31-07-2023

GENERALIZED
MECHATRONICS DESIGN
PROCESS:
Generalized Mechatronics Design Process: Phase I Modelling and Simulation,
Phase II Prototyping, Phase III Deployment/Lifecycle

Presented By Prof. Vikram Vyawahare , HOD Mechatronics Engineering

SEQUENTIAL VS CONCURRENT
DESIGN
• The traditional electromechanical-system design
approach attempted to inject more reliability and
performance into the mechanical part of the system
during the development stage.
• The control part of the system was then designed and
added to provide additional performance or reliability
and also to correct undetected errors in the design.
• Because the design steps occur sequentially, the
traditional approach is a sequential engineering
approach.

Presented By Prof. Vikram Vyawahare 1

 31-07-2023

SEQUENTIAL VS CONCURRENT
DESIGN
• A major factor in this sequential approach is the
inherently complex nature of designing a
multidisciplinary system.
• Essentially, mechatronics is an improvement upon
existing lengthy and expensive design processes.
Engineers of various disciplines work on a project
simultaneously and cooperatively.
• This eliminates problems caused by design
incompatibilities and reduces design time because
of fewer returns.

SEQUENTIAL VS CONCURRENT
DESIGN
• Design time is also reduced through extensive use of
powerful computer simulations, reducing
dependency upon prototypes.
• This contrasts the more traditional design process of
keeping engineering disciplines separate, having
limited ability to adapt to mid-design changes, and
being dependent upon multiple physical prototypes.

Presented By Prof. Vikram Vyawahare 2

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MECHATRONIC DESIGN PROCESS

• The mechatronic design process consists of

three phases:
• Phase I : Modeling and Simulation,
• Phase II : Prototyping, and
• Phase III : Deployment.

MECHATRONIC DESIGN PROCESS

Presented By Prof. Vikram Vyawahare 3

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STEPS IN PHASE I:
MODELLING AND SIMULATION
• Step 1: Recognition of Need
• Step 2: Conceptual Design and Functional
Specifications
• Step 3: First Principle Modular mathematical
modelling
• Step 4: Sensor and Actuator Selection
• Step 5: Detailed Modular Mathematical Modelling
• Step 6: Control System Design
• Step 7: Design Optimization

PHASE I : MODELLING AND SIMULATION

STEP-1: RECOGNITION OF NEED
• As any design process, the first step is about
recognizing the need for the design.
• The initial phase where even the objectives of the
design / design change are not clear.
• The designer may be able to understand a need by
analysing some activity. It could be about
specifications such as size weight speed etc.

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PHASE I : MODELLING AND SIMULATION

STEP 1: RECOGNITION OF NEED
• The expected outcome of this phase is just the
description of the need / requirement.

• Example outcome of this step:

• Example Design Requirement: A washing machine
that would use electric power and wash a
bucketful of clothes.

PHASE I : MODELLING AND SIMULATION

STEP 2 : CONCEPTUAL DESIGN AND
FUNCTIONAL SPECIFICATIONS
• Next stage is of conceptual design and functional
specification. A conceptual design may represent the
functional components along with topology and
structure. It could be block diagram , conceptual
sketch etc.

Presented By Prof. Vikram Vyawahare 5

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PHASE I : MODELLING AND SIMULATION

STEP 2 : CONCEPTUAL DESIGN AND
FUNCTIONAL SPECIFICATIONS
• Conceptual design could be a sketch or a block diagram

• The specifications could also specify regarding the expected capacity, duty
cycle, cycle time etc. For example in the washing machine case we could
specify the specifications as
• “Machine should be capable of washing 5 kg of clothes in maximum 1 hour
cycle and should be designed for 8 hrs /day of operation.”

PHASE I : MODELLING AND SIMULATION

STEP 3: FIRST PRINCIPLE MODULAR
MATHEMATICAL MODELLING
• Representation of the system using mathematical
models based on first principles and then simulation by
first programming the mathematical model and then
running the coded model through several iterations is
usually done.
• A first principle model is a simple model which
captures some of the fundamental behavior of a
subsystem.
• There could be domain specific components to a
model or a multidomain model with approaches such
as bond graph modelling can be used.

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PHASE I : MODELLING AND SIMULATION

STEP 3: FIRST PRINCIPLE MODULAR
MATHEMATICAL MODELLING
• Visual programming approaches such as using
Simulink and Simscape simplify the modelling and
simulation procedure by reducing the complexity of
mathematical modelling to component
interconnection.
• Results of simulation provide idea about the working
of the system to the design engineer.

PHASE I : MODELLING AND SIMULATION

STEP 4: SENSOR AND ACTUATOR
SELECTION
• Sensor selection is usually done based on identifying the
measurement requirement in the physical system and then
matching the rating parameters of available sensors with
the requirement.
• Some cases signal conditioning may be needed and some
cases complete development of new sensor may be
needed in order to match the application requirement.
• Actuator selection on the other hand requires
understanding the motion characteristics and load
requirements for providing particular motion.

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PHASE I : MODELLING AND SIMULATION

STEP 5: DETAILED MODULAR
MATHEMATICAL MODELLING
• The first principle modular mathematical model may
not have captured all aspects of the physical system
• Thus after specific sensor and actuator selection a
more detailed model can be constructed that
would be able to accurately model the multidomain
component interaction.

PHASE I : MODELLING AND SIMULATION

STEP 6: CONTROL SYSTEM DESIGN
• Once the detail mathematical model of physical
system is available a control system can be
designed.
• The system model may correspond to standard
system models of 1st or 2nd order.
• The model can be subjected to standard inputs
(step, ramp etc) and its behaviour can be observed.
• PID control or any other type of control can be
implemented and tuning can be done.

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PHASE I : MODELLING AND SIMULATION

STEP 7: DESIGN OPTIMIZATION
• Step 1 to 6 can be revisited based on some
optimization criteria to get a better design.
• Optimization is an iterative process and thus is done
multiple times.
• The objective function for optimization problem has
to be defined subject to constraints and the design
space can be explored.

MODULAR MODELLING
• All modeling, whether based on first principles (basic
equations) or the more detailed physics, should be
modular in structure.
• A first principle model is a simple model which
captures some of the fundamental behavior of a
subsystem.
• A detailed model is an extension of the first principle
model providing more function and accuracy than
the first level model.

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MODULAR MODELLING
• Connecting the modules (or blocks) together may
create complex models.

• Each block represents a subsystem, which

corresponds to some physically or functionally
realizable operations, and can be encapsulated
into a block with input/output limited to input signals,
parameters, and output signals.

IMPORTANT FEATURES
• Of course, this limitation may not always be possible
or desirable; however, its use will produce modular
subsystem blocks which easily can be maintained,
exercised independently, substituted for one
another (first principle blocks substituted for detailed
blocks and vice versa), and reused in other
applications.
• Modeling: Block diagram or visual interface for
creating intuitively understandable behavioral
models of physical or abstract phenomenon. The
ability to encapsulate complexity and maintain
several levels of subsystem complexity is useful.

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IMPORTANT FEATURES
• • Simulation: Numerical methods for solving
models containing differential, discrete, hybrid,
partial, and implicit nonlinear (as well as linear)
equations. Must have a lock for real-time
operation and be capable of executing faster
than real time.

• • Project Management: Database for

maintaining project information and subsystem
models for eventual reuse.

IMPORTANT FEATURES
• • Design: Numerical methods for constrained
optimization of performance functions based on
model parameters and signals. Monte Carlo type of
computation is also desirable.

• • Analysis: Numerical methods for frequency-

domain, time-domain, and complex-domain design.

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PHASE II: HARDWARE IN LOOP SIMULATION

• Hardware-in-the-Loop Simulation In the
prototyping step, many of the non-computer
subsystems of the model are replaced with
actual hardware.
• Sensors and actuators provide the interface
signals necessary to connect the hardware
subsystems back to the model.
• The resulting model is part mathematical and
part real.

REAL-TIME INTERFACING OR
HARDWARE-IN-THE-LOOP SIMULATION
• Because the real part of the model inherently
evolves in real time and the mathematical part
evolves in simulated time, it is essential that the two
parts be synchronized.
• This process of fusing and synchronizing model,
sensor, and actuator information is called real-time
interfacing or hardware-in-the-loop simulation, and
is an essential ingredient in the modeling and
simulation environment.

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DIFFERENT CONFIGURATIONS FOR

HARDWARE-IN-THE-LOOP SIMULATION

PHASE II: HARDWARE IN LOOP

SIMULATION
• Because no single model can ever flawlessly
reproduce reality, there always will be error
between the behavior of a product model
and the actual product.
• These errors, referred to as unmodeled errors,
are the reason that so many model-based
designs fail when deployed to the product.

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PHASE II: HARDWARE IN LOOP

SIMULATION
• The mechatronic design approach also uses a
model-based approach, relying heavily on
modeling and simulation.
• However, unmodeled errors are accounted for
in the prototyping step. Their effects are
absorbed into the design, which significantly
raises the probability of successful product
deployment.

PHASE II: HARDWARE IN LOOP

SIMULATION
• Real-Time Interface: A plug-in card is used to
replace part of the model with actual hardware by
interfacing to it with actuators and sensors. This is
called hardware in the loop simulation or rapid
prototyping and must be executed in real time.

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PHASE III: DEPLOYMENT

• Code Generator: Produces efficient high-level source
code from the block diagram or visual modeling
interface. The control code will be compiled and used
on the embedded processor. The language is usually C.
• Embedded Processor Interface: The embedded
processor resides in the final product. This feature
provides communication between the process and the
computer-aided prototyping environment. This is called
a full system prototype.

PHASE III : LIFE CYCLE DESIGN

• The mechatronic design methodology is not only
concerned with producing high-quality products but
with maintaining them as well—an area referred to
as life cycle design. Several important
• life cycle factors are indicated.
• • Delivery: Time, cost, and medium.

• • Reliability: Failure rate, materials, and tolerances.

• • Maintainability: Modular design.

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PHASE III: LIFE CYCLE DESIGN

• Serviceability: On board diagnostics, prognostics,

and modular design.

• Upgradeability: Future compatibility with current

designs.

• Disposability: Recycling and disposal of hazardous

materials.

PHASE III : LIFE CYCLE DESIGN

• In the mechatronic design approach, life

cycle factors are included during the product
design stages, resulting in products which are
designed from conception to retirement

Presented By Prof. Vikram Vyawahare 16