Mechatronics Systems and

Applications
Course Code: ES-451
LECTURE#08-10
Software Designing Approaches and
Results Validation Techniques
(CLO-1)
(PLO-1)
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 Course Outline
• Mechatronics as an Embedded System Design Services
• Mechatronics System Designing from Mechanical System
• Modeling and Simulation
• Developing Simulation Models
• Performing Simulation Analysis
• Mechatronics System Simulation: Power Steering Example
• Mechatronics System design.. Verification and Validation
Mechatronics as an Embedded System Design Services

• Mechatronics embedded system design

framework is based on product engineering
support from concept to prototyping and
manufacturing of new products, feature
enhancement and technology up-gradation
through electronic hardware design, Firmware
design, software application development and
mechanical design.
Mechatronics as an Embedded System Design Services

BOM-Bill of Materials
Mechatronics System Designing from Mechanical System
• The dynamic behaviour of complex mechanical structures can be improved by
use of mechatronic design concepts and methods.
• The mechanical parts of the mechatronic system are extended by actuators,
sensors and information processing and controlling systems.
• To determine and to optimize the functional dynamic features of the entire
mechatronic system, geometrical, physical-topological, and mathematical
models should be taken into account at an early stage in the design process
through system modeling and simulation before expensive test beds.
Mechatronics System Designing from Mechanical System
• The design process is subdivided into hierarchically structured
processes of the kinematic, dynamic and mechatronic functions.
• The kinematic, dynamic and mechatronic processes, lay out the
essential properties of the dynamic system behaviour.
• Based on the kinematic and dynamic system models are created
and detailed geometric system models can be created and
optimized in the subsequent design process.
• The dynamic system models must be derived from the
geometric shape in an iterative optimization process.
• To achieve optimal design results, a realistic system model of
the mechatronic products must be assembled, modified,
analyzed, and assessed in an iterative optimization process.
Realization of Mechatronics System Software Designing
• The realization of model-based design, requires
modern software systems.
• A tool coupling between the mechatronic development
system CAMeL (Computer-Aided Mechatronics
Laboratory) and commercial tools CAD/CAE/CAM
simplifies the design process.
• The automatic determination of dynamic models and
analysis results (CAMeL) from the geometric models
(CAD/CAE/CAM) is supported by solution elements like
bearings, gears, etc.
 Modeling and Simulation
• Modelling is the process of representing a model
which includes its construction and working.
– This model is like a real system, which helps the
analyst predict the effect of changes to the system.
– In other words, modelling is creating a model which
represents a system including their properties. It is
an act of building a model.
• Simulation of a system is the operation of a model in
terms of time or space, which helps analyze the
performance of an existing or a proposed system.
– In other words, simulation is the process of using a
model to study the performance of a system.
 System Simulation
• System simulation is a set of techniques that use
computers to initiate the operations of real-world
system through simulation.
• Computers are used to generate the numerical
models for the purpose.
• The complexity of the system arises from the
stochastic (probabilistic) nature of the events, rules
for the interaction of the elements and the difficulty
in perceiving the behavior of the systems with the
passing of time.
 Developing Simulation Models (1)
Simulation models consist of the following
components: system entities, input variables,
performance measures, and functional relationships.
Following are the steps to develop a simulation model.
• Step 1 − Identify the problem with an existing system
or set requirements of a proposed system.
• Step 2 − Design the problem while taking care of the
existing system factors and limitations.
• Step 3 − Collect and start processing the system data,
observing its performance and result.
• Step 4 − Develop the model using network diagrams
and verify it using various verifications techniques.
 Developing Simulation Models (2)
• Step 5 − Validate the model by comparing its
performance under various conditions with the real
system.
• Step 6 − Create a document of the model for future
use, which includes objectives, assumptions, input
variables and performance in detail.
• Step 7 − Select an appropriate experimental design as
per requirement.
• Step 8 − Induce experimental conditions on the model
and observe the result.
 Performing Simulation Analysis (1)
Following are the steps to perform simulation analysis.
• Step 1 − Prepare a problem statement.
• Step 2 − Choose input variables and create entities for
the simulation process.
– There are two types of variables - decision variables
and uncontrollable variables.
• Decision variables are controlled by the
programmer, whereas uncontrollable variables are
the random variables.
• Step 3 − Create constraints on the decision variables by
assigning it to the simulation process.
• Step 4 − Determine the output variables.
 Performing Simulation Analysis (2)
Step 5 − Collect data from the real-life system to input into
the simulation.
Step 6 − Develop a flowchart showing the progress of the
simulation process.
Step 7 − Choose an appropriate simulation software to run
the model.
Step 8 − Verify the simulation model by comparing its result
with the real-time system.
Step 9 − Perform an experiment on the model by changing
the variable values to find the best solution.
Step 10 − Finally, apply these results into the real-time
system.
 Modelling & Simulation ─ Advantages
• Easy to understand − Allows to understand how the system
really operates without working on real-time systems.
• Easy to test − Allows to make changes into the system and their
effect on the output without working on real-time systems.
• Easy to upgrade − Allows to determine the system requirements
by applying different configurations.
• Easy to identifying constraints − Allows to perform bottleneck
analysis that causes delay in the work process, information, etc.
• Easy to diagnose problems − Certain systems are so complex
that it is not easy to understand their interaction at a time.
– Modelling & Simulation allows to understand all the
interactions and analyze their effect.
– Additionally, new policies, operations, and procedures can be
explored without affecting the real system.
 Modelling & Simulation ─ Disadvantages
• Designing a model is an art which requires domain
knowledge, training and experience.
• Operations are performed on the system using random
number, hence difficult to predict the result.
• Simulation requires manpower and it is a time-
consuming process.
• Simulation results are difficult to translate. It requires
experts to understand.
• Simulation process is expensive.
Mechatronics System Simulation: Power Steering Example
Classical design issues:
• Is the electric motor powerful enough
• What is the time response of the system?
• What maximum pressure can be reached?
• Is there any risk of vibration?
• How to optimize the control design?
 Abstract level: Power Steering Example
• Can we build the complete system model with a CAD-based software?
– No, since we have no CAD at this stage of design
• Can we simulate it within an acceptable simulation (computational) time?
– No, as no 3D software is able to do that at this stage.
Solution:
We model another approach to
• Pre-design such systems
• Choose an architecture (hydraulic, electro-hydraulic, electric )
• Assess key function of the system
 Abstract level: Equation-Representation
• Equation are usually written as time dependent with a focus
on computing state derivative of variables to assess transient
evolution.
• Physical equations of component behaviour are represented
by readable objects (icons).

Q=Quantity (volume flow rate) T=Level of Tank R=radial separation b/w masses
 Power flow and Power conversion
• System simulation is linked to the power flow and power
conversion within a dynamical system.
• Each power network can be modeled using different physics
with gates between subsystems.
 1D System Simulation

ODE: ordinary differential equation DAE: differential-algebraic equation

Mechatronics System design.. Verification and Validation
Validation and verification are the two steps in any
simulation process to validate a model.
• Validation is the process of comparing two results.
– In this process, we need to compare the representation
of a conceptual model to the real system.
– If the comparison is true, then it is valid, else invalid.
• Verification is the process of comparing two or more
results to ensure its accuracy.
– In this process, we compare the model’s
implementation and its associated data with the
developer's conceptual description and specifications.
 System design Verification and Validation
• Validation is the process of checking whether the
specification captures the customer’s needs,
• Verification is the process of checking that the software
meets the specification.
 Verification and Validation Elements
• Verification includes all the activities associated with the producing high quality
software: testing, inspection, design analysis, specification analysis, and so on.
– It is a objective process where various products and documents are expressed
precisely enough, no subjective judgements are required to verify software.
• Validation is a subjective process. It involves making subjective assessments of how well
the (proposed) system addresses a real-world need.
– Validation includes activities such as requirements modelling, prototyping and user
evaluation.
 Verification and Validation- Tools
• Hardware-in-loop simulation (HIL)
• Customized Test
• Modeling and simulation
• Scripts based Automated Testing
• LabView/Matlab/Simulink
Techniques to Perform Verification of Simulation Model
• By using programming skills to write and debug the
program in sub-programs.
• By using “Structured Walk-through” policy in which
more than one person is to read the program.
• By tracing the intermediate results and comparing
them with observed outcomes.
• By checking the simulation model output using
various input combinations.
• By comparing final simulation result with analytic
results.
 Techniques to Perform Validation of Simulation Model
• Step 1 − Design a model with high validity.
– The model must be discussed with the system experts while designing.
– The model must interact with the client throughout the process.
– The output must supervised by system experts.
• Step 2 − Test the model at assumptions data.
– by applying the assumption data into the model and testing it
quantitatively.
– Sensitive analysis can be performed to observe the effect of change in
the result when significant changes are made in the input data.
• Step 3 − Determine the representative output of the Simulation model.
– Determine how close is the simulation output with the real system
output.
– Comparison can be performed using the Turing Test. It presents the
data in the system format, which can be explained by experts only.
– Statistical method can be used for compare the model output with the
real system output.
 Text References
TEXT BOOK:
• HGodfrey C. OnwuboluH, “Mechatronics: Principles and
Applications”, Elsevier Butterworth-Heinemann.
RECOMENDED BOOKS
• Louis G. Birta and Gilbert Arbez, “Modelling and
Simulation: Exploring Dynamic System Behaviour”
by Springer, 1st edition.
• Averill Law, “Simulation Modeling and Analysis” by
McGraw-Hill Series, 5th edition.
• Bernard P. Zeigler, Herbert Praehofer and Tag Gon
Kim, “Theory of Modeling and Simulation: Integrating
Discrete Event and Continuous Complex Dynamic
Systems, by Book News, Inc, 2nd Edition.
END OF LECTURE