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A tool for holistic optimization of mechatronic design concepts
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Mechatronics.
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Designing mechatronic systems is challenging. Even so, mechatronicproducts are regarded as one of the most important means in order toinnovate in many large industries, e.g. automobile and aerospace. Theinherent difficulty lies in the multiple engineering domains involved and howthese are treated during the development process. A holistic approach, whichtreats these domains concurrently, is needed in order to find hidden synergiesbetween domains and in the end find an optimal product design based ongiven requirements.

Traditional product development methodologies, even ones with amechatronic design focus, rely on treating the individual domains separatelyand only integrating them at a point in time rather far into the detailed designphase of the development process. In addition, in order to solve problems thatarise in later design stages, the design engineers need to backtrack to earlierstages and in the worst case repeat substantial parts of the work. This is bothtime and cost inefficient.

This dissertation summarizes and extends previously published research bythe author about a novel mechatronic design methodology and a supportingsoftware tool. The goal of the design methodology is to enable design of betterproducts, in terms of e.g. development cost, size, and sustainability, by findingsynergies and reducing backtracking through better analysis of systemconcepts. The methodology relies on using an optimizer to efficientlydetermine the potential of a system concept, described by combining a numberof component models, e.g. motors, transmissions, and structural ones, from acomponent library and specifying their parameters.

A number of design cases have been evaluated, some of which are presentedin this dissertation, including both one where a physical prototype is built, anda few virtual ones. These design cases have been instrumental in evaluating themethodology as well as the software tool.

It is concluded that the design methodology is able to properly evaluate aconcept against competing concepts, and that it is a useful addition to existingmethodologies. However, as always, a number of improvements are possible,some of which are presented in a concluding section.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. , xix, 71 p.
Series
TRITA-MMK, ISSN 1400-1179 ; 2015:01
Keyword [en]
Mechatronics, Design methodology, Conceptual design, Optimization, Modeling, Integrated design
National Category
Mechanical Engineering
Research subject
Machine Design
Identifiers
URN: urn:nbn:se:kth:diva-158886ISBN: 978-91-7595-418-9 (print)OAI: oai:DiVA.org:kth-158886DiVA: diva2:779734
Public defence
2015-01-30, Gladan, Brinellvägen 85, KTH, Stockholm, 13:00 (English)
Opponent
Supervisors
Funder
Swedish Foundation for Strategic Research
Note

QC 20150114

Available from: 2015-01-14 Created: 2015-01-13 Last updated: 2015-01-14Bibliographically approved
List of papers
1. A Holistic Optimization based Mechatronic Design Methodology with a Supporting SoftwareToolbox
Open this publication in new window or tab >>A Holistic Optimization based Mechatronic Design Methodology with a Supporting SoftwareToolbox
(English)Manuscript (preprint) (Other academic)
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-158919 (URN)
Note

QS 2015

Available from: 2015-01-14 Created: 2015-01-14 Last updated: 2015-01-14Bibliographically approved
2. Holistic design methodology for mechatronic systems
Open this publication in new window or tab >>Holistic design methodology for mechatronic systems
2014 (English)In: Proceedings of the Institution of mechanical engineers. Part I, journal of systems and control engineering, ISSN 0959-6518, E-ISSN 2041-3041, Vol. 228, no 10, 741-757 p.Article in journal (Refereed) Published
Abstract [en]

The wide range of engineering domains aggregated in mechatronic systems can cause problems for design engineers. It is important to treat the different domains in an integrated, concurrent manner during design to be able to achieve the frequently sought-for synergetic effects of mechatronic systems. Traditional design methods are usually based on the different engineering disciplines being treated separately and only integrated at a late stage of the development process. Consequently, those methods do not work sufficiently well for mechatronic systems, leading to a suboptimal product. Previous research by the authors presents a novel approach to mechatronic system design by allowing quick optimisation and evaluation of design concepts. This is done by front loading certain design activities, hence decreasing the need for time- and cost-consuming iterations in later design stages. The method is backed up by a supporting software tool prototype. This article extends the method by including the dynamic aspects of the designed systems while also implementing basic control aspects, hence creating a concurrent and holistic method for mechatronic system design. This allows the designer to take synergetic effects into account at an earlier stage of the design process, hence increasing product quality and decreasing development costs. A conceptual design case is used in this article for an initial evaluation of the method and the results show great potential for the methodology.

Keyword
Mechatronic design, concept evaluation, integrated control, holism
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-157020 (URN)10.1177/0959651814527936 (DOI)000344245100001 ()2-s2.0-84908884111 (Scopus ID)
Funder
Swedish Foundation for Strategic Research , V08.02
Note

QC 20141205

Available from: 2014-12-05 Created: 2014-12-04 Last updated: 2017-12-05Bibliographically approved
3. Optimization of Mechatronic Systems for supporting Early Design Decisions
Open this publication in new window or tab >>Optimization of Mechatronic Systems for supporting Early Design Decisions
2012 (English)In: The 13th Mechatronics Forum International Conference Proceedings / [ed] Rudolf Scheidl and Bernhard Jakoby, Linz: TRAUNER Verlag, 2012, 490-497 p.Conference paper, Published paper (Refereed)
Abstract [en]

It is a daunting task to design a modern mechatronic system. The many engineering fields coming together as one create integration issues and raise difficulties in finding the optimum solution to a design problem. This paper contributes to solving parts of this problem by presenting a novel approach for supporting design decisions in an early phase of the product development process of mechatronic products. In order to support decision making for a broad range of mechatronic products, a framework is presented which is capable of handling arbitrary system configurations consisting of standard mechatronic components, e.g. DC motors and gearboxes. Given according component models, the framework can optimize suggested concept ideas with regard to for instance system volume or inertia. In order to quickly optimize and evaluate different concepts, it is advisable to keep the underlying component models simple, yet powerful enough to be used for typical mechatronic systems. The presented approach therefore makes analytic usage of component models without requiring time-consuming numerical simulations. The results of the paper indicate that the presented method has good potential, especially for evaluating concepts in an early design phase, and further research effort should be put into developing it.

Place, publisher, year, edition, pages
Linz: TRAUNER Verlag, 2012
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-111529 (URN)
Conference
The 13th Mechatronics Forum International Conference, September 17 - 19, 2012, Linz, Austria
Funder
Swedish Foundation for Strategic Research
Note

QC 20130114

Available from: 2013-01-13 Created: 2013-01-13 Last updated: 2015-01-14Bibliographically approved
4. Holistically Integrated Design of a Haptic Steering Wheel
Open this publication in new window or tab >>Holistically Integrated Design of a Haptic Steering Wheel
2014 (English)In: Proceedings of the 14th Mechatronics Forum International Conference Mechatronics 2014, 2014Conference paper, Published paper (Other academic)
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-158921 (URN)
Conference
the 14th Mechatronics Forum International Conference, Karlstad, Sweden, June 2014
Note

QC 20150114

Available from: 2015-01-14 Created: 2015-01-14 Last updated: 2015-01-14Bibliographically approved
5. Optimal design of harmonic drive servo
Open this publication in new window or tab >>Optimal design of harmonic drive servo
2013 (English)In: 2013 IEEE/ASME International Conference on Advanced Intelligent Mechatronics: Mechatronics for Human Wellbeing, AIM 2013, IEEE , 2013, 1579-1584 p.Conference paper, Published paper (Refereed)
Abstract [en]

Design of modern mechatronic systems can be an overwhelming task. The underlying difficulty lies in that several different engineering domains are combined in one product, creating integration issues. Commonly used design methodologies are based on optimizing the different domains separately; hence creating a sub optimized final system. A cornerstone in many modern products is the mechatronic servo system which needs to be able to accurately control motion while still conforming to ever increasing demands on important factors such as cost, size and weight. This paper further builds upon a design methodology developed by the authors by adding design models for harmonic drives. The design methodology is capable of supporting the designer in developing mechatronic products by giving him/her a time efficient method to early on in the design process evaluate concepts. The new harmonic drive models are applied to a design case featuring a haptic steering interface for a steer-by-wire vehicle. It is concluded that the harmonic drive models are simple; yet accurate enough for the type of early design decisions they are to be used for.

Place, publisher, year, edition, pages
IEEE, 2013
Keyword
Early design decisions, Engineering domains, Integration issues, Mechatronic products, Mechatronic servo systems, Mechatronic systems, Steer-by-wire vehicles, Time-efficient methods
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-133284 (URN)10.1109/AIM.2013.6584321 (DOI)000328705300263 ()2-s2.0-84883672016 (Scopus ID)978-146735319-9 (ISBN)
Conference
2013 IEEE/ASME International Conference on Advanced Intelligent Mechatronics: Mechatronics for Human Wellbeing, AIM 2013; Wollongong, NSW; Australia; 9 July 2013 through 12 July 2013
Note

QC 20131031

Available from: 2013-10-31 Created: 2013-10-29 Last updated: 2015-01-14Bibliographically approved

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