Mechatronik Systems Guderjahn

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Turku, Finland, 14 - 27 March, 2010

LLP Erasmus Intensive Programme
An Introduction to Automotive Mechatronic Systems

Dipl.-Ing. Jan Guderjahn Cologne University of Applied Sciences Cologne Laboratory of Mechatronics
Partner: Cologne University of Applied Sciences

Contents
Overview What is Mechatronic? Components of a Mechatronic System Mechatronical Development Cycle Mechatronic System Applications

Contents (contd)
Closer Looks Mechatronical Development Cycle - Modeling Mechatronical Development Cycle - Analysis and Synthesis Rapid Control Prototyping
Conclusion Summary Examples Discussion

Introduction
Jan Guderjahn
(contact: jan.guderjahn@clm-online.de)
Graduated in Automotive Engineering at Cologne University of Applied Sciences in January 2007 Work at the Cologne Laboratory of Mechatronics (CLM) Vehicle dynamics simulation, HIL simulation, control system design and drive systems Graduating in Master of Science Mechatronics in 2010
This lecture is based upon the lecture Mechatronic Systems of Prof. Dr.-Ing. Henrichfreise, head of the Cologne Laboratory of Mechatronics.

Contents
Overview Closer Looks Conclusion

What is Mechatronic?
Mechatronic An Integrative Engineering Science
Development of optimal technical (mechatronical) systems


What is Mechatronic? (cont'd)
Contributions of participating disciplines Mechanical Engineering: Construction of mechanism Electronical Engineering: Actuators, sensors, signal/power processing Simulation Technology: Numeric simulation Control Engineering: System analysis and synthesis Informatics: Control system implementation

What is Mechatronic? (cont'd)
Aims and Characteristics Optimal system behavior for specified objectives Benefit from synergy effect Tool-based development environment Reduced overall development time and costs

Components of a Mechatronic System
Power Processing
Signal Processing

Mechatronical Development Cylce

Mechatronic System Applications
Control System Design Feedback of real process/plant is input for real-time CPU Real-time CPU computes control algorithms Output of real-time CPU is input for real process/plant Objective: Optimal control system design

Mechatronic System Applications (contd)
Hardware-in-the-Loop (HIL) Simulation Real production hardware and software, e.g. automotive production Electronic Control Unit (ECU) Real-time CPU computes simulation model (e.g. vehicle model) Objectives: Optimization of control parameters and simulation model

Mechatronic System Applications (contd)
Virtual Control Prototyping Hybrid form of control system design and HIL simulation Real-time simulation and animation of test system Implementation of control algorithms on 2nd real-time processor Coupling of both real-time systems Objective: Simultaneously optimization of mechanism and control system design

Contents

Mechatronical Development Cycle - Modeling
Modeling Stages 1. Real system or system idea 2. Physical analogue model 3. Free body diagram for mechanical parts 4. Laws of nature and applied sciences, components laws and phenomenons (*) 5. Mathematical model
* Spring, damper, weight, Newton's Laws of Motion, Euler's Equations, resistance, capacitor, inductance, Kirchhoff's Circuit Laws, Ampre's Circuital Law, Bernoulli's Principle , Continuity Equation

Components of Mechatronic Systems - Mechanisms
Mass-spring-damper-system Physical analogue system: Laws:
Free body diagram:
Mathematical model:

2-mass-spring-damper-system Physical analogue system: Laws:
Free body diagram:
Mathematical model:

Leaver mechanism Physical analogue system: Laws:

Gear box Physical analogue system: Laws:

Components of Mechatronic Systems - Actuators
DC motor Physical analogue system: Laws:
Free body diagram:
Mathematical model:

Hydraulic drive Physical analogue system: Laws:
Mathematical model:

Active magnetic bearing Physical analogue system: Laws:
Mathematical model:

Components of Mechatronic Systems - Sensors
Incremental encoder Position measurement via count of single events, e.g. electric impulses Signal processing unit Signal edge evaluation Identification of movement direction
Count Light bulb (LED) Blind Disc
Photo transistor Logic gate
Position

Components of Mechatronic Systems - Sensors
Tachometer Measurement of angular velocity Velocity proportional output voltage at the collector connectors Ripple, offset, noise and gain deviation Compensation of offset and gain deviation via signal conditioning Consideration of ripple and noise during control system design
Motor bearing 2 Rotor of DC Tacho
Rotor of Motor
Motor bearing 1
Nobel metal collector Nobel metal brushes

Interplay of Components of Mechatronic Systems
Electronic Power Steering (EPS) System Real system Physical analogue system:
5. VDI Mechatronik Tagung 2003, Innovative Produktentwicklung. Fulda, 07.-08. Mai 2003. Optimale Regelung einer elektromechanischen Servolenkung Hermann Henrichfreise, Jrgen Jusseit Labor fr Mechatronik (CLM), Fachhochschule Kln, www.clm-online.de Harwin Niessen Mercedes-Benz Lenkungen GmbH (MBL), Entwicklungszentrum Esslingen
+ actuators and sensors

Mechatronical Development Cycle - Analysis and Synthesis
Ways to describe mechatronic systems Ordinary Differential Equations (ODE) Frequency response Transfer functions Block diagrams State space systems

Linear Ordinary Differential Equations (ODE)
Simplest way to describe mechatronic systems
Solution of homogenous part with characteristic polynomial
and u(t) = 0 leads to the
Location of roots of the characteristical polynomial allow statements on system stability Computation of system responses for various system excitations u(t) via particular solution

Linear Ordinary Differential Equations (ODE) (cont'd)
Example:
Characteristic polynomial
Roots of characteristic polynomial

Linear Ordinary Differential Equations (ODE) (cont'd)
Partial solution for various system responses Step

time / sec
Ramp
Harmonic oscillation
time / sec
Frequency response
time / sec

Frequency Responses
Relation between system excitation and system amplitude and phase response
Amp / dB
Only harmonic oscillation as excitation and system response Only defined for stable systems Only linear time-invariant systems
Phase / deg
omega / rad/sec
Phase / deg
Easy to plot and analyze via Bode and Nyquist diagram

Transfer Functions
Relation between any system excitation and system response
Laplace transform maps signals from time-domain f(t) (original) to s-domain F(s) (image) Only single-input-single-output (SISO) systems Only linear time-invariant systems
Block diagrams

Block Diagrams
Numeric simulation with MATLAB/Simulink

State Space Systems
Overview Technical systems are often described by a system of coupled ODEs nth order for multiple inputs and ouputs Suitable transforms lead to a system of coupled 1st order ODE
state differential equation and output equation
General time-invariant linear state space system: x state vector y output vector u input vector
A B C D
state matrix input matrix output matrix feedthrough matrix

State Space Systems (contd)
Key benefits Linear, non-linear, time-variant and time-invariant systems with any excitation Multiple-input-multiple-output (MIMO) systems Most numeric simulations are based upon state space systems (e.g. MATLAB/Simulink) Many newer control theories are based upon state space systems (especially for MIMO systems) Classical control theories become easier to use (e.g. for SISO systems)

State Space Systems (contd)
Example:
Transform to system of coupled 1st order ODE and In matrix-vector form: leads to
state differential equations output equation
Eigen values of state matrix A are the roots of the characteristic polynomial

Interplay of Components of Mechatronic Systems
Electronic Power Steering (EPS) System
5. VDI Mechatronik Tagung 2003, Innovative Produktentwicklung. Fulda, 07.-08. Mai 2003. Optimale Regelung einer elektromechanischen Servolenkung Hermann Henrichfreise, Jrgen Jusseit Labor fr Mechatronik (CLM), Fachhochschule Kln, www.clm-online.de Harwin Niessen Mercedes-Benz Lenkungen GmbH (MBL), Entwicklungszentrum Esslingen

Rapid Control Prototyping
Overview Seamless tool chain as development environment for mechatronic systems MATLAB with toolboxes dSPACE real-time software and hardware Focus only on development objectives System validation and optimal prototype Specificate requirements for production hardware Reduction of development time and costs

Rapid Control Prototyping Steps and Tools
1. Modeling and analysis, reveal system deficiencies, specification of control design objectives 2. Control system synthesis, design of control system structure, computation of controller parameters 3. Analysis of non-linear closed-loop system via numeric simulation 4. Controller separation, augmentation of controller model, with real-time hardware interface blocks
MATLAB/Simulink and Control System Toolbox
MATLAB/Control System Toolbox
MATLAB/Simulink
MATLAB/Simulink, dSPACE real-time interface block library

Rapid Control Prototyping Steps and Tools (contd)
5. Controller implementation on prototyping hardware via automatic code generation 6. Real system setup, initialization of hardware and safety environment, visualization of signals for monitoring and control 7. Analysis of real system via experiments, comparison of measurement and simulation results Steps 4 to 6: Rapid Control Prototyping
MATLAB/Simulink and real-time workshop, dSPACE real-time interface and prototyping hardware dSPACE ControlDesk and MLIB
dSPACE Control Desk and MLIB MATLAB/Simulink

Contents

Summary
The presented formal design process, defined by the mechatronical development cycle, leads during the completely tool-based development of mechatronic systems to optimal results and reduces in comparison to traditional methods the overall development time and costs. This way the interdisciplinary character, the basic idea of optimization and the formal development method establish potentials for the products of the future.

Our work at the CLM - Automotive Mechatronic Systems
Activities Development of vehicle models Control algorithm design for steering systems Vehicle dynamics control Vehicle dynamics observation HIL simulation
Models and methods for the development and test of mechatronic autmotive systems

Development of Vehicle Models
Activities Development of specific vehicle multi-body systems Development of vehicle component models (suspension, power train, tires, brakes etc.) Development of models for roads and drivers
Real-time models for vehicle dynamics simulation


Control Algorithm Design For Steering Systems
Activities Electro-mechanical and hydraulical steering systems Superimposed steering systems Design of steering-feel adapted to current vehicle dynamics situation
EPS motor EPS-ECU sensor steering column
steering wheel
gear rack and pinion
steering lever and steering rod
wheels
Control concepts for safe and comfortable driving

Vehicle Dynamics Control
Activities Steering intervention via superimposition torques Driver assistance in critical vehicle dynamics situations Vehicle stabilizing via steering actuation Steering feel optimization
Control concepts for safe and comfortable driving

Vehicle Dynamics Observation
Activities Development of observer for the estimation of vehicle dynamics variables Use of signal models instead of tire models
sum lateral tire forces front / kN
Observer
Estimation of traction potential of tire contact patches
-2
-4
Reliable estimations independent of road and tire conditions

-6 0 1 2 3 4 5 6 7 8 9 10
time / s

HIL Simulation
HIL test bench for steering systems Haptic feedback via steering wheel Development of algorithms considering the steering feel Front-loading of tests with prototypes to the HIL simulation
ideal steering wheel
Development of algorithms in regard to the drivers acceptance of the steering feel


Our work at the CLM Other Activities
Drive systems Rapid Control Prototyping Development of software tools Aviation Estimation of gusts and structural loads for commercial aircrafts Active wing vibration damping Robotics Lectures for educational purposes

Discussion
www.clm-online.de
Thank you for your attention.
An Introduction to Automotive Mechatronic Systems

Dipl.-Ing. Jan Guderjahn Cologne University of Applied Sciences Cologne Laboratory of Mechatronics

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IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Turku, Finland, 14 - 27 March, 2010

An Introduction to Automotive Mechatronic Systems

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Conclusion Summary Examples Discussion

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Overview Closer Looks Conclusion

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Mechatronic An Integrative Engineering Science

Development of optimal technical (mechatronical) systems

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

What is Mechatronic? (cont'd)

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

What is Mechatronic? (cont'd)

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Components of a Mechatronic System

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Mechatronical Development Cylce

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Mechatronic System Applications

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Mechatronic System Applications (contd)

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Mechatronic System Applications (contd)

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Overview Closer Looks Conclusion

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Mechatronical Development Cycle - Modeling

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Components of Mechatronic Systems - Mechanisms

Mass-spring-damper-system Physical analogue system: Laws:

Free body diagram:

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Components of Mechatronic Systems - Mechanisms

2-mass-spring-damper-system Physical analogue system: Laws:

Free body diagram:

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Components of Mechatronic Systems - Mechanisms

Leaver mechanism Physical analogue system: Laws:

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Components of Mechatronic Systems - Mechanisms

Gear box Physical analogue system: Laws:

Partner: Cologne University of Applied Sciences

IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles

Components of Mechatronic Systems - Actuators