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National Instruments Confidential

Introduction to Mechatronics

Marco Castellano

Field Sales EngineerSouth Italy

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The Evolution of Machines

Mechanical SystemGears, cams, and limi t switches Electromechanical SystemElectronic controls,

motor drives

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Modern Machine Bui lders Diverse Requirements

MechanicalDesign

Discrete and Sequential Logic

Motion Control Design

Logging , Database

HMI

Networking

Machine ConditionMonitoring

Machine VisionMotors and

Actuators

Sensors and SignalConditioning

Modern

Machine

Embedded System

Design

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Trends to Reduce Development Time

Sequential Design Concurrent Design

Physical

First Prototype

Virtual

First Prototype

Separate Design

Tools

Integrated Design Tools

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Traditional Approach to

Electromechanical Machine Design

Poor communication between design groups

Long development time with high riskPoorly optimized design

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Mechatronics

Mechatronics is a holistic approach to designing

machines that combines mechanical, electrical, control

and embedded software

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Mechatronics Approach to

Electromechanical Machine Design

Shorter, lower cost development cycles Improved quality, reliability, and performance

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Mechanical

Design

Electrical

Design

VirtualPrototype

(Simulation)

1. Design Tool Integration

Embedded

Design

Control

Design

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Level of Design Tool Integration

Ultimate One design tool for all disciplines

Manual Manually pass data between tools

Basic Data transferred via standard file formats Motion profile data as CSV file to CAD

Advanced Complete tool automation

NI LabVIEW automating SolidWorks through ActiveX

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Open Connectivity to Design Tools

MATLAB and Simulink are registered trademarks of The MathWorks, Inc.

Mechanical DesignSolidWorksSolidWorks

PTCPro/EngineerMSCNastran andAdams

AutodeskAutoCAD

MathematicsNI LabVIEW Math

The MathWorks, Inc. MATLAB

MaplesoftMaple

MathSoftMathcad

Control DesignNI LabVIEW Control Design

The MathWorks, Inc. Simulink

DynasimDymola

PleximPLECS

Embedded SoftwareNI LabVIEW Real-Time/Embedded

Wind RiverWorkbenchAnalog Devices VisualDSP++

FreescaleCode Warrior

XilinxSystem Generator

Electrical DesignNI LabVIEW (Motor Sizing)

NI Multisim

ORCADPSpice

AnsoftDesigner

Virtual

Prototyping

Platform

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LabVIEW: Virtual Prototyping Platform

Intuitive graphical tools fordomain experts

Built-in control design and

simulation

Design tool integration Flexible, open architecture

Ability to target multiple

industrial hardware platforms

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Virtual Machine Prototyping

Conceptual

Design

Design

Requirements

Virtual Machine

Prototype

(Simulation)

Mechanical: Design visualization

Electrical: Motor sizing

Control: Verify control logic

Embedded Software: Easy implementation

TeamCustomer

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Challenge: Understanding the requirements

Solution: Electromechanical simulation

Benefits:

Improved customer communication Confidence builder: showing proof of concept Competitive advantage in the bidding process

Improved design team communication

Refining design specifications

Evaluating high-level architectural design

Mechanical Design Challenges

Use control logic to visualize the working machine.

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Electromechanical Simulation Steps

1. Determine machine logic

2. Generate profile data with virtual prototyping software

3. Send to 3D design tool

4. Use CAD tool to animate machine functionality

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Software Tools SolidWorks Professional

COSMOSMotion

LabVIEW Professional

Free SolidWorks/LabVIEW ActiveX Interface VIs

NI Motion Assistant

SolidWorks LabVIEW

Interface Functio ns

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Mechanical

Design

Electrical

Design Virtual

Prototype(Simulation)

System

Specification Manufacturing

Test System

Design

Manu-

facturing

Support

and

Service

Sustaining

Engineering

Physical

Prototype

Electrical Design

Embedded

Design

Control

Design

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Challenge: Specifying correct motor size

Solution: Virtual motor sizing

Benefits:

Apply motor sizing principles interactively

Virtually test various motors

Electrical Design Challenges

Type (AC/DC, brushed, and so on)

Torque versus speed requirements

Heat dissipation

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Virtual DC Motor Sizing

+

-

+

-

+

-

R Li

dt

dKv

ee

=

dt

diLv

L =

iRvR=

mv

DO5

+

-

+

-Vsup

id

1. Acquire motor specifications from data sheet

2. Simulate motor response to velocity and torque profile

from CAD

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Mechanical

Design

Electrical

Design Virtual

Prototype(Simulation)

System

Specification ManufacturingTest System

Design

Manu-

facturing

Support

and

Service

Sustaining

Engineering

Physical

Prototype

Control Design

Embedded

Design

Control

Design

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Challenges:

Software development in critical path

Physical prototype needed to test control algorithm

Solution: Develop and test control algorithm on virtual model

Benefits:

Control Design Challenges

Get head start on control development

Refine control strategy before physical prototyping

Detect interferences and resonance

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Integrating Control and Mechanical

Design

Command

Control Software Simulation

1. Develop machine control logic

2. Animate model and identify potential issues

Feedback

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1. Motion Profile

2. Interference Detection

Demo: Interference Detection

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Mechanical

Design

Control

Design Virtual

Prototype(Simulation)

System

Specification ManufacturingTest System

Design

Manu-

facturing

Support

and

Service

Sustaining

Engineering

Physical

Prototype

Embedded Software Design

Embedded

Design

Electrical

Design

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Challenge: Implementing embedded algorithms

Solution: Using control design software that runs

natively on embedded hardware

Benefits: Reduced development time and cost

Less chance for translation errors

Embedded Software Design

Challenges

Rewriting code for hardware platform

Flexibility to implement advanced algorithms

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Algorithm Engineering

Design

Software Hand Code

Prototype

Hardware

Verify

Algorithm

Its the term used to describe this process of designing a control

algorithm and taking it to a prototyping hardware for physicaltesting and final deployment.

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Algorithm Engineering

DesignSoftware

PrototypeHardware

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Challenge: Choosing the right prototyping platform

Solution: Using packaged FPGA-based PAC

hardware platform

Benefits:

Prototyping and Deployment Challenges

Reliably run custom control algorithms

Integrate any I/O including machine condition monitoring and

vision

Protect IP (Intellectual Property)

Controller speed and memory

I/O from specialty signals Ability to implement advanced control

algorithms

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Deployment Hardware

Desktop PCs

Industrial PCs

Programmable automation

controllers (PACs) Programmable logic

controllers (PLCs)

Custom boards

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Programmable Automation Controller (PAC)

Ruggedness and reliability of PLC

Software capabilities of PC

Modular and diverse I/O

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Custom

PLCSBC

FPGA-Based Programmable

Automation Control ler

NI CompactRIO

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Integral part of all mechatronics systems

Improves machine productivity

NI PACs for motion control:

PCI and CompactPCI/PXI

Custom motion control with FPGA

Distributed motion over CANopen

Additional Design Considerations:

High-Performance Motion Control

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New for NI Motion

Two new stepper drives 1-axis, DC-powered: 300 W

1-axis, AC-powered: 525 W

Range of 30 new stepper motors NEMA 17, 23 and 34 sizes

Torque up to 1710 oz-in

Motor sizing software

ni.com/motion/stepper

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Why use machine vision? Increase product throughput

Reduce product inspection cost

Use infrared, X-ray

Applications Manufacturing

Product testing

Product packaging

Robot guidance

Additional Design Considerations:

Machine Vision

Addi i l D i C id i

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Additional Design Considerations:

Machine Condition Monitoring

DataAcquisition

DataAnalysis

Diagnosis andControl

Motor

Gear

Health

Alignment

Unbalance

MechanicalResonances

Loose

Mounting

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Conclusion

Mechatronics concurrent development:

Reduces development time and risk

Requires design tool integration

NI offers an easy path to deploy mechatronics

systems