Mechatronics in University

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2006 ASEE New England Section ConferenceMechatro
nicsin University and Professional Education

• Prof. Kevin Craig
• Rensselaer Polytechnic Institute
  

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Technology Strategy Question
How can Samsung continue to lead the world in
industries where electronics, computers, and
control systems are integral parts of the overall
system and reliability, low cost, and robustness
are absolutely essential ?
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University Strategy Question
How can Rensselaer lead in educating students for
the practice of engineering in a world where
electronics, computers, and control systems are
integral parts of the overall engineering system
and a multi-disciplinary, systems approach to
engineering analysis and design is absolutely
essential ?
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Two Elements to the Answer

• Learning what the practicing engineer needs the
  knowledge, the skills, the tools to effectively
  solve 21st-century engineering problems. This is
  accomplished through industrial interaction.
• Incorporating the mechatronics approach to
  engineering analysis and design throughout the
  engineering curriculum.

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Industrial Interaction M.S. and Ph.D. Research,
Training Practicing Engineers, Consulting
Shapes
Engineering Curriculum
Freshman Year To Senior Year
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Current Situation

• Electronics, Microcontrollers, Precision Sensors
  Actuators Are Everywhere!
• With the explosively increasing
  cost/size-effectiveness of computers, mechatronic
  systems are becoming common in any engineering
  discipline dealing with the modulation of
  physical power.
• In mechatronic systems, computing is central.

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• The past few years have seen mechatronics have an
  increasing impact on engineering and engineering
  education as a defining approach to the design,
  development, and operation of an increasingly
  wide range of engineering systems.
• In addition, mechatronics is now recognized as
  involving not only the technical aspects of its
  core disciplines mechanical, electronics,
  controls, computers but also aspects of
  organization, training, and management.

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What is Mechatronics?
Mechatronics is the synergistic combination of
mechanical engineering, electronics, controls
engineering, and computers, all integrated
through the design process. It involves the
application of complex decision making to the
operation of physical systems. Mechatronic
systems depend for their unique functionality on
computer software.
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The Design Challenge

• The cost-effective incorporation of electronics,
  computers, and control elements in a system to
  achieve high performance, robustness, and
  reliability requires a new approach to design.
• The modern engineer must draw on the synergy of
• Mechatronics

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Difficulties in Mechatronic Design

• Requires System Perspective
• System Interactions Are Important
• Requires System Modeling
• Control Systems Go Unstable
• The Realm of Mechatronics
• High Speed, High Precision, High Efficiency
• Highly Robust
• Micro-Miniature

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Mechatronic Design Concepts

• Direct-Drive Mechanisms
• Simple Mechanics
• System Complexity
• Accuracy and Speed from Controls
• Efficiency and Reliability from Electronics
• Functionality from Microcomputers

Think System !
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Is Mechatronics New?

• Mechatronics is simply the application of the
  latest, cost-effective technology in the areas of
  computers, electronics, controls, and mechanical
  systems to the design process to create more
  functional and adaptable products.
• Just Good Design Practice!
• Many Forward-Thinking Designers and Engineers
  have been doing this for years!

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There Is Something New Here!

• Mechatronics encompasses the knowledge base and
  the technologies required for the flexible
  generation of controlled motion.
• Mechatronics demands horizontal integration among
  the various disciplines as well as vertical
  integration between design and manufacturing.
• Mechatronics is a significant design trend an
  evolutionary development a mixture of
  technologies and techniques that together help in
  designing better products.

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• Mechatronics is having a profound influence on
  the way all mechanical engineers are now expected
  to design.
• And on the way professors must now teach design!

Mechatronics has gained industrial and academic
acceptance worldwide as a field of study and
practice.
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The WHY of Mechatronics?

• In an increasingly competitive and global market,
  companies need to have the ability to increase
  the competitiveness of their products through the
  use of technology and must be able to respond
  rapidly and effectively to changes in the market
  place.
• Mechatronic strategies have been shown to support
  and enable the development of new products and
  markets, as well as through enhancing existing
  products, while responding to the introduction of
  new product lines by a competitor.

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• However, whatever the level of technology, the
  motivation for the adoption by a company of a
  mechatronic approach to product development and
  manufacturing must be one of providing the
  company with a strategic and commercial advantage
  either through the development of new and novel
  products, through the enhancement of existing
  products, by gaining access to new markets, or
  some combination of these factors.

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The HOW of Mechatronics?

• The achievement of a successful mechatronics
  design environment essentially depends on the
  ability of the design team to communicate,
  collaborate, and integrate.
• Indeed, a major role of the mechatronics engineer
  is often that of acting to bridge the
  communications gaps that can exist between more
  specialized colleagues in order to ensure that
  the objectives of collaboration and integration
  are achieved.

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• This is important during the design phases of
  product development and particularly so in
  relation to requirements definition where errors
  in interpretation of customer requirements can
  result in significant cost penalties.

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Balance The Key to Success
Experimental Validation Hardware Implementation
Modeling, Analysis, Controls
The Mechatronic Design Process
Computer Simulation Without Experimental
Verification Is At Best Questionable, And At
Worst Useless!
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Engineering System Investigation Process The
cornerstone of modern engineering practice
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ModelingPhysical and Mathematical
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?
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Mechatronic System Elements (all energetically
isolated)
Real-time software is at the heart!
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Design Control Integration

• Traditionally, plant design and control system
  design have been separate activities.
• Control system design normally has not been
  initiated until after the plant design is well
  underway and major pieces of equipment have been
  ordered.
• Serious Limitations to this approach! The plant
  design determines the plant dynamic
  characteristics as well as the operability of the
  plant.

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• Dynamics and Control Issues need to be considered
  early in the plant design.
• This is most important for modern plants which
  tend to have a larger degree of material and
  energy integration and tighter performance
  specifications.

Plant Design
Plant Dynamics Control Structure
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What Deficiencies Do Professional Engineers Have?

• Control Design and Implementation are still the
  domain of the specialist.
• Controls and Electronics are still viewed as
  afterthought add-ons.
• Few engineers perform any kind of modeling.
• Mathematics is a subject not viewed as enhancing
  ones engineering skills but as an obstacle to
  avoid.
• Few engineers can balance the modeling / analysis
  / control design and hardware implementation
  essential for success.

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Engineering Problem
Systematic, Structured Approach to Design
Electronics
Computers
Integrated Design Concept
Sensors
Actuators
Controls
Mechanical
Build Test
Model, Analyze Predict
NO!
YES!
?
Cost-Effective, High-Quality, Timely, Robust
Design
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Professional Engineering WorkshopsHas This
Approach Been Successful?

• YES! For organizations who need their engineers
  to
• Design with synergy and integration
• Balance modeling / analysis / control with
  hardware implementation
• Past Successful, Highly-Rated Workshops

Xerox (4) Pitney Bowes NASA KSFC Langley ASME
(12)
Procter Gamble (4) Dana (2) U.S. Army
ARDEC Plug Power Fuel Cells
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University Education

• Rensselaer Polytechnic Institute
• Fall Semester Mechatronics
• Mechatronics at a theoretical and practical
  level balance between theory/analysis and
  hardware implementation is emphasized emphasis
  is placed on physical understanding rather than
  on mathematical formalities.
• A case-study, problem-solving approach, with
  hardware demonstrations, either on video or in
  class, and hardware lab exercises, is used
  throughout the course with LabVIEW MatLab.
• This course covers mechatronic system design,
  modeling and analysis of dynamic physical
  systems, control sensors and actuators, analog
  and digital control electronics, continuous
  controller design and digital implementation,
  interfacing sensors and actuators to a
  microcomputer/microcontroller, and real-time
  programming for control.

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Stepper Motor System Design Ink-Jet Printer
Application
Stepper Motor Open-Loop and Closed-Loop Control
Experimental System
Engineering Application
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Pneumatic System Closed-Loop Position Control
Brushed DC Motor Position and Speed Control
with Magneto-Rheological Fluid Rotary
Brake/Damper System
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• Spring Semester Mechatronic System Design
• Students work in teams to put it all together and
  make it happen in one semester!
• Past and Present Projects
• Rotary and Arm-Driven Inverted Pendulum
• Ball-on-Plate Balancing System
• Balancing Robot and Segway-like Human Transporter
• Automobile Traction-Control Testbed
• Inverted Wedge Balancing System
• Hybrid Hydraulic / Pneumatic Positioning System

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Mechatronic System Design
Ball-on-Plate Balancing System
Rotary Inverted Pendulum System
Arm-on-Arm Inverted Pendulum System
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Foundations of Engineering
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Steel Cantilever Beam
Cantilever Beam Mechanical System
Eddy-Current Damper
Strain Gage
Accelerometer
Vibration Exciter
MEMS Accelerometer
Hard-Drive Read-Write Head