept model, functional model etc. 2. Solution clement: realised and proven solution to fulfill a
function; generally a module or an assembly based on a working
principle. e.g. bearing, sensor (Gausemeier et aI., 2001).

788
to reach a product maturity ready for mass production.
The number of the macro-cycles and the individual
steps to be passed through in the V-shaped model have
to been specified case by case.

].] Process modulesfor repeating design steps

Some design steps that occur regularly during the

design can be described more precisely in terms of
partly predefined process modules. In the following
the process module S)'ste/II tlesipt will be explained
(figure 5). The guideline specifies furthermore the
process modules modelling and model analysis,
domain-spec(jic design, system integration and
ver(jication/valtdation.
System design
The system design starts with the abstraction ofthe
product idea described in the requirement list. Pre-
fixations (prepossessions) which limit the possible
range of solutions unnecessarily are supposed to be
avoided through that. It is the objective to elaborate the
essential and the universally valid of the problem. This
is achieved for example by reduction of the
requirement list to essential statements and the
solution-neutral formulation of the problem (Pahl and
Beitz, 1996).
Establishing functional structures: The overall
function is derived from the problem specification. It
represents the objective function for the behavior of
the system under its conditions of use. The conditions Figure 5. Design steps specifying the phase of system
of use are represented by input variables. The output design, according to (Kallenbach et aI.,
variables describe the wanted behavior. With the aid 1997; Pahl and Beitz, 1996).
of the general flow variables - materia/, energy and
information - and the block representation the elements. Catalogs (catalogs for physical effects and
interrelation between input and output variables can be working principles, e.g. (Roth, 2000); product
specified. Usually the design task to be solved is too catalogs, e.g. bearings) and electronic market places
complex to derive the technical realisation (e.g. CompoNETI) facilitate the search. The found
immediately from the overall function . Therefore the working principles and/or solution elements are linked
structuring of the overall function into sub-functions together to the working structure combining several
is necessary. Subfunctions of mechatronic systems working principles and/or solution elements. It is the
are, for example, drive, control, measuring, transfer aim to recognize the physical compatibility between
etc. The sub-functions are also connected via material, the elements and to guarantee an undisturbed material,
energy and information flows for the functional energy and information flow. The further specification
structure in order to describe the behavior and to leads to the building structure. The building structure
recognize inconsistencies at an early stage. It is the considers the spatial connections and the requirements
objective to subdivide the functional structure until of manufacturing, assembly etc. Building spaces, later
working principles and solution elements for the components and assemblies with their corresponding
fulfillment of the sub-functions can be found. This connections that represent the future manufactured
occurs as an interaction of analysis and synthesis steps item are defined. The spatial compatibility especially
(cf. chapter 3.1). in case of spatial integration can be verified (Pahl and
Searching for working principles and/or solution Beitz, 1996).
elemenu to fulfil) the sub-functions: In an iterative Working out into principle solution varianu: The
process suitable working principles and/or solution so far elaborated ideas for a solution are usually not
elements are determined. These are optimized detailled enough to define the final cross-domain
successively considering the useful and disturbing solution concept and to continue the specific design
functions as well as the compatibility conditions. The
process is continued as long as all sub-functions are
fulfilled by suitable working principles and/or solution I. CompoNET: Online market place for component suppliers;
hup:llwww.CompoNET.de

789
within the involved domains. Further aspects such as
fault liability, weight, service life etc. have to be
considered. For infonnation retrieval, calculations
(finite element method, analysis of multi-body
systems), sketches and design studies, building of
display models, technology analyses are used among
other things. The working principles and/or solution
elements are worked out on the base of the newly
gained infonnation so far until principle solution
variants of the design task are detectable. These
solution variants will be evaluated in accordance with
technical and economic criteria.
Result of the system design is a cross-domain solution
concept which describes the essential physical and
logical characteristics of the future product and the
type and topology of its working principles and/or
solution elements.
4. CONCLUSION
Mechatronics offers success potentials for the creation
of new products, makes however special requirements
to the design process: Mechatronic systems are
characterized by high complexity caused by the great
number of connected elements which are realized
furthermore in different engineering domains (hetero-
geneity). In order to manage these requirements a
cross-domain methodology for the systematic design
ofmechatronic systems ist needed.
The article presented the draft of the VDI 2206
guideline structuring procedures, methods and tools
for the early phase of mechatronic design. It particu-
larly addresses design engineers of mechatronics in
practice. Key element of the methodology is a flexible
procedure model which comprises three main
elements: I) the general cycle of problem solving on
the micro-level, 2) the V-shaped model on the macro-
level and 3) predefined process modules for recurring
operation steps during the design of mechatronic
systems.
The guideline treats furthermore the bases of
mechatronic systems (term mechatronics, basic
structure ofmechatronic systems, potential benefit and
the specifics for the design of mechatronic systems),
the methods of modelling and model analysis,
supporting computer-aided tools and selected aspects
of the organization. The application and practical
handling of the design methodology is illustrated in
the guideline by means offour examples.
5. ACKNOWLEDGEMENTS
The guideline VDI 2206 has been worked out by the
guideline committee with about 40 well-known
specialists in the field of mechatronics. The results
could only be obtained owing to a close cooperation
between industry and academia. The authors want to
thank all members of the guideline committee for the
excellent collaboration and the supply of knowledge,
tables and figures. Thanks are also given to the VDI
790
for the organizational support.
Special thank is due to the following members:
Prof. T. Bertram, Technical University ofIlmenau
C. Germer, Technical University of Braunschweig
C. Jung, Technical University of Munich
Prof. E. Kallenbach, Technical University ofIlmenau
Dr. F. Kallmeyer, Wincor Nixdorf, Paderbom
O. Oberschelp, University of Paderborn
Dr. U. Oldendorf, Technical University of Dannstadt
D. Reiners, DairnlerChrysler AG, Frankfurt
J. Seuss, Hella KG Hueck & Co, Lippstadt
J. Wulf, Technical University of Munich
F. Zohm, Aachen University of Technology
6. REFERENCES
'~..: .
'
Brohle, A.-P. and Droschl. W. (1993). Das V-Model/-
Der Standard for di~" uojtwareentwicklung mit
Praxisleitfaden, Oldenbourg Verlag, Miinchen,
Wien.
Daenzer, W.F. and Huber, F. (1994). Systems Engi-
neering - Methoden und Praxis, 8. verbesserte
Auflage, Verlag Industrielle Organisation, ZUrich.
Dorner, D. (1994). Gediichtnis und Konstruieren. In:
Pahl, G. (Hrsg.): Psychologische und Piidagogi-
sche Fragen beim methodischen Konstruieren, Er-
gebnisse des Ladenburger Diskurses, Mai 1992-
Oktober 1993, TOY Rheinland, Koln.
Gausemeier, J., Ebbesmeyer, P. and Kallmeyer, F.
(2001). Produktinnovation - Strategische Planung
und Entwicklung der Produkte von morgen, Carl
Hanser Verlag, Miinchen, Wien.
Kallenbach, E., Birli, 0., Saffert, E. and Schaffel, C.
(1997). Zur Gestaltung integrierter mechatroni-
scher Produkte. In: Tagung Mechatronik im Ma-
schinen- und Fahrzeugbau, Moers, 10.-12. Miirz
1997, VDI Berichte 1315, VDI-Verlag, Diissel-
dorf, pp. 1-14.
Kranach, M. von, Ochsenbein, G. and Valach, L.
(1986). The Groupe as Selfactive System: Outline
of a Theorie of Groupe Action. European Journal
ofSocial Psychology, 16, pp. 193-229.
Uickel, J., Koch, T. and Schmitz, J. (2000). Mechatro-
nik als integrative Basis fUr innovative Produkte.
In: VDI- Tagung: Mechatronik - MechanischlElek-
trische Antriebstechnik, 29./30. Miirz 2000, Wies-
loch, VDI-Verlag, Diisseldorf.
Pahl, G. and Beitz, W. (1996). Engineering design.
Springer, London.
Roth, K. (2000). Konstruieren mit Konstruktionskata-
logen, 3. Auflage, Springer Verlag, Berlin et al.
VDI 2206 (2002). Entwicklungsmethodik for mecha-
tronische Systeme - Richtlinienentwurf, VDI-
RichtlinienausschuB A127NDI 2206, Paderborn.
VD! 2221 (1993). Methodikzum Entwickeln und Kon-
struieren technischer Systeme und Produlcte,
Beuth Verlag, Berlin.
VDI 2422 (1994). EntwickJungsmethodik for Geriite
mit Steuerung durch Mikroelelctronik; Beuth Ver-
lag, Berlin.