2006 ASEE New England Section Conference
Mechatronics
in
University and Professional Education
Prof. Kevin Craig
Rensselaer Polytechnic Institute
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
1
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 ?
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
2
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 multidisciplinary, systems approach to
engineering analysis and design is absolutely
essential ?
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
3
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
4
Industrial Interaction
M.S. and Ph.D. Research, Training Practicing Engineers, Consulting
Shapes
Engineering Curriculum
Freshman Year
To
Senior Year
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
5
Current Situation
• Electronics, Microcontrollers, Precision Sensors
& Actuators Are Everywhere!
• With the explosively increasing cost/sizeeffectiveness of computers, mechatronic
systems are becoming common in any
engineering discipline dealing with the
modulation of physical power.
• In mechatronic systems, computing is central.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
6
• 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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
7
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
8
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
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
9
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
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
10
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 !
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
11
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!
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
12
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
13
• 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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
14
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
15
• 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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
16
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
17
• 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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
18
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!
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
19
Engineering System Investigation Process
START HERE
Physical
System
Engineering
System
Investigation
Process
The cornerstone of
modern engineering
practice
System
Measurement
Parameter
Identification
Physical
Model
Mathematical
Model
Measurement
Analysis
Mathematical
Analysis
Comparison:
Predicted vs.
Measured
YES
Design
Changes
Is The
Comparison
Adequate ?
NO
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
20
Modeling:
Physical 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?
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
21
Mechatronic System Elements
(all energetically isolated)
Other Components
Communications
Operator Interface
Human Factors
Real-time
software is
at the heart!
Computation
Software, Electronics
At The Center!
Actuation
Power Modulation
Energy Conversion
Controlling Power
Delivery
Instrumentation
Energy Conversion
Signal Processing
Target System
Mechanical, Fluid,
Thermal, Chemical,
Electrical
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
What’s Happening
What All The Fuss
Is About!
K. Craig
March 18, 2006
22
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
23
• 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
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
Plant Dynamics
&
Control Structure
K. Craig
March 18, 2006
24
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
one’s engineering skills but as an obstacle to avoid.
• Few engineers can balance the modeling / analysis /
control design and hardware implementation
essential for success.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
25
Engineering
Problem
Systematic, Structured
Approach to Design
Electronics
Sensors
Controls
Computers
Integrated
Design
Concept
Actuators
Mechanical
Build
&
Test
Model,
Analyze &
Predict
YES!
NO!
Cost-Effective, High-Quality,
Timely, Robust Design
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
?
26
Professional Engineering Workshops:
Has 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)
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
Procter & Gamble (4)
Dana (2)
U.S. Army ARDEC
Plug Power Fuel Cells
K. Craig
March 18, 2006
27
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.
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
28
Stepper Motor System
Design:
Ink-Jet Printer
Application
Stepper Motor Open-Loop
and Closed-Loop Control
Experimental System
Engineering Application
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
29
Pneumatic System ClosedLoop Position Control
Brushed DC Motor Position
and Speed Control with
Magneto-Rheological Fluid
Rotary Brake/Damper
System
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
30
Vbias
Vcommand
+ 
-
+
Controller
+

Vsensor
Magnetic
Levitation
System
Current
Amplifier
i
Magnet +
Ball
X
Sensor
Electromagnet
Phototransistor
Infrared LED
Levitated Ball
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
31
– 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
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
32
Mechatronic
System Design
Ball-on-Plate
Balancing System
Rotary Inverted Pendulum System
Arm-on-Arm
Inverted Pendulum
System
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
33
Foundations of Engineering
Engineering System Investigation Process
START HERE
Physical
System
System
Measurement
Parameter
Identification
Physical
Model
Mathematical
Model
Measurement
Analysis
Mathematical
Analysis
Comparison:
Predicted vs.
Measured
YES
Design
Changes
Is The
Comparison
Adequate ?
NO
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
34
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
35
Steel Cantilever Beam
Cantilever Beam
Mechanical
System
Eddy-Current
Accelerometer Damper
Vibration Exciter
Strain Gage
MEMS Accelerometer
Hard-Drive Read-Write Head
Mechatronics in University & Professional Education
2006 ASEE NE Section Conference
K. Craig
March 18, 2006
36