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Design methodology for mechatronic systems based on shape memory

technology

Article · June 2014

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Design methodology for mechatronic systems
based on shape memory technology
K. Lygin1, S. Langbein2, C. Rathmann1, D. Otibar1 and H. Meier1
1Chair of Production Systems, Ruhr-University Bochum, Bochum, Germany
2FG-Innovation GmbH, Bochum, Germany

Abstract:
A lot of technical applications are realizable with SMA actuators. Nevertheless industry use of SMA is limited
only to a few actuator applications, because companies are overwhelmed with the complexity of this technology.
This paper fills this gap by presenting a design methodology for mechatronic systems of SMA actuators, which
guides users through the developing process from system concept to assurance of properties. To take into
account the SMA specific aspects during actuator development the SMA design methodology considers the
mechanical solution concept, thermo-mechanical treatment of SMA material and design of actuator. The
presented design methodology helps especially engineers to develop proper SMA actuators and reduces the
complexity regarding SMA specific influences and interactions.

Keywords: shape memory alloys, shape memory actuators, guideline, product development

Introduction
Shape memory alloys (SMA) are smart materials considers mechanical solution concept, thermo-
with the ability to remember a previous imprinted mechanical treatment of SMA material and design of
shape after plastic deformation [1]. The shape actuator. It is divided into the phases: “pre
memory actuator effect is induced by thermal energy. assessment”, “system concept”, “discipline specific
Since the late sixties SMA are well known in design”, “system integration” and “assurance of
research and industry. A lot of technical applications properties” (Fig. 1).
are realizable with SMA actuators, for example in
automotive sector [2]. Nevertheless industry use of
pre SMA-actuator-
SMA is limited only to a few actuator applications in assessment system
small scale. Despite the fact that most technical
challenges are solved, companies are overwhelmed assurance of properties
with the complexity of this technology. Reasons for of complete system
this are namely lack of norms for material
composition, guidelines for the development process
and experience with this technology. of subsystems
This paper contributes by presenting a design
methodology for mechatronic systems of SMA-
actuators. The methodology guides users through the of components

developing process from system concept to

assurance of properties and thus provides the discipline specific design
required knowledge. Basis for the presented SMA smart material engineering
design methodology is the German VDI guideline mechanical engineering
VDI-2206 “Design methodology for mechatronic electrical engineering
systems” [3], which is the industrial standard for the information technology
quality
product development process. This paper focuses the modeling and model analysis gates
theoretical and process orientated view of the
product development process. A practical and
solution-orientated view of the challenges during the Fig. 1: SMA-design methodology
development process of SMA actuators can be found
in another publication of the authors [4]. The aim of the phase “pre assessment” is the check
of technical feasibility of the project. Here the
Fundamentals of SMA design methodology features of SMA alloy will be compared with the
requirements on the behavior of the actuator. On the
To take into account the SMA specific aspects
basis of few key factors the chances of success can
during actuator development the design methodology
be assessed. With the phase “system design” a

ACTUATOR 2014, MESSE BREMEN 1/4

framework is presented that guides users through provide this transformation behaviour. The product
conceptual design of SMA-actuators, focusing on development project can be aborted at this point.
specific mechanical characteristic of these actuators.
The phase which matters most regarding SMA is
“discipline specific design”. On the one hand, the milestones tasks results
development of the SMA actuator material will be planning the task
investigated. The aim of this part is the setting of list of requirements
required actuator behavior with reference to • systematical analysis of initial

assessment
transformation temperatures. For example start and situation
finish temperatures for actuator movement. On the • identification of requirements with

pre
other hand, the “discipline specific design” focuses reference to SMA actuator system
• identification of features applicable
on the mechanical design of the SMA actuator, his SMA material
bias element and its mechanical connection to the • comparison of requirements with
case. To design proper SMA actuators technical and SMA features and assessing
environmental parameters which influence the
assessment sheet
actuator will be also covered in this phase. The
phase “system integration” concerns the integration quality gate 1
of all components and sub systems to the complete
system. The aim of the phase “assurance of quality gate 1
properties” is the validation of components, sub iteration break
systems and complete SMA actuator system. The
stepwise validation of product properties gives early continuation
identification of problems and failures in the system.
Fig. 2: Tasks and result of phase “pre assessment”
Each phase of the design methodology contains
milestones for the development process, tasks, which Second phase “system concept”
needs to be done, and results. By evaluation of the
results in quality gates the project status will be The phase “system concept” supports the finding of
checked. After the assessment the actual project solution concepts for the actuator system (Fig. 3).
phase can be repeated (step iteration), closed (step
continuation) or stopped (step break).

First phase “pre assessment”

milestones tasks results
The phase “pre assessment” supports the assessment
planning the task
of technical feasibility of the project in form of its
list of requirements
start. Here the features of SMA alloy will be
compared with the requirements on the behavior of • abstraction of initial problem
the actuator (Fig. 2). • creation of functional structure
system concept

• searching for solution elements for

SMA actuator system
• structure of actuator
Critical feature of SMA actuators are:
• movement type of actuator
 transformation temperatures of the SMA effect • restoring principle of actuator
• searching for solution elements for
 width of the temperature hysteresis other elements of the system
 operation temperatures of the actuating system • assessing and selecting
• establishing of the discipline
 operating force and stroke embracing solution concept
 stability and durability of SMA effect solution concept
quality gate 2
In front of the product development project the
engineer should check critical parameter of SMA quality gate 2
materials and compare them with the requirements of iteration break
the actuator system.
continuation
An example: Required transformation/ operation
temperatures of a system are between 180 and
200 °C. On the market available SMA are not able to Fig. 3: Tasks and result of phase “system concept”

ACTUATOR 2014, MESSE BREMEN 2/4

The initial point of this phase is the list of element and transformation components will be
requirements. The result is the solution concept of detailed. The results of this phase are constructed
the complete system. After abstraction of the and dimensioned components.
technical problem, a functional structure will be
created. It describes on an abstract level the relations
Fourth phase “system integration”
between needed functions of the system. After this
the abstract description is transformed into a The aim of this phase is the structural integration of
concrete level with the search of solution elements the distributed system components, identification of
for identified functions. This search focuses on the incompatibilities and finding the optimum overall
one hand SMA specific solution elements. On the solution (Fig. 5). The result is the final complete
other hand the search details mechanical and SMA actuator system.
mechatronical elements of the system.
After identification of potential solution elements
their assessing and selection for the solution concept
of the complete system follows. Afterward the
components of the solution concept will be related to milestones tasks results
different mechatronical disciplines, like smart
assurance of pr.
material engineering or mechanic. Their detailing
take place in the next phase. complete system
• bringing together the component

integration
solutions to form sub systems or the
Third phase “discipline specific design”
system complete system
The aim of the phase “discipline specific design” is • identifying the incompatibilities
between components or sub systems
the technical specification of the system components. • eliminating incompatibilities
Usually the components of a technical system are • Finding the optimum solution for the
relatable to different technical disciplines like complete system
mechanics, materials engineering, electrical
discipline specific
engineering or information technology. This paper
components
focuses on the discipline “smart material quality gate 3
engineering”, because it is a novel and less
researched discipline (Fig. 4).

smart material Fig. 5: Tasks and result of phase “system

quality gate 3a
quality gate 2

engineering integration”
break

• selection of SMA Fifth phase “assurance of properties”

material
quality gate 3a

• if need, definition of The aim of this phase is the assurance of properties

thermo mechanical
pre treatment of the product on basis of the requirements. In SMA
• identification of based products the validation of properties regarding
continuation

material properties transformation behavior of the actuator is important,

• detailing of actuation
because it influence the system behavior especially.
detailed actuator

components
solution concept

(actuator, return
element,
Typical investigations are the identification of
transformation) stroke/ force-activation energy (e.g. thermal or
iteration

• definition of electrical) properties and the identification of

interfaces to the
complete system
durability.

Example of use
Fig. 4: Tasks and result of phase “smart material The applicability of presented methodology will be
engineering” illustrated on an example of use. The results of the
development process of a SMA based assembling
tool will be demonstrated in this chapter.
Starting with the solution concept for SMA specific
sub system the SMA material will be specified and The function of this assembling tool is the supply of
the actuation components, like SMA actuator, return a mechanical force (100N) and a stroke (20mm) on

ACTUATOR 2014, MESSE BREMEN 3/4

 the gripper arms. The assembling tool should be
applicable as a hand tool without an external energy
support. Additionally the typical transformation
temperature should be higher than 60°C.
After a positive assessment of technical feasibility a
solution concept is be created. Figure 6 shows this
concept in a sketch. Essential elements of the system
are a SMA wire (1), a transmission pulley (2), a
transfer wire (3), a return spring (4) and gripper
arms (5).
direction
motion

(3)

(2) (1)
(4) Fig. 7: Detailed system design of the assembling
(5) machine

Conclusion and Outlook

The presented design methodology helps especially
engineers to develop proper SMA-actuators and
reduces the complexity regarding SMA-specific
influences and interactions. Further research should
investigate the applicability of this methodology to
various industrial applications based on thermal or
Fig.6: First system concept of the assembling electro-thermal activation, to proof its uniformness
machine or need for adjustment.

SMA wire is responsible for the motion function. Acknowledgments

The transmission pulley transforms small elongation
of the SMA wire in to high stroke of the gripper. A The authors acknowledge funding of the hyProFGA
project by the NRW.BANK through Ziel2.NRW-
transfer wire transfer mechanical energy from the
programm Automotive+Produktion.NRW.
pulley to the gripper.
In the next design phase the system will be detailed
in different disciplines. Figure 7 shows the result of References
the phase discipline specific design. [1] K. Otsuka, C.M. Wayman: “Mechanism of shape
Calculation and dimension of solution elements memory effect and superelasticity”. In: Shape
cause a lot of changes in the structure of the Memory Materials, editors: K. Otsuka, C.M.
complete system. For example: to achieve the Wayman, Cambridge, 1998, pp. 27-48.
required stroke three parallel placed SMA wires are [2] A. Coda, F. Butera, G. Vergani, L. Fumagalli, L.
needed, the transformation pulley needs a higher Toia: “SMARTFLEX NiTi Wires for Shape
transmission and the return spring required a lot of Memory Actuators”, Proceedings of SMST 2007,
space. The combination and integration of elements Tsukuba, Japan
from different mechatronical disciplines result in a [3] VDI Guideline 2206, “Design methodology for
practicable and compact casting. mechatronic systems”, Beuth, 2004
[4] K. Lygin, A. Czechowicz, H. Meier: “Using a R-
Phase SMA Methodology to Design an Energy
Harvesting Unit with tight Temperature
Hysteresis”, Proceedings of SMASIS 2013,
Snowbird, Utah, USA

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