Browse Topic: Mechatronics
Designing, manufacturing, and controlling a high-precision gantry positioning system is a complex, multidisciplinary task demanding expertise in structural mechanics, thermal modeling, mechatronics, and advanced motion control.
Manufacturers of fans/propellers using hydraulically-actuated pitch control claim energy efficiency gains up to 75% over fixed-pitch solutions. Unfortunately, the added cost, weight, reliability and maintenance considerations of hydraulic solutions has limited the introduction of pitch control for small-to-medium fans and propellers leaving a large market unserved by the efficiency gains associated with changing the pitch of a blade when the blade shaft’s speed changes. Pilot Systems International and Cool Mechatronics are developing an electromagnetically controlled pitch (EMCP) fan/propeller that will produce a new pareto optimal in size, weight, power, cost and cooling (SWaP-C2). The technology will substantially improve the efficiency of military ground vehicle cooling fans which is typically the third greatest power draw (~20kW)1 in the entire vehicle and provide critical performance improvements during silent watch. It will be a key enabler for the electrification of aircraft.
The automotive industry faces the challenge of developing vehicles that meet current customer needs while being future-proof. Surveys conducted for this study show that customers are concerned about the financial risks of essential components such as energy storage systems, mainly due to aging and performance degradation, which significantly affect vehicle lifespans. Based on vehicle developer surveys, a clear need for action was identified. Given the rapid technological advancements in electrified drive systems, there is a need for innovative approaches that can easily adapt to changing requirements. Therefore, this paper presents a strategy combining foresight-based planning of system upgrades with product architecture design to create adaptable and sustainable vehicles through modularity. First, dynamic subsystem characteristics are identified to establish future energy storage technology requirements. Subsequently, future energy storage system technologies are examined to determine those that meet the identified dynamic characteristics. Based on this information, the technologies are analyzed technically-functional and geometrically to create flexible design spaces within the product architecture. This enables the future integration of new, more efficient, or higher-performance energy storage technologies into vehicles during their utilization phase. The integrability and functional efficacy of the selected technologies are assessed through a combination of impact and criticality analysis based on virtual modeling, resulting in a ranking of the most suitable energy storage technologies. Implementing upgradable mechatronic systems during the development process already considers future requirements. The result is a product architecture with flexible design spaces and standardized interfaces that facilitate the integration of future performance-adapted technologies. This enhances the sustainability of vehicles, extends their service life, and improves resale value, benefiting both customers and manufacturers.
Manually checking the quality of components or products in industry is labor-intensive for employees and error-prone on top of that. The Fraunhofer Institute for Mechatronic Systems Design IEM is unveiling a solution that provides total versatility in this area. In an it’s OWL supported collaboration with Diebold Nixdorf and software specialist verlinked, Fraunhofer IEM has created a combination of collaborative robot (cobot), AI-based image analysis and IoT platform. The system frees employees from having to perform visual inspections and can be incorporated into all kinds of testing scenarios. The Fraunhofer researchers presented a demonstrator of the cobot/IoT platform at the 2024 Hannover Messe Trade Show in February.
The paper deals with the status of development and qualification/certification of electromechanical actuation for Helicopters and VTOL applications with the focus on aspects relevant to the Fault-Tolerance. In particular a linear Electromechanical Actuator (EMA) architecture is presented, derived from a fault tolerant ballscrew-based differential (speed-summing arrangement) actuation system patented by UMBRAGROUP S.p.A. The focus is on safety-critical and high reliability/availability requirements for electromechanical actuation certification. The main characteristic is the use of two independent mechanical actuation channels in the same envelope driven by independent Motor Control Electronics (MCEs). At the state of the art, the presented fault-tolerant architecture is under development in flight-critical swashplate application for eVTOL platform and under feasibility study in flight-critical swashplate application for CS27 platform.
Industrial startup and mechatronic pioneer Mirmex Motor has developed a new method of manufacturing high-power density electric micromotor windings. Constructed from flexible printed circuits and developed using artificial intelligence (AI), the micromotors can be up to 50 percent more compact and 70 percent more dynamic than traditional micromotors. They have three times fewer heat losses and are assembled 10 times faster than most existing motors that use conventional windings made from copper wire.
NVH has always been an important performance parameter for Automotive requirements, both from comfort standpoint as well as regulatory perspective. Over the years, lots of refinement has happened in a vehicle in NVH field, especially in the powertrain, vehicle structure, aerodynamic and tyre side. However, the customer sensitivity and expectations have only increased and even a slight discomfort from lesser contributing sources like mechatronic systems, which are increasingly getting commoditized with the introduction of newer safety regulations, have potential to create annoyance for the customer. The objective of this work is to investigate and subsequently mitigate the noise issues emanating from a small mechatronic brake system, using experimental (objective and subjective testing) and numerical modelling approaches. The paper highlights the details, which goes into identification of systemic root causes and how design corrections (including software changes) could lead to increased comfort for the rider and meet future safety regulatory requirements, which are only going to get stringent, with more and more electric vehicles populating the market.
During the 21st century, our society has been at the forefront of discovering new solutions through advanced technology for medical device and clinical laboratory applications. These innovative solutions have utilized linear motion to develop state-of-the-art medical imaging, diagnostic, and surgical equipment. Linear motion is a common need for all types of advanced equipment and machines; but precise, smooth, reliable, and repeatable linear motion is fundamentally important for several applications within the medical industry. Precision ground ball screws have become the preferred choice for precise linear motion because they deliver smooth and accurate movement ensuring reliable and repeatable results.
The tightening of the emission legislation and political and social demands for sustainable mobility are forcing the automotive industry to develop complex, high precision mechatronic drive systems. The increasing precision of mechatronic components generally leads to an increase in structural excitation and thus to a rise in noise. The so-called ticking of the fuel injection system has a rather low sound pressure level compared to the residual engine noise. Nevertheless, the impulsive and high frequency noise character leads to a decline concerning the perception of comfort and sound quality. In order to identify the sound quality of fuel injection systems as a frontloading measure, a system test bench has been developed which represents the structure-borne and airborne sound radiation of the stand-alone injection system in a close to series configuration. In this paper, measures for the acoustic optimization of injection systems and their effects on the robustness of the system are discussed. The focus is on engine idling, since at this operating point the ticking of the injectors and high-pressure pump can be perceived most clearly due to the low masking effects of other noise sources. For this purpose, the injection parameters were measured during full engine operation and transferred to the system test bench. By using a special development control unit, it was possible to modify the parameters, quantify their influence on the acoustic behavior and, based on this, define NVH optimized control strategies. For the robustness evaluation of the NVH optimized control strategies, key functions of the injection system were analyzed under varying boundary conditions in system operation on an injection rate test bench.
Tier-1 supplier Magna evaluates its proven Puro virus-killing technology for a potentially new role: sanitizing vehicle interiors. An ozone-generating process that kills germs is being evaluated by supplier Magna for potential use in vehicle cabins, as the mobility industry seeks sustainable solutions for protecting passenger health. Magna's Puro branded product, soon to enter volume production, is a portable, plastic container that sanitizes clothing, toys, stuffed animals or other items placed inside a latched and locked bin. “Our immediate focus for our sanitizing technology is to help with the current personal protection equipment (PPE) shortage being experienced by our front-line coronavirus workers. That said, we hope to leverage this Magna technology to sanitize ride sharing vehicles and other future mobility applications,” Scott Mitchell, global director of New Technology & Innovation for Magna Mechatronics, told SAE's Autonomous Vehicle Engineering.
To polish the 2020 mid-engine Corvette's driving prowess, GM and Tremec engineers joined forces to create a new and better automated transaxle. Explaining Corvette's move to one transmission for all buyers, global chief engineer Tadge Juechter notes, “Our customers began requesting a dual-clutch automatic transmission [DCT] several years ago. Following the introduction of the C7 Corvette in 2014, our take-rate for sticks [manual gearboxes] fell from 50 percent to less than 20 percent this year.” Searching the globe - read Europe - for a suitable DCT, Juechter's team found none with sufficient torque capacity to survive behind the lively LT2 6.2-L V8 planned for the all-new 2020 mid-engine edition of GM's reimagined sports car. To solve that dilemma, discussions began with Tremec, the Mexico City-based manufacturer which has supplied GM, Ford and FCA with manual transmissions for two decades. While Tremec had the expertise to make the mechanical components packed inside a dual-clutch box, the automated half of the equation - mechatronic actuators to engage the clutches and shift the gears - was beyond their ken. Tremec filled that need in 2012 by purchasing Hoerbiger Drivetrain Mechatronics, a Belgium-based supplier of electronic dual-clutch actuators with a customer list including AMG-Mercedes, Ferrari and McLaren.
South Ural State University Chelyabinsk, Russia
With an ever-increasing number of vehicles on Indian roads, the safety and ease of driving has become a very important criterion for the customers. In passenger and commercial vehicles, while launching a vehicle on gradient or stop and go traffic in hilly region, the vehicle tends to roll back/forward in the opposite direction of the intended movement. This undesirable movement is also a safety issue, as this may cause collision with the vehicle on the rear or in front. It requires a skilled driver to coordinate between the clutch pedal, brake (also handbrake in some situations) and accelerator pedal to prevent the vehicle from rolling back while handling such situations. It also leads to clutch disc wear and heating as the driver may tend to slip the clutch to prevent the vehicle from rolling back. Hill hold is a driver assist feature which prevents the vehicle roll back/roll forward during launch operation on uphill/downhill conditions. Hill-hold is offered as an add-on feature on most vehicles equipped with Electronic Stability Program (ESP). Hill hold is achieved in ESP by applying the rear or all four brakes of the vehicle. ESP is not commonly provided in entry level vehicles due to its higher cost because of a lot of additional components and controls. Another shortcoming of the Hill-hold through ESP is that, due to its control strategy it holds the brakes only for approximately 3-5 seconds, after which the vehicle will start rolling back. At Schaeffler India, two hill hold concepts have been developed for entry level vehicles and above. These systems achieve the Hill-hold and Auto Park brake function either by purely mechanical or mechatronic means. The mechanical system consists of a transmission integrated Hill-hold system. The mechatronic system is designed for easy integration in the existing parking brake (hand brake) system with minimal modifications. The paper describes the various development phases from collecting the voice of customer, input requirements, system arrangements and architecture, design and development steps till validation and results.
As electronics make their way into the fuel system, a shift in problem solving can be seen. Previously high risk items were tackled mainly through proving component durability and decreasing the statistical odds of the problem occurring. With an electronically controlled system however it is possible and necessary to define degraded modes, in the event that certain components fail, in order to provide at least a limited functionality for the customer. This paper will discuss some different use cases, and how embedded software can be used to improve functionality over a passive system.
Manual transmissions play a dominant role in India with a market share of more than 90%. Any technology that improves their fuel consumption and their comfort for end users is highly welcome if it is affordable regarding “value for money”. Schaeffler offers a technology to meet these challenges with the concept of Electronic Clutch Management (ECM). By implementing an intelligent mechatronic clutch actuator with specific, integrated sensors directly inside the actuator, this development prepares the ground for a new era that says farewell to the clutch pedal and achieves the target of using a 2-pedal system.
In the coming half-century, the global transport industry is expected to be affected by two technological revolutions - the first will start upon admission of autonomous vehicles to public roads, while the second will finalize a complete removal of manned vehicles away from them. As a result of the above revolutionary shocks, several major changes are anticipated: the modification of whole paradigm of ground vehicles; introduction of new business models in the transport sector, as well as new vehicle ownership forms; transition to technologies of collective and cooperative management and synchronized parrying the dangerous traffic collisions. The paper defines the major goals of intelligent transport systems development for the next decade, namely: creation of highly adaptable mechatronic modules and systems, accumulation of knowledge about the variability of road situations and creation of dangerous situations scenarios; development of methods for evaluating and proving the safety of the autonomous control; and implementation of a harmonized reform of the international property and technical regulations with respect to autonomous vehicles. Proper understanding the inevitability of changes followed by foresight of the technology development and related challenges will allow not only to avoid a chain of industry crises, typical for any revolution and accompanied by losses and bankruptcies, but also to transform both revolutions to a smooth evolutionary process.
This paper presents a power assisted braking control based on a novel mechatronic booster system. A brake pedal feel control unit is first discussed which includes a pedal emulator with an angular sensor to detect driver’s pedal travel, a signal processing module with a Kalman filter for sensor signal conditioning, and a driver braking intention detection and behavior recognition module based on the displacement and velocity of the pedal travel. A power assisted braking control is then presented as the core of the system which consists of controls on basic power assist, velocity compensation and friction compensation. The friction is estimated based on a generic algorithm offline. A motor controller is designed to provide the desired torque for the power assist. Finally, a novel mechatronic booster system is designed and built with an experimental platform set up with a widely adopted rapid prototype system using dSPACE products, such as MicroAutoBox, RapidPro, etc. Extensive experiments have been conducted which demonstrate the validity and effectiveness of the proposed control for the power assisted braking system.
Nowadays, the vehicle market puts forward urgent requirement for new kinds of braking booster because the traditional vacuum booster cannot meet the demands of new energy vehicles anymore. However, one problem that all the new plans should face is how to guarantee an ideal pedal feeling. In this paper, a novel mechatronics braking booster is proposed, and servo motor introduced into the booster makes the assist rate can be adjusted under a great degrees of freedom, so the structural parameters and control parameters of the booster should be determined elaborately to get an optimal pedal feeling. The pedal feeling is always represented by the pedal stoke-force curve which is influenced by different parameters. In this paper, the pedal stoke-force curve is firstly studied by batch simulation using AMESim, different structural and control parameters, such as the parameters of the decelerating devices, the stiffness coefficient of the return spring, the assist rate of the booster, are investigated. Results show that structural parameters influence the pedal feeling in a rigid way, such as, the lead angle of the screwing gearing can cause self-locking if not chose well, resulting in bad pedal feeling and cause security problems; yet control parameters can influence the pedal feeling flexibly, so we can adjust the assist rate to get a good pedal feeling under different conditions. Finally, the bench test is carried out under different operating conditions whose results show that the booster has an ideal pedal force-stroke curve just similar with traditional vehicle. The method that verified in this paper can be used to eliminate the time-consuming calibration work, providing a theoretical basis for the design of new braking boosters.
Current vehicles, especially the electric ones, are complex mechatronic devices. The pickup vehicles of small sizes are currently used in transport considerably. They often operate within a repeating scheme of a limited variety of tracks and larger fleets. Thanks to mechatronic design of vehicles and their components and availability of high capacity data connection with computational centers (clouds), there are many means to optimize their performance, both by planning prior the trip and recalculations during the route. Although many aspects of this opportunity were already addressed, the paper shows an approach developed to further increase the range of e-vehicle operation. It is based on prior information about the route profile, traffic density, road conditions, past behaviour, mathematical models of the route, vehicle and dynamic optimization. The most important part of the procedure is performed in the cloud, using both computational power and rich information resources. Suitable route discretization into sections is most important part of the algorithm. The various information resources are used. Accumulated experience coming from fleet operation is very important as well. Methods for automation of this procedure are presented. Subsequently, feasible initial values of section parameters are found using heuristic rules devised from good driver’s practice and backward calculation based on dynamic programming principals. Designed velocity profile is further optimized based on simplified, but very fast energy consumption models, verified and fine-tuned on detailed simulation model of the vehicle. The velocity profile is updated when requested and finally loaded into on-board control unit. Model based predictive controller is used to keep the vehicle with its driver efficiently on defined track. The proposed strategy is verified in simulation environment and prepared to be implemented on test vehicle and cloud system.
An electro-hydraulic servo system makes the basis for a mechatronic locomotion module (LM) and for a complex comprising an LM and an undercarriage of a vehicle. The servo system of the wheel module/LM complex is a combination of the information and power channels of the electro-hydraulic wheel drive within the steering system. A combination of the servo systems makes up a complex of servo systems of the steering system of the multi axis wheel mover of the vehicle. Theoretical and experimental studies of the functioning all-wheel steering were aimed on substantiation the rational algorithmic maintenance of the automatic control system. The results of the study allowed formulating the basic principles of designing and calculating the functionality algorithms for the steering system of the complex of mechatronic modules of the multi-axis vehicle. A comparative analysis and evaluation of the impact of different algorithms of the control system on the parameters of turning of the vehicle with all steered wheels are presented. The paper contains an analytical description of these algorithms.
Despite the increasing application of automated systems, manual tasks still plays an important role in industrial production. The intelligence and flexibility of human enable quick response and adaptive production for the individual requirements and the changes in market. Moreover, some manufacturing tasks with sensible and high-value components (e.g., in electronic and aircraft production) requires attentive manual handling. Regarding the requirement of increasing productivity as well as ergonomic improvement and the aging of the employees, there is a significant need for technologies which support the staff individually by performing tasks. Human Hybrid Robot, a hybrid system with direct coupling (serial and/or parallel) of human and mechatronic elements, is a new trend in application of robotic technologies for supporting manual tasks. It realizes a synchronous and bidirectional interaction between human and mechatronic and/or mechanic elements in the same workspace. This paper will discuss the challenges to realize the concept of Human Hybrid Robot for industrial application. According to the challenges we will give an overview of relevant technologies. Finally, it will concludes with the economic implications of such systems as well as an outlook on future research.
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