Mechatronic Mechanism Design and Implementation Process Applied in Senior Mechanical Engineering Capstone Design
Mechatronic Mechanism Design and Implementation Process Applied in Senior Mechanical Engineering Capstone Design
American
c Society for Engineering Education, 2019
Paper ID #26215
to collaborate with business and industry to foster innovation, where all intellectual property (IP) belongs
to the sponsor. He has created a 12-month, 12-module, on-line Mechatronics Certificate Program for
Practicing Engineers. He is an Adjunct ME Professor at Stony Brook University.
American
c Society for Engineering Education, 2019
Mechatronic Mechanism Design and Implementation Process
Applied in Senior Mechanical Engineering Capstone Design
Abstract
Mechanisms have been around for millennia dating back to the Egyptians. More
recently, the slider-crank mechanism was invented by Leonardo da Vinci over 500 years ago.
Up until 30 years ago, the design of mechanisms was mechanical, but in the present mechatronic
age, the design is multidisciplinary, i.e., mechanical, electrical, electro-mechanical, hydraulic,
and pneumatic. Mechatronics is the synergistic integration of physical systems, electronics,
controls, and computers through the design process, and is the best practice for synthesis by
engineers driven by the needs of industry and human beings.
One of the most common mechanisms in the world is the slider crank. Its most common
application is the internal combustion engine, but it is also used in an automatic toothbrush. A
mechatronic approach to the design and implementation of any mechanism has been developed
and is applied in a case study to the slider crank. The approach reflects both the traditional
mechanism analysis and synthesis methods together with the best industry practices, e.g.,
Rockwell Automation, Procter & Gamble.
The mechatronic mechanism design process was implemented, and a slider crank was
built to accomplish a prescribed task. This process was used in Mechanical Engineering Senior
Capstone Design during the fall 2018 semester. Seven design teams, with four students in each
team, created four-bar mechanism applications using this mechatronic process, first creating a
MatLab Simulink virtual prototype of the complete system, and then building a working
prototype with LabVIEW and the NI myRIO. The 7 four-bar mechanisms were: robot gripper,
quick return, pick and place, windshield wiper, landing gear, flipping mechanism, and straight
line. This paper documents this capstone design experience, including extensive student
evaluation of the course.
Introduction Mechatronics is the best
practice by engineers driven by the needs of
industry and human beings. It is the
synergistic integration of physical systems,
electronics, controls, and computers through
the design process, from the very start of the
design process, thus enabling complex
decision making. Integration is the key
element in mechatronic design as complexity
has been transferred from the mechanical
domain to the electronic and computer
software domains. Mechatronics is an
evolutionary design development that
demands horizontal integration among the
various engineering disciplines, as well as
vertical integration between design and
manufacturing, and is what modern
mechanical engineering needs to be. K. Craig,
as a professor at Rensselaer Polytechnic Institute from 1989-2008, created the mechatronics
undergraduate and graduate programs there, and, in 1995, created the Mechatronics diagram
(Figure 1), now used around the world to illustrate this concept.
Design, above all else, defines the difference between an engineering education and a science
education. Design represents the bridge between theory and reality. It is the process by which
our ideas enter and influence the world around us. Design distinguishes us as engineers. This
one-semester, three-credit senior capstone design course for mechanical engineers is intended to
be a challenging multidisciplinary design experience prior to graduation. This course builds
upon the knowledge and skills that students have gained from other engineering courses taken as
part of the mechanical engineering curriculum, in particular, the junior-level, four-credit required
courses Modeling, Analysis, & Control of Dynamic Systems, Mechanical Engineering Design,
and Mechatronic System Design. It provides a meaningful culminating experience that
introduces students to the multidisciplinary, mechatronic aspects of design and to the essential
model-based approach to design, rather than the design-build-test approach that is so common in
a senior capstone design course. Under the guidance of the instructor, students develop an
appreciation for the depth and breadth of knowledge and skills necessary for successful
implementation of a significant development effort. The integrative and iterative aspects of a
capstone design experience are emphasized. Students are required to apply their skills in
multidisciplinary design, modeling, analysis, simulation, verification, and computer-control
design, with electronics, sensors, actuators, microcontrollers, and real-time programming.
Professional development in areas of team dynamics, interpersonal relationships, and technical
communications are learned via active participation.
All mechanical engineering programs have a senior capstone design course. It is an ABET
(Accreditation Board for Engineering and Technology) requirement. A review of senior
mechanical engineering capstone courses around the country will uncover considerable
differences. Among the differences are:
Mechatronic Mechanism Design A modern mechatronic machine is like the human body. The
actuators are the muscles that make things happen. The sensors are the senses that tell us what is
happening. The links and joints of the mechanisms are the legs, arms, hands, and joints of the
human body, and the microcontroller, which performs the complex decision making it has been
programmed to do, is the human brain. Mechanisms have been around for millennia dating back
to the Egyptians. Up until 30 years ago, the design of mechanisms was purely mechanical, often
with mechanical cams, but, in the present mechatronic age, the design is multidisciplinary, i.e.,
mechanical, electrical, electro-mechanical, hydraulic, and pneumatic, all computer-controlled,
with electronic cams and complex motion profiles.
What does it mean to mechatronify
[1] a mechanism or machine? In
life, how you do something is more
important than what you do.
Mechatronics is more than just
adding a sensor, an actuator, and a
computer control system. They
must be added in an integrated way
from the very start of the design
and, just as importantly, using a
model-based design process that
takes advantage of analysis
techniques and simulation software
and leads to optimum designs
without trial and error. Combining
old inventions with new technology
fosters innovative ideas, but it is the
process that transforms these ideas
into reality. A mechatronic
approach to the design and
implementation of any mechanism
has been developed that reflects
both the traditional mechanism
analysis and synthesis methods
together with the best industry
practices, e.g., Rockwell
Automation, Procter & Gamble. It
is shown in the flow chart (Figure
2). It is through this process that
innovative ideas become a reality.
Sweating the details with a
combination of knowledge, old and
new, process, and determination will
make innovation happen.
Once the kinematic and kinetic analyses are completed, the desired end-point trajectory must be
defined, and then, through inverse kinematics, which includes here the crank and connecting rod
lengths, the necessary motion profile for the actuator is computed. This is accomplished by
trajectory planning. This profile needs to be defined in a way to avoid or reduce the mechanical
vibration and stress on components and actuators, as well as to reduce overshoot response and
excessive position error during motion. This is accomplished by electronic cams. The inverse
kinetic analysis, which includes masses, center-of-mass locations, and mass moments of inertia,
is used to generate the required actuator torque / force for the motion profile, and results in a
speed / torque-force diagram on which to base actuator selection. The chosen actuator now
becomes part of the system, and, with the updated system, a control system, with feedback and
feedforward control, is designed, which then results in a new speed / torque-force profile. The
entire system should now be simulated, with the addition of any parasitic effects, for design
validation.
To create a mechatronic machine requires an integrated approach and a process that results in a
complete virtual prototype before any work is done to create the actual working prototype. Once
the virtual prototype – complete with models of the mechanical elements, electronics, controller,
microcomputer, sensors, and actuators – is shown to work as desired, then work towards building
the actual prototype can begin. When completed, the working prototype should work as
expected the first time power is turned on. That is called model-based design and it is the
cornerstone of modern engineering practice.
Senior Capstone Design Course The mechatronic mechanism design process was implemented,
and a slider crank was built to accomplish a prescribed task. This process is essential to modern
engineering practice and this case study was used as a guide in Mechanical Engineering Senior
Capstone Design during the fall 2018 semester. The four-bar linkage is probably the most
common mechanism in the world and is used in a great variety of applications. Twenty eight
senior ME students, working in teams of 4, were assigned a four-bar mechanism application:
aircraft landing gear, quick-return mechanism, pick-and-place mechanism, robot gripper,
straight-line mechanism, flipping mechanism, and windshield wiper, and then proceeded through
a process to create a virtual prototype and then, a working prototype.
Process Steps:
Table 1
Course Milestones Due Dates
Form Teams & Develop Challenge Concept Week #1
Virtual Prototype Demonstration and Presentation Week #7
Working Prototype Demonstration and Presentation Week #14
Final Presentation with Virtual & Working Prototypes and Exam Week
Design Notebook
The course learning objectives, major deliverables, course organization, course policies, grade
summary, and weekly team tasks are shown below.
1. To provide the student with an experience that requires active student participation.
2. To enhance the student’s skills in engineering design methodology, including research,
modeling, analysis, computer simulation, virtual and real prototype testing, and participation
in design reviews.
3. To simulate the advanced product development process used in industry including the
incorporation of customer requirements, performing a state-of-the-art search, keeping an
engineering notebook, and organizing a commercial presentation of the work.
4. To illustrate the interaction between competing technical and non-technical issues and the
role of compromise, constraints and the interplay of potential benefits versus risks.
5. To provide the student with exposure to various phases of the design process, from the
specification of requirements and constraints to product realization. All phases of new
product development are practiced: concept formulation, technology search, preliminary
design and layout, virtual prototyping, detailed design, fabrication, parts procurement,
assembly, testing, and documentation.
6. To help develop an understanding of the planning, coordination, cooperation, and
communication required in a team effort.
7. To have the student understand what is required to meet a firm technical deadline where
funds and technical assistance are limited: scheduling work, developing contingencies,
specifying, procuring and incorporating purchased parts, identifying and using available
fabrication and test equipment.
8. To allow for innovation.
9. To allow the student to apply the skills learned in previous engineering courses to a
challenging project.
Major Deliverables:
1. The engineering details of a concept design (physical and mathematical modeling, model
analysis and verification, virtual prototype, computer-aided design drawings, electrical
schematics, performance test results) as described in an engineering notebook with a
presentation.
2. A working prototype which the team members design, fabricate, test, and demonstrate at a
design exposition.
Course Organization:
• The course consisted of two mandatory 85-minute sessions each week for all students. The
first session each week was spent in a classroom setting during which the instructor covered
fundamental engineering content essential for successful completion of the challenge. In the
second session each week, each team worked together and with the instructor, as well as
discussed and presented their work in a mini-design review format to the other teams.
• Students were organized into four-person multidisciplinary teams during the first period of
the course.
• During the first period, each team was assigned a four-bar mechanism design challenge. The
system necessarily was dynamic with sensors, electronics, actuators, and computer control as
integral parts of the design, i.e., a mechatronic system.
• Design is not a spectator sport. Active participation is required for a meaningful capstone
experience. Students were expected to attend and participate in all class sessions and make
relevant contributions in team meetings outside of regularly scheduled class time. Active
participation and initiative were critical parts of the student’s individual success and that of
the team.
• Attendance at all classes was mandatory.
• Student participation in class was strongly encouraged.
• Preparation for class was essential.
• All course notes / announcements were posted on the course web site.
• Students were expected to conduct themselves in a professional manner at all times with
integrity, honesty, and respect for others.
Grade Summary:
Table 2
Team Tasks Week #
Form 4-Person Teams; Select & Research 4-Bar Mechanism Task; Set Up Week #1
Design Notebook
Define Mechanism Requirements & Motion Profile for the Selected 4-Bar Week #2
Mechanism Task; Perform Forward and Inverse Kinematic Analysis &
Implement in Simulink
Perform Forward & Inverse Kinetic Analysis using Newton-Euler Week #3
Approach; Determine Equation of Motion using the Lagrange Approach;
Implement in Simulink
Determine Motor Speed-Torque Requirement; Identify Candidate Brushed Week #4
DC Motors; Choose Motor & Justify
Augment System with Motor (Inertia and Friction); Design PID Controller Week #5
using MatLab; Implement Closed-Loop System in Simulink; Reevaluate
Motor Selection
Complete the Virtual Prototype Design & Prepare Presentation & Report; Week #6
Order Motor
Virtual Prototype Presentation and Report Week #7
Develop Mechanism Detailed Design using Machine Design Principles Week #8
Detailed Design & Build Week #9
Detailed Design & Build Week #10
Detailed Design & Build Week #11
H-Bridge Set-Up; LabVIEW Real-Time Programming; System Closed- Week #12
Loop Testing
Complete the Actual Prototype Build & Test; Prepare Presentation & Week #13
Report
Actual Prototype Presentation and Report Week #14
Course Evaluation Twenty-seven students evaluated the course. (Questionnaire and results are in
Appendix B). The questionnaire had an overall quality question plus three parts. In Part A,
students rated their ability to apply knowledge and tools required for industry; in Part B, students
rated which skills were most useful for a practicing engineer; and in Part C, students ranked how
the course prepared them for the future. Parts A and C applied specifically to the course. A rating
of one meant the course strongly achieved the goal, while a five meant the course did not. The
overall course quality was rated 1.63. Students strongly agreed that the course will help them meet
industry needs, that the professor helped achieve the course goals, and that they feel confident
applying engineering design principles and processes to solve a new engineering problem.
Conclusion A new approach to mechanical engineering capstone design has been described and
implemented. All seven four-person teams designed a four-bar mechanism for an assigned
application. This allowed the instructor to teach fundamentals of kinematics and dynamics of
mechanisms, both forward and inverse, in particular, the four-bar mechanism. Nonlinear
kinematic and dynamic analyses, both forward and inverse, were performed in Simulink.
Control design was performed using MatLab, computer simulations were performed for the
virtual prototype using Simulink, and the real-time control was programmed using LabVIEW
with the NI myRIO controller. Students selected the brushed DC motors for their applications,
developed the power electronics, interfaced the incremental optical encoder, and programed the
real-time control code. The mechanical design of the mechanism (links and bearings), support
structure, and motor coupling was performed using mechanical design principles. Performance
requirements were continuously evaluated and updated. See mechanism pictures in Appendix A.
Students had the opportunity for a hands-on, real-world mechatronic design experience, just as
they will be expected to perform after graduation as real practicing engineers.
References
1. Craig, K., “Mechatronify Common Mechanisms,” Design News, August 2012.
2. Craig, K., “Modeling and Simulation for Motor Selection,” Design News, June 2011.
3. Nagchaudhuri, A., “Mechatronic Redesign of Slider Crank Mechanism,” ASME Proceedings
of IMECE 2002, November 2002.
Appendix A: Senior Design Mechanisms Figures 3-9
Appendix B: Mechanical Engineering Senior Design Questionnaire
Part A
This course has provided me with:
_____ An ability to apply knowledge of mathematics, science, and engineering.
_____ An ability to design and conduct experiments, as well as analyze and
interpret data.
_____ An ability to design a system, component, or process to meet desired needs
within realistic constraints such as economic, social, political, ethical,
health and safety, manufacturability, and sustainability.
_____ An ability to function on multidisciplinary teams.
_____ An ability to identify, formulate, and solve engineering problems.
_____ An understanding of professional and ethical responsibility.
_____ An ability to communicate effectively.
_____ The broad education necessary to understand the impact of engineering
solutions in a global, economic, environmental, and societal context.
_____ A recognition of the need for, and an ability to engage in, life-long learning.
_____ A knowledge of contemporary issues.
_____ An ability to use the techniques, skills, and modern engineering tools
necessary for engineering practice.
Part B
The following skills and knowledge, and their corresponding growths, are essential
to a career as a practicing engineer.
_____ Communication
_____ Teamwork
_____ Project Management
_____ Problem Solving
_____ Organization
_____ Leadership
_____ Statics / Dynamics
_____ Strength of Materials / Machine Design
_____ Modeling, Analysis, and Control of Dynamic Systems
_____ Electromechanics
_____ Electronics
_____ Fluid Mechanics
_____ Thermodynamics
_____ Heat Transfer
_____ Computer Graphics (e.g., Solid Works)
_____ MatLab / Simulink
_____ LabVIEW
_____ Real-Time Computer Programming
Part C
_____ This course will help you to meet industry needs.
_____ This course resulted in improved student learning.
_____ The professor in this course helped achieve the course goals.
_____ You feel confident in applying engineering design principles and processes
in the solution of a new engineering problem.
_____ The approach used, i.e., to teach subject matter (e.g., mechanisms) and then
use that knowledge in the current design process, was very effective.