Interdisciplinary design methodology for systems of mechatronic systems focus on highly dynamic environmental applications

This paper discusses a series of research challenges in the design of systems of mechatronic systems. A focus is given to environmental mechatronic applications within the chain “Renewable energy production - Smart grids - Electric vehicles”. For the considered mechatronic systems, the main design targets are formulated, the relations to state and parameter estimation, disturbance observation and rejection as well as control algorithms are highlighted. Finally, the study introduces an interdisciplinary design approach based on the intersectoral transfer of knowledge and collaborative experimental activities

Health monitoring of feedback controlled mechatronic systems

Health monitoring is essential in guaranteeing the safe, efficient, and correct operation of complex engineering systems. This PhD thesis presents a simulation of a non-linear, experimental-based model of a coupled tank apparatus CE105 under LabVIEW environment. The consideration of a traditional simple tank system is extended via the inclusion of non-linear elements. The simulation is used to accelerate the timescales of the monitoring and controller signals for nominal and faulty behaviour for several operating scenarios. In this study, a detailed simulation with several sources of fault was produced and run with the variety of operating scenarios to study the nominal and faulty behaviour of such mechatronic system. It is concluded that the liquid level will not be affected by fault nature and intensity in the presence of PID controller that covers hidden faults until its signal reaches a certain threshold. Hence, the end of useful life can be predicted by tracking the PID signal at any stage of the operating scenario. Technology advances have impacted upon monitoring, diagnostics and prognostics activities for increasingly sophisticated industrial systems and their operations. In particular, for integrated mechatronic systems, the facility provided by dynamic simulation models in presence of deteriorating faults has been investigated. For informed data-driven prognostic extrapolations, the long-term, time-varying operational profile of the mechatronic system requires recording and analysis. The contribution reported in this study relates to the simulation and experimentally validated, of a CE105 coupled-tank liquid level control system and three individual-thank liquid level system. A Sign Chart Algorithm (SCA) was developed and utilised as a novel controller-based health monitored (CBHM) system. Moreover, from the SCA and the PID signal trend, the remaining useful life of the system has been estimated. Results are reported and discussed for leakage or blockage and pump performance deterioration faults

Organizational Patterns for Multidisciplinary Development of Mechatronic Systems

The concurrent development of a mechatronic system by a multidisciplinary team requires an intense collaboration between disciplines (e.g. software, mechanics, and electronics). This way of working can encounter problems with: the collaboration and dependencies between disciplines and the integration of deliverables. These problems can lead to system integration issues and project delays. This problem statement leads to the following research question: 'Is it possible to formulate organizational patterns that can be used for the development and integration of a mechatronic system in a multidisciplinary environment developed concurrently?' The results of this research are new organizational patterns that provide practical solutions to counter these problems. It is the first time that these solutions are formalized and presented as an organizational pattern and integrated into the organizational pattern language of (Coplien & Harrison, 2005). This result can benefit a multidisciplinary team that develops a mechatronic system concurrently. It will make them aware of: a solution to their problem, when to apply it, the forces and trade-offs of the solution, and how the solution can be implemented. These patterns will empower a multidisciplinary team to approach the stated problems

Design of a mechatronic measurement system for surface fatigue of dental composites

PhD ThesisThis thesis focuses on the design and development of a rolling-ball mechatronic system for on-line testing and measurement of surface contact fatigue of dental composites, and is based on a technique initially developed at the Newcastle Dental School. The mechatronic system synergistically combines the mechanical/electronic hardware with a low-cost embedded digital signal controller (DSC microcontroller) hardware and software to monitor and measure in real-time surface wear due to contact fatigue. ISO/TS 14569-2.2001 standard specification for testing of dental materials was used for selecting appropriate test variables. The mechatronic system attempts to simulate the human oral environment with temperature and moisture being controlled. A closed-loop PI control algorithm combining both optical encoder pulse timing and counting methods is used to drive a dc brushless motor at speeds of 240 and 2040 rpm. A small (2mm diameter) ruby ball is mounted in a V-grooved mandrel which over time creates a circular orbital wear path in the dental composite material. One algorithm has been designed to acquire and process the on-line measurement of wear using a linear voltage differential transformer (LVDT), with another monitoring the fatigue cycling process. A graphical user interface (GUI) has also been designed and implemented on a laptop which is connected to the rig embedded controller. A kinematic model of the rolling ball constrained in a V-groove has been developed along with a finite element analysis of the surface deformation. This has been augmented by a comprehensive test programme, in dry, moisturized and elevated temperature (i.e. 37°C), using Synergy D6 specimens. Using ANOVA test, 70% reproducibility of fatigue track measurements was attained. A comparison of LVDT transducer and profilometer measurements indicated 5% consistence with each other. The insight gained from the testing programme sets a basis for an extensive programme to qualify and validate the measurement system basing on ISO/TS 14569-2.2001 specifications.The Tanzania Government: The University of Dar es Salaam