Mechatronics for Complex Products and Systems

Project-Based Design Approaches for Robots, Cyber-Physical Systems, Digital Twins, and Other Emerging T

Bi, Zhuming 저자(글)

Wiley · 2025년 03월 11일

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저자(글) Bi, Zhuming

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• Preface xvii  About the Companion Website xix  1 Introduction 1  1.1 Introduction 1  1.2 Growing Complexity of Engineering Designs 1  1.2.1 Products 3  1.2.2 Manufacturing Technologies 5  1.2.3 Business Environments 6  1.2.4 Engineering Design 6  1.3 Integrated Engineering Design 7  1.4 Mechatronics for Multi- or Interdisciplinary Designs 9  1.5 Mechatronic Design Examples 11  1.5.1 Development of Football Robot Team 11  1.5.2 Reusing Robots to Unload Heat Sinks Automatically 12  1.5.3 Rebuilding Rail Test Machine 14  1.5.4 Testing of Electric Hardness 16  1.5.5 Valve Needle Assembly Station 16  1.5.6 Ejecting Engine Fans from Performance Tester 18  1.5.7 Demonstrator of Automated Spacer Removals in Truck Assembly Line 19  1.6 Group Technologies (GTs) for Mechatronic Designs 21  1.7 Mechatronics and Mechatronic Functional Modules (MFMs) 22  1.8 Mechatronic Design Methodologies 24  1.9 Organization of the Book 25  1.10 Summary 26  Problems 28  References 28  2 Mechatronic Designs - Innovations, Theories, and Methods 31  2.1 Innovative Thinking 31  2.2 Theory of Inventive Problem-Solving (TRIZ) as Tactic Methodology 34  2.3 Innovations of Mechatronic Systems 39  2.3.1 Modularization 39  2.3.2 Integrability 41  2.3.3 Coupled Discipline Modeling 42  2.3.4 Concurrent Design 43  2.3.5 Decentralized Controls 45  2.3.6 Event-Driven Automation 46  2.3.7 Adaptability and Re-configurability 46  2.3.8 Predictability 48  2.3.9 System Resilience 49  2.3.10 Continuous Adaptation (CA) 50  2.4 Architecture of Mechatronic Systems 51  2.5 Design of Mechatronic Systems 54  2.6 Mechatronic Design Methodologies 57  2.6.1 System Modeling Language (SysML) 58  2.6.2 Model-Based System Engineering (MBSE) 59  2.6.3 Axiomatic Design Theory (ADT) 61  2.6.4 Concurrent Design Optimization (CDO) 63  2.6.5 Virtual Verification and Validation (VVV) 65  2.7 Project-Based Mechatronic Design (PBMD) 65  2.7.1 Existing Assistive Evacuating Technologies 66  2.7.2 Proposed Assistive Evacuation Device 69  2.7.3 Main Functional Requirements from Use Cases 69  2.7.4 Project-Based Mechatronic Designs 72  2.7.4.1 Folding and Unfolding Mechanism 72  2.7.4.2 Reaction Forces on Tracks for Structural Elements 72  2.7.4.3 Motor for Lifting Mechanism 74  2.7.4.4 Control of Evacuation Device 76  2.7.4.5 PBMD in Mechatronic Design 77  2.8 Summary 77  Problems 78  References 81  3 Power Generation, Storage, Supply and Transmission 87  3.1 Introduction 87  3.2 Energy, Work, and Power 87  3.3 Energy Source 90  3.4 Driving Components - Functional Requirements (FRs) 91  3.5 Power Transmission 93  3.5.1 Functional Requirements (FRs) 94  3.5.2 Machine Elements for Power Transmission 95  3.5.3 Types of Machine Elements 95  3.5.4 Procedure in Designing or Selecting Machine Elements 95  3.5.5 Machine Elements in Mechatronic Systems 98  3.5.6 Mechanical Power Transmission Examples 98  3.6 Power Generation 100  3.6.1 Internal Combustion (IC) Generator 102  3.6.2 Solar Power Generator 103  3.6.3 Wind Turbine Generator 105  3.6.4 Geothermal Generator 105  3.6.5 Other Generators 106  3.6.6 Selection of Power Source for Mechatronic System 107  3.7 Requirements of Power Supplies and Storages 109  3.7.1 Requirements of Power Supplies 109  3.7.2 Classification of Energy Storage Systems 111  3.7.3 Flywheel Energy Storage System (FESS) 112  3.7.4 Pumped Hydro Energy Storage (PHES) 114  3.7.5 Compressed Air Energy Storage (CAES) 115  3.7.6 Gravity Energy Storage (GES) 115  3.7.7 Electrical Energy Storage (EES) 116  3.7.8 Thermal Energy Storage (TES) 118  3.7.9 Comparison of Different Energy Storages 120  3.8 Selection of Power Supplies 122  3.9 Summary 122  Problems 122  References 123  4 Actuating Systems 127  4.1 Introduction 127  4.2 Functional Requirements (FRs) 129  4.3 Design Variables (DVs) 132  4.4 Basics of Energy Conversion 135  4.4.1 Mechanical Energy Conversion 135  4.4.2 Electromechanical Energy Conversion 140  4.4.3 Thermomechanical Energy Conversion 148  4.4.4 Electro-stimulated Materials 149  4.4.5 Magneto-rheological Fluid Energy Conversion 151  4.4.6 Nano-level Energy Conversion 152  4.5 Main Components 153  4.6 Valve and Electric Actuators 154  4.6.1 Valve Actuators 155  4.6.2 Electric Actuators and Motors 157  4.6.3 Selection of Motors 160  4.7 Summary 161  Problems 161  References 162  5 Sensing Systems 165  5.1 Introduction 165  5.2 Sensors, Actuators, and Transducers 169  5.3 Classifications 170  5.3.1 Types of Quantities to be Measured 170  5.3.2 Requirements Related to Measurement 171  5.3.3 Specifications Related to Measurement 171  5.4 Working Principles 173  5.4.1 Hooke's Law 173  5.4.2 Ohm's Law 175  5.4.3 Photoconductivity 176  5.4.4 Hall Effect 177  5.4.5 Faraday's Law of Induction 178  5.4.6 Curie-Weiss Law 179  5.4.7 Time of Flight (ToF) 181  5.5 Types of Physical Quantities 182  5.5.1 Displacement, Position, and Proximity 182  5.5.2 Velocity 184  5.5.3 Acceleration 186  5.5.4 Force 188  5.5.4.1 Direct Contact Sensors 188  5.5.4.2 Piezoelectric Sensors 189  5.5.4.3 Conventional Force Sensors 190  5.5.5 Pressure 191  5.5.6 Contacts 193  5.5.7 Temperature 195  5.5.8 Chemical Particles 197  5.6 Optical Encoders 199  5.6.1 Resolutions 199  5.6.2 Decoding 202  5.7 Sensors in MEMS 203  5.8 Summary 205  Problems 205  References 207  6 Bridging Physical and Cyber Systems 209  6.1 Introduction 209  6.2 Characteristics of Signals 209  6.2.1 Analog Signals 209  6.2.2 Digital Signals 211  6.3 Conversions of Digital and Analog Signals 212  6.4 Basic Electronic Elements for DSP 213  6.4.1 Operational Amplifiers (Op-Amps) 213  6.4.2 Comparators 216  6.5 Digitization 217  6.5.1 Sampling 217  6.5.2 Quantizing 220  6.5.3 Sampling and Quantizing in Analog-to-Digital Conversion (ADC) 221  6.6 Analog-to-Digital Conversion (ADC) 225  6.6.1 Integrating ADC 226  6.6.2 Flash Converter 227  6.6.3 Successive Approximation 228  6.7 Holding Process in Sampling 236  6.8 Digital-to-Analog Conversion (DAC) 237  6.8.1 Weighted Resistor DAC 237  6.8.2 R-2R Ladder DAC 239  6.8.3 Quantization Noise 240  6.9 Summary 241  Problems 241  References 242  7 Signal Conditioning and Processing 245  7.1 Introduction 245  7.2 Basic Concepts in Electronic Circuits 245  7.2.1 Charge, Current, Voltage, and Power 245  7.2.2 Resistor, Capacitor, and Inductor 248  7.2.3 Input Loading and Output Loading 250  7.2.4 Basic Types of Signals 251  7.2.5 Main Parameters of Periodical Signals 254  7.2.6 Amplitude and Phase Changes 254  7.2.7 Wheatstone Bridges 257  7.3 Signal Cleaning 259  7.4 Signal Isolation 260  7.4.1 Optical Isolation by Light-Emitting Diodes (LEDs) 260  7.4.2 Capacitive Isolation by Capacitor 261  7.4.3 Inductive Isolation by Inductor 261  7.5 Signal Transmission 262  7.5.1 Switches 262  7.5.2 Multiplexer 262  7.5.3 Protection from High Voltage and Current 264  7.5.4 Modulation/Demodulation 265  7.6 Signal Conditioning 266  7.6.1 Amplification 266  7.6.2 Attenuation 271  7.6.3 Filtering 271  7.6.4 Linearization 275  7.6.5 Conditioning Digital Signals 275  7.6.6 Signal Clipping 277  7.7 Signal Clamping 277  7.8 Summary 278  Problems 278  References 279  8 System Controls 281  8.1 Basics of Control Systems 281  8.1.1 Complexity of Control Problem 281  8.1.2 Types of Control Problems 283  8.1.3 Architecture of Control Systems 284  8.1.4 Design of Control Systems 285  8.2 Control Theory 286  8.2.1 Open-Loop Control Versus Closed-Loop Control 286  8.2.2 Process Control Versus Motion Control 287  8.2.3 Steady Response Versus Transient Response 288  8.2.4 Transfer Functions 288  8.2.5 Orders of Control Systems 292  8.2.6 Stability Analysis 295  8.2.7 Accuracy of Control Systems 299  8.2.8 Classification of Control Systems 302  8.2.9 Frequency Responses 303  8.3 Proportional-Integral-Derivative (PID) Controls 305  8.4 Analog and Digital Implementation of PID Controllers 307  8.5 Advanced Controls 309  8.6 Intelligent Controls 309  8.6.1 Fuzzy Logic 310  8.6.2 Artificial Neural Network (ANN) 310  8.7 Design of Control System 312  8.7.1 Microcontrollers 313  8.7.2 Digital Signal Processing (DSP) 313  8.7.3 Field Programmable Gate Arrays (FPGA) 315  8.7.4 Microcomputers 316  8.7.5 Programmable Logic Controller (PLC) 316  8.8 Programming in PLC 318  8.8.1 Data Structure and Flow 318  8.8.2 Operating Cycle 319  8.8.3 I/O Modules and Addresses 319  8.8.4 Elements of Logic Control 322  8.8.5 Ladder Logic Diagrams 325  8.8.6 Timers and Counters 327  8.8.7 Sequencers 328  8.9 Summary 330  Problems 331  References 333  9 Digital Twins (DT-I), Digital Triads (DT-II), and Internet of Digital Triads Things (IoDTT) 335  9.1 Introduction 335  9.2 Digital Twins (DT-I) 338  9.3 Enabling Technologies 339  9.3.1 Data Acquisition 339  9.3.2 Modeling and Simulation 340  9.3.3 Communication Technologies 340  9.3.4 Cloud Technologies 340  9.3.5 Big Data Analytics (BDA) 342  9.4 From Digital to Physical Twins by Manufacturing 342  9.5 DT-Is in Manufacturing 343  9.5.1 System Digitization 347  9.5.2 Interactions of Physical and Digital Worlds 348  9.5.3 Historical Development of DT-I 349  9.5.4 Communication and Integration 351  9.5.5 System Architecture 353  9.6 Limitations of DT-Is 354  9.7 Advanced Attributes of Digital Entities in Manufacturing 355  9.8 Concept of Digital Triad (DT-II) 356  9.9 The Internet of Digital Triads Things (IoDTT) 360  9.10 DT-Is and DT-IIs in Sustainable Mechatronic Systems 362  9.10.1 Monitoring and Controlling 362  9.10.2 Data-Driven Decision-Making 364  9.10.3 Fault Detections 366  9.10.4 Predication of Fatigue Life 368  9.10.5 Virtual Verification and Validation (V and V) 370  9.11 Summary 371  Problems 371  References 374  10 Cyber-Physical Systems 379  10.1 Introduction 379  10.2 Characteristics of CPSs 382  10.3 Basic Features of Cyber System of CPS 384  10.3.1 Reactive Computation 385  10.3.2 Parallel Computing 385  10.3.3 Feedback Controls 385  10.3.4 Realtime-Ness 385  10.3.5 Dependability, Reliability, and Safety Assurance 386  10.3.6 Biological Intelligence 387  10.3.7 Hybrid Systems 387  10.3.8 Embedded Computation 387  10.3.9 Standards of Cyber Systems 387  10.4 Design of CPSs 387  10.5 Mathematical Modeling 388  10.5.1 Modeling Continuous Dynamics 391  10.5.2 Discrete Event Dynamic System (DEDS) 396  10.5.3 Hybrid Modeling 398  10.5.4 State Machines 400  10.6 Development Standards 403  10.7 Model-Based System Engineering (MBSE) 404  10.7.1 Modeling in MBSE 404  10.7.2 Design Stages in MBSE 405  10.7.3 Acausality Modeling by Modelica 406  10.7.4 Programming in Modelica 409  10.7.5 Formal Semantics 412  10.7.6 Verification and Validation (V&V) 414  10.8 Summary 415  Problems 416  References 418  11 Internet of Things 421  11.1 Introduction 421  11.1.1 IoT Concepts 422  11.1.2 Smart Things 424  11.1.3 Communication Protocols 425  11.2 Characteristics of IoT-Enabled Systems 427  11.3 Importance of IoT in Mechatronics 428  11.4 Data Flows in IoT-Enabled Systems 431  11.5 IoT-Enabled Capabilities 432  11.5.1 Interactions 433  11.5.2 Big Data Analytics (BDA) 435  11.5.3 Digital Manufacturing (DM) 435  11.6 Project-Based IoT-Enabled System Development 438  11.6.1 Ubiquitous Sensing 439  11.6.2 Fusing and Integrating Data from Heterogeneous Sources 439  11.6.3 Methods of Coping with Big Data 440  11.6.4 Surveillance and Data Visualization 441  11.6.5 Workflow Composition 441  11.6.6 Standardization of Specifications 444  11.6.7 Data Acquisition, Classification, and Utilization 444  11.7 Summary and Conclusion 445  Problems 447  References 447  12 Robotics 451  12.1 Introduction 451  12.2 Classifications 454  12.3 Basic Terminologies in Robotics 456  12.3.1 Mechanical Structure 457  12.3.2 Degrees of Freedom (DOF) 458  12.3.3 Workspaces 462  12.3.4 Modeling and Simulation 464  12.3.5 Accuracy, Precision, and Calibration 464  12.3.6 Other Specifications 465  12.4 Kinematic Modeling 466  12.4.1 Positions of Points, Links, and Bodies in 2D and 3D Space 466  12.4.2 Motions of Particles, Links, and Bodies 468  12.4.3 Vector-Loop Method for Motion Analysis of Plane Mechanism 473  12.4.3.1 Kinematic Parameters and Variables 477  12.4.3.2 Inverse Kinematics 477  12.4.3.3 Forward Kinematics 478  12.4.4 Denavit-Hartenberg (D-H) Notation 479  12.4.5 Jacobian Matrix for Velocity Relations 481  12.5 Dynamic Modeling 491  12.5.1 Inertia and Moments of Inertia 491  12.5.2 Newton-Euler Formulation 493  12.5.3 Lagrangian Method 498  12.6 Kinematic and Dynamics Modeling in Virtual Design 500  12.6.1 Motion Simulation 502  12.6.2 Model Preparation 502  12.6.3 Creation of Simulation Model 504  12.6.4 Define Motion Variables 504  12.6.5 Setting Simulation Parameters 506  12.6.6 Run Simulation and Visualize Motion 506  12.6.7 Analyze Simulation Data 507  12.6.8 Structural Simulation Using Motion Loads 508  12.6.9 Summary on Kinematic and Dynamic Modeling 510  12.7 Mobile Robots 511  12.7.1 Three-Wheeled Robots 514  12.7.2 Four-Wheeled Robots 515  12.7.3 Unmanned Aerial Vehicles (UAVs) 516  12.8 Robotic Programming 519  12.9 Summary 521  Problems 521  References 524  13 End-Effectors 527  13.1 Introduction 527  13.2 Grasping Theory 528  13.2.1 Contacts on Object 528  13.2.2 Motions and Forces 530  13.2.3 Frictions 531  13.2.4 Grasping Model 533  13.2.5 Form Closure 534  13.2.6 Force Closure 536  13.2.7 Quality of Grasping 537  13.3 Mechatronic Design of End-Effectors 537  13.3.1 Mechanical and Actuating Components 538  13.3.2 Sensing Components 541  13.3.3 Control Components 542  13.4 Evaluation of Grasping Performance 544  13.5 Grasping Configurations 545  13.6 Types of End-Effectors 546  13.6.1 Types of Grippers 546  13.6.2 Types of Processing Tools 548  13.6.3 Multifunctional Tools 549  13.6.3.1 Concepts 550  13.6.3.2 Classification 550  13.6.3.3 Advantages and Disadvantages 554  13.6.3.4 Selection Principles 556  13.6.3.5 Development Trends 556  13.7 Main Factors in Designing an End-Effector 558  13.8 Computer-Aided Design Tools for End-Effectors 560  13.9 Summary 560  Problems 560  References 561  14 Metaverses for Sustainability Mechatronic Systems 565  14.1 Introduction 565  14.2 FRs of Sustainable Mechatronic Systems 566  14.2.1 Scalability, Accessibility, Security, Privacy, and Legal Issues 568  14.2.2 First-Time-Right from Virtual to Physical World 568  14.2.3 Ubiquitous Data and Computing 568  14.2.4 Diagonalizability, Predictability, and Adaptability 569  14.2.5 Human Intelligence for Uncertainty and Changes 570  14.2.6 Data-Driven Decision-Making Supports 571  14.3 Metaverse and Relevant Technologies 573  14.3.1 Architecture or Framework 574  14.3.2 Virtual Reality (VR), Augmented Reality (AR), Mixed Reality (MR), and Extended Reality (ER) 576  14.3.3 Digital Twins (DTs), Cyber-Physical Systems 578  14.3.4 Internet of Things (IoT) and Edge Computing 579  14.3.5 Big Data Analytics (BDA) and Cloud Computing (CC) 581  14.3.6 Blockchain Technologies (BCTs) 581  14.3.7 Artificial Intelligence (AI) 583  14.3.8 Human-Machine Interactions (HMI) 585  14.3.9 Data-Driven Decision-Making Systems 586  14.4 Metaverses for Sustainability 587  14.4.1 Metaverses to Deal with Changes and Uncertainties 588  14.4.2 Sustainable Manufacturing 590  14.4.3 Framework of Metaverse Use Cases 590  14.4.4 Metaverses for Remote Access 592  14.5 Summary and Future Work 593  Problems 593  References 594  15 Human Cyber-Physical Systems (HCPS) 603  15.1 Introduction 603  15.2 Humans' Roles in CPS 605  15.3 Enabling Technologies 608  15.4 Human-Machine Interactions (HMI) 610  15.4.1 Collaborative Robots 610  15.4.2 Types of HMIs 612  15.4.3 Collaborative Machines in Manufacturing 613  15.4.4 Critical Requirements of Cobots 613  15.4.5 Safety Assurance Mechanisms for Cobots 616  15.4.5.1 Safety-Rated Monitored Stop (SRMS) 616  15.4.5.2 Hand Guiding (HG) 617  15.4.5.3 Speed and Separation Monitoring (SSM) 618  15.4.5.4 Power and Force Limiting (PFL) 618  15.4.6 Cobotic Systems 618  15.4.7 End-Effectors of Cobots 620  15.4.7.1 Affordable Force Monitoring 620  15.4.7.2 Ergonomic Protection of Grippers 621  15.4.8 Safety Assurance in HCPSs 622  15.5 Example of Assistive Technologies 622  15.5.1 Cobots in Healthcare 622  15.5.2 Conceptual Design of Cobot 623  15.5.3 Kinematic Model 624  15.5.4 Motion for Arbitrary Explicit Trajectory 625  15.5.5 Motions of Omniwheels 626  15.5.6 Dynamic Control Model 626  15.5.6.1 Analyses of Force on Omniwheels 627  15.5.6.2 Analyses of Force on Cobot Platform 628  15.5.6.3 Constraints to Maintain Contacts to Ground 629  15.5.6.4 Strategies of Cobot Controls 630  15.5.7 Simulation 631  15.5.8 Summary of HCPS as Assistive Technologies 632  15.6 Brain-Computer Interfaces (BCI) for Supervisory Controls 634  15.6.1 Unmanned Aerial Vehicles (UAVs) 634  15.6.2 UAV Controls 635  15.6.3 BCI for Effective HMI 636  15.6.4 Development of BCIs 638  15.6.4.1 Brain Signals 639  15.6.4.2 Data Acquisition 640  15.6.4.3 Feature Classification and Detection 642  15.6.5 BCI Development Platform 645  15.7 Summary 648  Problems 649  References 649  Index 657

기본정보

ISBN	9781394209590 ( 1394209592 )
발행(출시)일자	2025년 03월 11일
쪽수	704쪽
총권수	1권
언어	영어