Survey on mechatronic engineering: A focus on design methods and product models

According to the principles of concurrent engineering and integrated design, engineers intend to develop a mechatronic system with a high level integration (functional and physical integrations) based on a well-organised design method. As a result, two main categories of issues have been pointed out: the process-based problems and the design data-related problems. Several approaches to overcome these issues have been put forward. To solve process-based problems, a dynamic perspective is generally used to present how collaboration can be improved during the mechatronic design. For design data-related problems, solutions generally come from product models and how to structure and store the data thanks to the functionality of data and documents management of Product Lifecycle Management systems. To be able to assess design methods and product models, some criteria are proposed in the paper and used to evaluate their added value on integrated design of mechatronic system. After this assessment, main outcomes which focus on the combination of design method and product model for improving the design of mechatronic system are finally discussed.     

A SysML-based methodology for mechatronic systems architectural design

Mechatronic systems are characterized by the synergic interaction between their components from different technological domains. These interactions enable the system to achieve more functionalities than the sum of the functionalities of its components considered independently. Traditional design approaches are no longer adequate and there is a need for new synergic and multidisciplinary design approaches with close cooperation between specialists from different disciplines.SysML is a general purpose multi-view language for systems modeling and is identified as a support to this work.In this paper, a SysML-based methodology is proposed. This methodology consists of two phases: a black box analysis with an external point of view that provides a comprehensive and consistent set requirements, and a white box analysis that progressively leads to the internal architecture and behavior of the system.     

Category theory-based collaborative design methodology for mechatronic systems

Recent advances in companies are characterized by highly dynamic, knowledge-intensive and collaborative process. This has become primary concern for mechatronic systems since they involve multiple disciplines and knowledge. This requires a close exchange in order to share knowledge between the different design teams. The first step in knowledge sharing is to identify the most important knowledge that need to be capitalized, which we call “crucial knowledge”. During this exchange, heterogeneous knowledge and modelling languages are involved in the design process, which can lead to conflicts. Hence, the challenge is to continuously capture and handle such conflicts between expert models. Thus, the focus of this paper is to propose a new collaborative design model suitable for mechatronic concurrent design. Our contribution lies in identifying crucial knowledge and resolving conflicts in a formal way in order to ensure efficient collaboration. Our methodology called Category Theory-based Collaborative Design (CaTCoD) is described with its associated meta-model. A demonstrator is also used to validate the proposed methodology using an example from the aeronautic field.     

A multi-agent methodology for multi-level modeling of mechatronic systems

Mechatronic design aims to integrate the models developed during the mechatronic design process, in order to be able to optimize the overall mechatronic system performance. A lot of work has been done in the last few years by researchers and software developers to achieve this objective. However, the level of integration does not yet meet the purposes of mechatronic system designers, particularly when dealing with modeling changes. Therefore, new methodologies are required to manage the multi-view complexity of mechatronic design. In this paper, we propose a multi-agent methodology for the multi-abstraction modeling issue of mechatronic systems. The major contribution deals with proposing a new method for the decomposition of the multi-level design into agents linked with relationships. Each agent is representing an abstraction level and both agent and relationships are managed with rules. By considering an application to a piezoelectric energy harvesting system, we show how we associate agents, rules and inter-level relationships to multi-abstraction modeling. We also show how modeling errors are identified using this approach.     

Perspectives on hierarchical modeling in mechatronic design

Hierarchical modeling helps to describe product models and data from different viewpoints that, representing the different disciplines involved in the design process of mechatronic systems. This paper gives an overview of hierarchical modeling techniques. This includes the investigation of systems, which requires handling different issues that address very specific views of the system (system aspects) and come from various disciplines. Also the model granularity which describes the extent to which an object or model is broken down into smaller elements it an important aspect. The different phases of the product life cycle require models with different objectives and levels of detail. Some models are needed mainly in specific phases of the product life cycle, which are discussed in detail in the paper. Especially in the conceptual design phase some design-characteristic aspects such as hierarchy of parameters, modularity of the design should be analyzed, because in this phase the largest part of the later resulting product costs is predetermined or even fixed. As a consequence, the scope for design is limited to merely small changes in the subsequent design phases. Therefore the interaction between the design phases and the related models plays an important role the development process of mechatronic systems.     

Tool support for the design of self-optimizing mechatronic multi-agent systems

Complex technical systems, such as mechatronic systems, can exploit networking as well as the computational power available today to achieve an automatic improvement of the technical system performance at run-time through self-optimization. To realize this vision, appropriate means for the design of such self-optimizing mechatronic systems are required. Well-established techniques and tools for the modeling of cognitive behavior, reflective behavior, and control behavior exist. However, to really enable self-optimization and its full potential, these different aspects have to be safely integrated in a manner that remains comprehensible to the designer. In this article, we present how this required integration has been realized at the semantic level by extending the unified modeling language (UML), and at the tool level by integrating the CAE tool CAMeL and the CASE tool Fujaba real-time tool suite. The presented Mechatronic UML approach supports the design of verifiable, complex, reconfigurable mechatronic systems using the multi-agent system metaphor. This work was developed in the course of the Special Research Initiative 614—self-optimizing concepts and structures in mechanical engineering—University of Paderborn, and was published on its behalf and funded by the Deutsche Forschungsgemeinschaft. Sven Burmester, Oliver Oberschelp, Florian Klein and Peter Scheideler are members of the respective research group which left after the paper was submitted.     

Parametric reconfiguration improvement in non-iterative concurrent mechatronic design using an evolutionary-based approach

Parametric reconfiguration plays a key role in non-iterative concurrent design of mechatronic systems. This is because it allows the designer to select, among different competitive solutions, the most suitable without sacrificing sub-optimal characteristics. This paper presents a method based on an evolutionary algorithm to improve the parametric reconfiguration feature in the optimal design of a continuously variable transmission and a five-bar parallel robot. The approach considers a solution-diversity mechanism coupled with a memory of those sub-optimal solutions found during the process. Furthermore, a constraint-handling mechanism is added to bias the search to the feasible region of the search space. Differential Evolution is utilized as the search algorithm. The results obtained in a set of five experiments performed per each mechatronic system show the effectiveness of the proposed approach.     

An integrated approach for simulation of mechatronic systems applied to a hexapod robot

Mechatronics is the integration of mechanism, electronics and computer control to produce a functional system. The design process involves application of many engineering areas and various approaches are possible. Computer programs are available in different engineering areas. Engineers define systems and inputs, and user-friendly programs establish mathematical models, solve them and give simulation outputs. In this study, SolidWorks is used for solid modeling and assembly, CosmosMotion is used for rigid body dynamics, CosmosWorks is used for finite element vibration and strength analyses, and Adlink module is used for actuator control. The integration of the design process is achieved with a main program developed in Visual Basic, which uses the application programming interface (API) capabilities. The procedure is applied to a hexapod robot. The robot has been produced to develop and test the procedure. CosmosMotion results are verified by the analytical results obtained from the dynamic equations of the hexapod. Besides known kinematic workspace definition of robots, kinetic and rigidity workspace concepts are introduced. Mechatronic systems can be designed and evaluated easily and effectively by using the design process developed in this work.     

A knowledge-based master model approach exemplified with jet engine structural design

Successful product development requires the consideration of multiple engineering disciplines and the quantification of tradeoffs among conflicting objectives from the very early design phases. The single-largest challenge to do so is the lack of detailed design information. A possible remedy of this issue is knowledge-based engineering. This paper presents a knowledge-based master model approach that enables the management of concurrent design and analysis models within different engineering disciplines in relation to the same governing product definition. The approach is exemplified on an early phase structural design of a turbo-fan jet engine. The model allows geometric-, structural mechanics- and rotor-dynamic- models to be concurrently integrated into a multi-disciplinary design and optimization loop.     

Optimal design of reconfigurable parallel machining systems

A reconfigurable machining system is usually a modularized system, and its configuration design concerns the selections of modules and the determination of geometric dimensions in some specific modules. All of its design perspectives from kinematics, dynamics, and control have to be taken into considerations simultaneously, and a multidisciplinary design optimization (MDO) tool is required to support the configuration design process. This paper presents a new MDO tool for reconfigurable machining systems, and it includes the following works: (i) the literatures on the computer-aided design of reconfigurable parallel machining systems have been reviewed with a conclusion that the multidisciplinary design optimization is essential, but no comprehensive design tool is available to reconfigurable parallel machining systems; (ii) a class of reconfigurable systems called reconfigurable tripod-based machining system has been introduced, its reconfiguration problem is identified, and the corresponding design criteria have been discussed; (iii) design analysis in all of the disciplines including kinematics, dynamics, and control have been taken into considerations, and design models have been developed to evaluate various design candidates; in particular, the innovative solutions to direct kinematics, stiffness analysis for the design configurations of tripod-based machines with a passive leg, and concise dynamic modelling have been provided; and (iv) A design optimization approach is proposed to determine the best solution from all possible configurations. Based on the works presented in this paper, a computer-aided design and control tool have been implemented to support the system reconfiguration design and control processes. Some issues relevant to the practical implementation have also been discussed.     

To support multidisciplinary communication in VR-based virtual prototyping of mechatronic systems

A typical mechatronic product includes mechanical parts, software techniques, electrical and electronic components. This interdisciplinary character significantly increases the complexity of mechatronic products. Therefore, inefficient communication between the engineers, who come from different domains, becomes one of the main challenges in the development of mechatronic systems. Although, innovations in the field of virtual prototyping can help the engineers to handle a complex system and then accelerate the development processes, the technique itself does not offer a solution to the problem of multidisciplinary communications. In this paper, we present a practical solution of supporting knowledge sharing and communication within a multidisciplinary developing group, whose members need to work cooperatively for doing virtual prototyping of mechatronic systems in VR environment.     

Design and implementation of an agent-based collaborative product design system

The evolution of computer science and technology has brought new opportunities for multidisciplinary designers and engineers to collaborate with each other in a concurrent and coordinated manner. The development of computational agents with unified data structures and software protocols contributes to the establishment of a new way of working in collaborative design, which is increasingly becoming an international practice. In this paper, based on the analysis of the dynamic nature of collaborative design process, a new framework for collaborative design is described. This framework adopts an agent-based approach and relocates designers, managers, systems, and the supporting agents in a unified knowledge representation scheme for product design. In order to model the constantly evolving design process and the rationales resulted from design collaboration, a Collaborative Product Data Model (CPDM) and a constraint-based Collaborative Design Process Model (CDPM) are proposed to facilitate the management and coordination of the collaborative design process as well as design knowledge management. A prototype system of the proposed framework is implemented and its feasibility is evaluated using a real design scenario whose objective is designing a set of dining table and chairs.     

A web services-based multidisciplinary design optimization framework for complex engineering systems with uncertainties

With the increased complexity of complex engineering systems (CES), more and more disciplines, coupled relationships, work processes, design data, design knowledge and uncertainties are involved. Currently, the MDO is facing unprecedented challenges especially in dealing with the CES by different specialists dispersed geographically on heterogeneous platforms with different analysis tools. The product design data integration and data sharing among the participants and the workflow optimization hamper the development and applications of MDO in enterprises seriously. Therefore, a multi-hierarchical integrated product design data model (MiPDM) supporting the MDO in web environment and a web services-based MDO framework considering aleatory and epistemic uncertainties are proposed in this paper. With the enabling technologies including web services, ontology, workflow, agent, XML, and evidence theory, the proposed framework enables the designers geographically dispersed to work collaboratively in the MDO environment. The ontology-based workflow enables the logical reasoning of MDO to be processed dynamically. Finally, a proof-of-concept prototype system is developed based on Java 2 Platform Enterprise Edition (J2EE) and an example of supersonic business jet is demonstrated to verify the web services-based MDO framework.     

Multidisciplinary design optimization on vehicle tailor rolled blank design

Tailor rolled blank (TRB) is an emerging steel rolling process to produce lightweight vehicle components. It allows continuous metal thickness changes, and as a result, it offers opportunities for automotive design in weight reduction, part complexity reduction, reduced capital investment, yet, maintains equal to or better strength characteristics. The objective of this research is to take advantages of the TRB manufacturing technology and combine with the advanced multidisciplinary design optimization (MDO) methodology to optimize vehicle structure. The process begins with noise vibration and harshness (NVH) optimization. The outputs of the optimal NVH response sensitivities are employed to build the first order response surface models. Uniform Latin Hypercube sampling and subset selection regression methods are used to construct the response surface models for the highly nonlinear impact and seatbelt pull responses. The optimal NVH design is then used as the starting point for MDO to obtain the optimal thickness profiles for the TRB parts. A vehicle application considering multiple impact modes, seatbelt pulls, and NVH, is used to demonstrate the proposed process for vehicle underbody TRB design. Results of this MDO TRB study is presented and discussed.     

Integrative development of product and production system for mechatronic products

The increasing penetration of mechanical engineering by information technology enables considerable benefits. The arising new discipline is referred to by the term mechatronics, which expresses the close integration of mechanics, electrics/electronics, control engineering and software engineering. Hence, the design and production of such systems is an interdisciplinary and complex task. An effective and continuous cooperation and communication between developers from different domains during the whole development process is required. Moreover, the multidisciplinary and synergetic effectiveness of mechatronic systems as well as new production technologies cause strong interdependencies between system parts, which are to be produced. As a consequence, the production system determines the product concept. Restrictions by manufacturing technologies have to be considered already during the early stages of the product development. This contribution deals with the stated problem by providing both, a generic procedure model and a specification technique for the integrative development of mechatronic products and their production systems.     

Socio-technical systems: From design methods to systems engineering

It is widely acknowledged that adopting a socio-technical approach to system development leads to systems that are more acceptable to end users and deliver better value to stakeholders. Despite this, such approaches are not widely practised. We analyse the reasons for this, highlighting some of the problems with the better known socio-technical design methods. Based on this analysis we propose a new pragmatic framework for socio-technical systems engineering (STSE) which builds on the (largely independent) research of groups investigating work design, information systems, computer-supported cooperative work, and cognitive systems engineering. STSE bridges the traditional gap between organisational change and system development using two main types of activity: sensitisation and awareness; and constructive engagement. From the framework, we identify an initial set of interdisciplinary research problems that address how to apply socio-technical approaches in a cost-effective way, and how to facilitate the integration of STSE with existing systems and software engineering approaches.     

战争设计工程专家群体研讨模型*

针对战争设计工程中专家群体研讨问题,根据研讨的主题以及目标,将专家群体研讨划分为三类:寻求信息研讨、质询研讨和商议研讨。在研讨类型划分的基础上,建立了战争设计工程群体专家研讨模型。该模型主要用于对战争设计工程中专家群体研讨过程建模,有利于专家对研讨进程的了解。最后阐述了该模型在战争设计工程中的应用。     

Reverse innovative design — an integrated product design methodology

Today’s product designer is being asked to develop high quality, innovative products at an ever increasing pace. To meet this need, an intensive search is underway for advanced design methodologies that facilitate the acquisition of design knowledge and creative ideas for later reuse. Additionally, designers are embracing a wide range of 3D digital design applications, such as 3D digitization, 3D CAD and CAID, reverse engineering (RE), CAE analysis and rapid prototyping (RP). In this paper, we propose a reverse engineering innovative design methodology called Reverse Innovative Design (RID). The RID methodology facilitates design and knowledge reuse by leveraging 3D digital design applications. The core of our RID methodology is the definition and construction of feature-based parametric solid models from scanned data. The solid model is constructed with feature data to allow for design modification and iteration. Such a construction is well suited for downstream analysis and rapid prototyping. In this paper, we will review the commercial availability and technological developments of some relevant 3D digital design applications. We will then introduce three RE modelling strategies: an autosurfacing strategy for organic shapes; a solid modelling strategy with feature recognition and surface fitting for analytical models; and a curve-based modelling strategy for accurate reverse modelling. Freeform shapes are appearing with more frequency in product development. Since their “natural” parameters are hard to define and extract, we propose construction of a feature skeleton based upon industrial or regional standards or by user interaction. Global and local product definition parameters are then linked to the feature skeleton. Design modification is performed by solving a constrained optimization problem. A RID platform has been developed and the main RE strategies and core algorithms have been integrated into SolidWorks as an add-in product called ScanTo3D. We will use this system to demonstrate our RID methodology on a collection of innovative consumer product design examples.     

Sequential optimization and reliability assessment for multidisciplinary systems design

With higher reliability and safety requirements, reliability-based design has been increasingly applied in multidisciplinary design optimization (MDO). A direct integration of reliability-based design and MDO may present tremendous implementation and numerical difficulties. In this work, a methodology of sequential optimization and reliability assessment for MDO is proposed to improve the efficiency of reliability-based MDO. The central idea is to decouple the reliability analysis from MDO with sequential cycles of reliability analysis and deterministic MDO. The reliability analysis is based on the first-order reliability method (FORM). In the proposed method, the reliability analysis and the deterministic MDO use two MDO strategies, the multidisciplinary feasible approach and the individual disciplinary feasible approach. The effectiveness of the proposed method is illustrated with two example problems.