Master Program

Mechatronic and Cyber-Physical Systems

(Faculty Mechanical Engineering and Mechatronics, Deggendorf)
Module Functional Safety
Class Design of Safe Systems, , WS 2023/2024
Design of Safe Systems, Wednesdays, 2:00 pm to 3:30 pm (CET,CEST) 25.10. start 3 pm
Reunifcation Day
2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
October 2023 Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu
number of lecture 1 2 3
All Saints' Day
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
November 2023 Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th
number of lecture 4 5 6 7
Christmas Holidays
1 ## ## 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
December 2023 Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su
number of lecture 8 9 10
Christmas Holidays
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
January 2024 Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Tu Tu Tu Tu Tu Tu
number of lecture 11 12 13 exam period Tu Tu Tu Tu Tu Tu

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
February 2024 dfdf We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Mo
number of lecture exam period *
exam: tba, together with "Design of Safe Systems"
auxiliary means: three two-sided sheets in DIN A4 format with own handwritten formulary, non-programmable hand calculator, ruler for whole exam
*semester break Feb. 15 to Mar. 14, 2024

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 1
Previous Lecture

• What is a safe system?

• First view on product design process PDP and formal methods for
safety assessment

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 2
Promise of Today’s Lecture

Getting to know…

… examples from own research for safe systems

… differences between verification and validation

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 3
 Design of Safe Systems
Contents

• Introduction to Safe Systems, Product Design Process PDP

• VDI 2206 – Design methodology for Mechatronic Systems, 2006
• VDI 2206 – Development of Mechatronic and Cyber-Physical Systems, 2021
• Model Based Systems Engineering and Design, using Matlab-Simulink and Matlab-
Simscape, Hardware in the Loop (HIL) Testing, Design of Experiments (DoE)
• Safety Oriented Development Process: Reliability/Durability/Life Test
• Exam Preparation

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 4
 recap lecture 01
Product Design Process (PDP) with Reliability Assessment Tools

knowledge quality
from ABC-analysis, design management, collecting field
qualitative specification sheet experience review FMEA*, FTA*, … audits data

quantitative reliability targets non-deterministic and Weibull analysis, statistical analyzing field
probability measures DoE, Boole*, process data
Markov-Chains*, planning
FTA*

*in “Principles of Functional Safety”

[cf. Bertsche 2004 – Zuverlässigkeit im Fahrzeug- und Maschinenbau (Reliability in Automotive and Mechanical Engineering)]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 5
 recap lecture 01
Product Design Process PDP

optimiza- realiza- serial

idea definition concept design
tion tion/ test prod.

Parallel “life cycles” in product development

[Asiedu, Gu 1998 – Product life cycle cost analysis: State of the art review]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 6
 recap lecture 01
Research Examples

active buckling control [SFB 805]

semi-active vibration control via [SFB 805]

shunt-Damping

semi-active dynamic load redistribution

and health control

quantification of model
and data uncertainty / [SFB 805]

health monitoring
[Fraunhofer LBF]

adaptronics
passive/active vibration isolation
dynamic / electric / thermal
reliability of high-voltage batteries
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 7
 recap lecture 01

Weiterentwicklung Rundstab (bis zum MAFDS)

[Aeropol Aviation Services Corp.]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 8
 recap lecture 01
Modular Active Spring-Damper System (MASDS)

• load distribution
• stability
• vibration control
• health control
12 year research
collaboration: Controlling
Uncertainty in Load
Carrying Systems
(ended 2021)

[Patent: Enß, G., Gehb, C., Götz, B., Melz, T., Ondoua, S., Platz, R., Schäffner, M., (2015)]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 9
Weiterentwicklung Rundstab (bis zum MAFDS)

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 10
 [Fraunhofer LBF, 2016]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 11
modular active spring-damper system (MASDS)

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 12
Balken unter axialer Last, Systemintegration
100 mm

[SAM/Fraunhofer LBF]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 13
Active Buckling Control – Increasing Critical Load

𝜋𝜋 2 𝐸𝐸𝐸𝐸
𝐹𝐹𝑐𝑐𝑐𝑐 ≈ H strength,
0.7 � 𝑙𝑙 2
passive
tincrease
F F ΔS
b
loading
E t lred
l
tincrease

x Fcr F Fcr Fcr,p F

3
2 t E
ΔS
1 l
[Enss, Platz, 2011]
0 1 ∙E, l, t 2
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 14
Active Buckling Control – Increasing Critical Load

strength,
𝜋𝜋 2 𝐸𝐸𝐸𝐸 active
𝐹𝐹𝑐𝑐𝑐𝑐 ≈ 2 H
0.7 � 𝑙𝑙
tincrease strength,
F F passive
b
loading
E t lred
l
tincrease

F
F Fcr Fcr,a > Fcr
x Fcr
3
t
2 Fa E
1 l
0 1 ∙E, l, t 2
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 15
Active Buckling Control – Increasing Critical Load

t F
F
Fcr,a instable
EI
instable
stable real

l F = Fcr
w real

stable
la
Fa
w
𝜋𝜋 2 𝐸𝐸𝐸𝐸
𝐹𝐹𝑐𝑐𝑐𝑐 ≈ 2
0.7 � 𝑙𝑙

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 16
Numerical Verification
axial force
axial force

axial force

active lateral
force
active lateral
force

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 17
 Experimental Validation

300 mm
[Fraunhofer LBF, 2016]
[Enß, Platz; Mech. Syst. Signal Process., 2014]
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 18
 State Space Model with Linear Quadratic Control (LQC) in

controlled system

300 mm
controller

𝑢𝑢1 (𝑡𝑡) active force 𝑩𝑩(𝐹𝐹𝑥𝑥 ) input matrix

𝑢𝑢2 (𝑡𝑡) disturbance force 𝑪𝑪(𝐹𝐹𝑥𝑥 ) output matrix
𝑞𝑞̇ 𝑡𝑡 lateral modal velocity, state vector 𝑨𝑨(𝐹𝐹𝑥𝑥 ) system matrix
𝑞𝑞 𝑡𝑡 lateral modal displacement, state vector 𝑲𝑲 𝐹𝐹𝑥𝑥 control matrix
𝑦𝑦 𝑡𝑡 strain

[Enß, Control of uncertainty in a system stabilised actively against buckling, Dissertation, 2016] [Fraunhofer LBF, 2016]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 19
 Experimental Validation

40 31 trials
Fx
in N
Fa(t) ≠ 0
35
axial load P in N

 ≈40% higher bearable critical axial

300 mm
load with less uncertainty
Fcr,p,exp.
30
31 trials
Fa(t) = 0
25

20
0 0.005 0.01 0.015
displacement w in m
[Fraunhofer LBF, 2016]
[Enß, Platz; Mech. Syst. Signal Process., 2014]
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 20
Further Development – Elastic Support

Fx

active
lateral
force

[Patent: Enß, G., Gehb, C., Götz, B., Melz, T., Ondoua, S., Platz, R., Schäffner, M.,(2015)]
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 21
Further Development – Piezo-Elastic Support

[Patent: Enß, G., Gehb, C., Götz, B., Melz, T., Ondoua, S., Platz, R., Schäffner, M.,(2015)]
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 22
 Further Development – Test Rig

[Fraunhofer LBF, 2016]

w

[Schäffner, Götz, Platz, Melz; Smart Mater. Struct., 2016]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 23
Experimental Validation – Active Buckling Control

passive
active

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 24
 Research Examples
semi-active distribution control

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 25
 semi-active load distribution control

[Gehb, Platz; Mech. Syst. Signal Process., 2019]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 26
 semi-active load distribution control

𝐹𝐹(𝑡𝑡) 𝐹𝐹(𝑡𝑡)

𝑀𝑀𝑎𝑎 (𝑡𝑡)
𝑧𝑧 𝑧𝑧
𝑥𝑥 𝑥𝑥

[Gehb, Platz; Mech. Syst. Signal Process., 2019]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 27
 semi-active load distribution control

[Gehb, Platz; Mech. Syst. Signal Process., 2019]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 28
 semi-active load distribution control

numerical
simulation

experimental
simulation

[Gehb, Platz; Mech. Syst. Signal Process., 2019]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 29
 Semi-active load distribution control

conceptual model of
friction brake

[Gehb, 2019] simplified conceptual mechanical free body

model for mathematical concept diagram
modeling
DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 30
Semi-active load distribution control

LuGre-Friction model using bristles

[Gehb, 2019]

surface contact idealized surface average

roughness contact by bristle
bristles deflection

friction coefficient

semi-active moments

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 31
Semi-active load distribution control

block diagram combining all sub-models to the full open loop model

functional
[Gehb, 2019]
safety system

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 32
 Verification and Validation

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 33
Mathematical Models

“Mathematical representations of hardware and software systems (formal methods)

have emerged in the past 40 years as a promising approach to allow a more thorough
verification of the system’s correctness with respect to the requirements, using
automated and hopefully exhaustive verification procedures.”
[Bozzano, 2010]

however

“All models are wrong, some are useful.”

[George Edward Pelham Box, 18 October 1919 – 28 March 2013, British statistician]

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 34
From the Conceptual to the Computational Model

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 35
Verification and Validation

verification answers the question, if…

validation answers the question, if…

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 36
 End of Lecture

DIT Deggendorf Institute of Technology – WS2324 – Design Safe Systems – 02 V&VMechatronicSys – Oct 18, 2023 – R. Platz, Slide 37