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Transcript of Mechatronic Overview
R. I.TU Darmstadt 2005
MECHATRONISCHE SYSTEME MECHATRONISCHE SYSTEME FÜR KRAFTFAHRZEUGEFÜR KRAFTFAHRZEUGE
(Automotive (Automotive MechatronicsMechatronics ))
Prof. Dr.Prof. Dr.--IngIng. R. . R. IsermannIsermann
Institut für AutomatisierungstechnikTechnische Universität Darmstadt
R. I.TU Darmstadt
AUTOMOTIVE MECHATRONICSAUTOMOTIVE MECHATRONICS
• INTRODUCTION
• DESIGN PROCEDURE
• HISTORICAL DEVELOPMENT
• MECHATRONIC SUSPENSIONS
• MECHATRONIC BRAKE SYSTEMS
• MECHATRONIC STEERING SYSTEMS
• ACTIVE FRONT STEERING CONTROL
• CONCLUSIONS
2005
R. I.TU Darmstadt
Mechatronics: Synergetic integration of different d isciplines
MECHATRONICS
informationtechnology
system theorymodelingautomation technologysoftwarecomputational intelligence
electronics
micro electronicspower electronicssensorsactuators
mechanics
mechanical elementsmachinesprecision mechanics
R. I.TU Darmstadt
sensors
measuredvariables
Mechanical process and information processing devel op towards mechatronic systems
mechanics &energy converter
mechanicalhydraulicthermal
electrical
energy flow
energysupply
energycon-
sumer
monitoredvariables
referencevariables
manipulatedvariables information flow
man/machineinterface
informationprocessing
actua-tors
auxiliaryenergysupply
R. I.TU Darmstadt
o Definition
• Many technical processes and products show an increasingintegration of MECHAnics with elecTRONICS and informationprocessing
• The integration is between the components (hardware) and theinformation-driven functions (software)
• Their development involves finding– an optimal balance between the basic mechanical structure, sensor and
actuator implementation– automatic digital information processing– overall control
• This synergy results in innovative solutionsIFAC T.C. Mechatronic Systems (2000)
R. I.TU Darmstadt
MechatronicSystems
Mechatronicmotion
generators
- integratedelectricalservo drives
- integratedhydraulicservo drives
- integratedpneumaticservo drives
- robots(multi-axis,mobile)
Mechatronicmachine
components
- semi-activehydraulicdampers
- magneticbearings
- automaticgears
Mechatronicpower
producingmachines
- brushless DCmotors
- integrated ACdrives
- mechatroniccombustionengines
machine tools
- integratedmulti-axis
- integratedhydraulicpumps
Mechatronicpower
consumingmachines
Mechatronicautomobiles
- antilock brake(ABS)
- electro-hydraulicbrake (EHB)
- activesuspension
- active frontsteering
Mechatronictrains
- tilting trains- active boogie- magnetic
levitated
(MAGLEV)trains
Examples for mechatronic systems
R. I.TU Darmstadt
o Functions and integration of mechatronic systems
• Distribution of functions• Operating properties• New functions• Integration forms
R. I.TU Darmstadt
o Functions and integration of mechatronic systems
• Distribution of functions• Operating properties• New functions• Integration forms
R. I.TU Darmstadt
• New functions– Control of nonmeasurable variables
• Tire slip• Slip angle and ground speed of vehicles• Internal temperatures or tensions• Damping parameters
– Advanced supervision and fault diagnosis– Fault-tolerant systems with redundancy– Teleservice functions
• monitoring, maintenance, repair
– Programmable functions• flexible adaptation through software change• changes during design, commissioning, after-sales• shorter time-to-market
R. I.TU Darmstadt
• Integration forms- consideration of integrated overall system- generation of synergetic effects→ classical mechanical-electronic system :
“addition of available components”
micro-computer actuators process sensors
integration of components
R. I.TU Darmstadt
Spatial integration (integration of the components)
“Integration of the components at different places”
� actuator and microcomputer� smart actuator
� process and microcomputer� sensor and microcomputer
� smart sensor
micro-computer
actuators process sensors
integration of components
Hardware-Integration
R. I.TU Darmstadt Mechatronic overall integration
supervisiondiagnosis
adaptationoptimizationcontrol
online information processing
knowledge baseintegration by information processing
mathematicalprocess models
performancecriteria
information gaining- identification- state observer
design methods- control- supervision- optimization
software-integration
micro-computer
actuators process sensors
integration of components
hardware-integration
R. I.TU Darmstadt
Runge, ATZ 2000
Mechatronic control module for a 6-gear-automatic tr ansmission(ZF 6HP26)
R. I.TU Darmstadt
128k
Byt
e
ABS 2ABS 2
6,2 kg
ABS 5.0ABS 5.0
3,8 kg
ABS 5.3ABS 5.3
2,6 kg
ABSR 5.7ABSR 5.7
2,5 kg
ABS 8ABS 8
1,8 kg
Tend
enz
stei
gend
!
48kB
yte
24kB
yte
16kB
yte
8kB
yte
1989 1992 1995 1998 2001
3
6
kg kByte200
100
History of ABS Systems
Rob. Bosch GmbH
Anti-lock braking systems (ABS)
R. I.TU Darmstadt
Quelle:ATZ/MTZ Extra „Der Neue Golf“ Oktober2003
Direct automatic shift gear box with double clutch (2003)
Volkswagen
R. I.TU Darmstadt
Quelle:ATZ/MTZ Extra „Der Neue Golf“ Oktober2003
Electro-hydraulic control system for DSG
Volkswagen
R. I.TU Darmstadt
AUTOMOTIVE MECHATRONIC SYSTEMSAUTOMOTIVE MECHATRONIC SYSTEMS
• INTRODUCTION
• DESIGN PROCEDURE
• HISTORICAL DEVELOPMENT
• MECHATRONIC SUSPENSIONS
• MECHATRONIC BRAKE SYSTEMS
• MECHATRONIC STEERING SYSTEMS
• ACTIVE FRONT STEERING CONTROL
• CONCLUSIONS
2005
R. I.TU Darmstadt
DESIGN PROCEDURE FOR MECHATRONICSYSTEMS
o Mechatronic engineeringo Modelling and simulationo Software tools
R. I.TU Darmstadt
Design procedure for mechatronic systems (iterationa l steps not indicated )
systemdefinition
requirementsengineering
(specification)
mechanical& electricalengineering
electronicengineering
information& control
engineeringoperating
engineering
process/component
design
electronichardware
design
inform. proc-cessing & soft-
ware design
human-ma-chine inter-face design
traditionalengineering
integration of components(hardware)
integration by informationprocessing (software)
integrated(concurrent)engineering
R. I.TU Darmstadt
reliability &safety
engineering
manufacturingengineering
mechatronicsystem
Design procedure for mechatronic systems (iterationa l steps not indicated)
integrated(concurrent)engineering
integration of components(hardware)
integration by informationprocessing (software)
integrated mechan.electronic systemgeneration of
synergeticeffects
R. I.TU Darmstadt
o Modelling and Simulation for design and integratio n:
– Software-in-the-loop simulation (SiL)• Process and controller (ECU) simulated (not real-time)
– Rapid-control-prototyping (RCP)• Real process and high-performance prototyping computer (real-time)
– Hardware-in-the-loop simulation (HiL)• Simulated process and real ECU (real-time)
R. IsermannTU Darmstadt
real process real ECU + real actuator
RCP
SiL
integratedmechatronic
system
HiL
process-model
simulation tool
θFW
nengT2,stat T2
p2,stat p2
ECU-model
high performancereal-time computer
(full pass, by pass)
θFW
neng
p 2,Setpoint
p 2
controlalgorithm
u pwm
Simulations for mechatronic development
real-time
real-time
R. I.TU Darmstadt
Diesel engines
Truck engine Passenger car engine
R. I.TU Darmstadt
Hardware-in-the-Loop Simulator für truck engine controlHardware-in-the-Loop Simulator für truck engine control
HiL-Simulator, dSpace DSP & Power PC
IAT/DC1992-1999
R. I.TU Darmstadt HiL-simulation of a single injection pump valve cut off
R. I.TU Darmstadt HiL-simulation of a full power acceleration of a 40 tons truck
1 gear shifts
2 drive train oscillations
3 soot limitation
4 speed limitation
5 turbo charger inertness
R. I.TU Darmstadt
AUTOMOTIVE MECHATRONIC SYSTEMSAUTOMOTIVE MECHATRONIC SYSTEMS
• INTRODUCTION
• DESIGN PROCEDURE
• HISTORICAL DEVELOPMENT
• MECHATRONIC SUSPENSIONS
• MECHATRONIC BRAKE SYSTEMS
• MECHATRONIC STEERING SYSTEMS
• ACTIVE FRONT STEERING CONTROL
• CONCLUSIONS
2005
R. I.TU Darmstadt
Anti-skid control (1993)Acceleration sensor
Anti-lock brake system(1979)
Wheel speed sensor
Electronic stability progr.(1995)Yaw rate sensor
Active Body Control(2000)
Susp.deflect.
Adaptive Cruise Control(1999)
Radar sensor
Steer-by-Wire(20??)
Figures: Continental Teves AG & Co. oHGCollision Avoidance
(20??)
Brake assist(1996)
EMB-force sensor
Brake-by-Wire (EHB )(2001)
Active front steering (2003 )
EHB-pressure
Pedal position
Brake-by wire (20??)
Vehicle dynamics control systems
R. I.TU Darmstadt
Sensors and Sensors and actuatorsactuators forfor gasolinegasoline enginesengines
� Electronic fuel injection(1967, D-Jetronic)
� Microelectroniccontrolled ignition and injection(1979, Motronic)
� Exhaust gas valve
� Tank vent valve
� Secundary air valve(1994)
� Variable geometrymanifold
� Electronic throttle (1997)
� Variable camshafttiming
� Variable valve lift(2001)
Actuators� Engine speed (1967),
camshaft phase
� Engine temperature (1967)
� Manifold pressuremanifold temperature (1967)
� Knock sensor (1969)
� Airmass flap (1973)
� Oxygen (lambda) (1976)
� Airmass hot-film (1981)
� Ambient pressure
� Throttle- and pedal-position(1997, E-Gas)
� Tank pressure
� Ion current (20??)
� Combustion pressure (20??)
Sensors
Abbildung: Adam Opel AG
�ca. 15-25 measurements
�ca. 6-8 manipulation variables
�ca. 80-120 look-up-tables
Sensors and actuators for gasoline engines
R. I.TU Darmstadt
Mechatronicautomobiles
Mechatroniccombustion
engines
- electricalthrottle
- mechatronicfuel injection
- mechatronicvalve trains
- variable geo-metry turbo-charger (VGT)
- emission control- evaporative
emission control- electrical pumps
& fans
Mechatronicdrivetrains
- automatichydrodynamictransmission
- automaticmechanicshift transm.
- continuouslyvariable trans-mission (CVT)
- automatic tractioncontrol (ATC)
- automatic speedand distance control (ACC)
Mechatronicsteering
- parameter-izable power-assistedsteering
- electro-mechanical power-assistedsteering (EPS)
- active frontsteering (AFS)
Mechatronicbrakes
- hydraulic anti-lock braking (ABS)
- electronic stabilityprogram (ESP)
- electro-hydraulicbrake (EHB)
- electro-mechanicalbrake (EMB)
- electrical parkingbrake
Mechatronicsuspensions
- semi-activeshock-absorbers
- active hydraulicsuspension(ABC)
- active pneumatic suspension
- active anti-roll bars (dynamic drive control (DDC) or roll-control)
R. I.TU Darmstadt Control units and data exchange
40 - 75 Electronic Control Units30 - 150 electrical motors2- 4 km cables (harness): 40 - 80 kg4 bussystems2500 signals
Source: VDA 2001
R. I.TU Darmstadt
Bordnetz des VW Phaeton
Quelle: ATZ Sonderheft VW Phaeton
VW Phaeton: Elektrisches Bordnetz
R. I.TU Darmstadt
AUTOMOTIVE MECHATRONIC SYSTEMSAUTOMOTIVE MECHATRONIC SYSTEMS
• INTRODUCTION
• DESIGN PROCEDURE
• HISTORICAL DEVELOPMENT
• MECHATRONIC SUSPENSIONS
• MECHATRONIC BRAKE SYSTEMS
• MECHATRONIC STEERING SYSTEMS
• ACTIVE FRONT STEERING CONTROL
• CONCLUSIONS
2005
R. I.TU Darmstadt
Stabilisation through single wheel braking with ESP
VDA 2001
R. I.TU Darmstadt
Electro-Hydraulic Brake System
VDA 2001
R. I.TU Darmstadt
EHB1 Hydraulic Unit Components
Suction connectionSealings for pressure sensor modul
Contact springPressure sensor modul
ECU
Sealing for ECUMagnet group
Valve
Medium separatorPump element
Accumulator withmultilayer diaphragm
Electric motor
Rob. Bosch GmbH
Electrohydraulic brake
R. I.TU Darmstadt
Chassis SystemsElectro Hydraulic Brake System EHB1
Rob. Bosch GmbH
R. I.TU Darmstadt
Continental Teves (2003)
Electro-mechanical brake (prototype)
R. I.TU Darmstadt
AUTOMOTIVE MECHATRONIC SYSTEMSAUTOMOTIVE MECHATRONIC SYSTEMS
• INTRODUCTION
• DESIGN PROCEDURE
• HISTORICAL DEVELOPMENT
• MECHATRONIC SUSPENSIONS
• MECHATRONIC BRAKE SYSTEMS
• MECHATRONIC STEERING SYSTEMS
• ACTIVE FRONT STEERING CONTROL
• CONCLUSIONS
2005
R. I.TU Darmstadt
ElectricalPower Steering
(EPS)
Electrical PowerAssisted Steering
(HPS + EPS)
Active FrontSteering
(AFS)
Mechatronic steering systems
HydraulicPower Steering
(HPS)
hydraulicactuator
hydraulicpump
hydraulicvalve
HydraulicPower Steering
(HPS)
ElectricalPower Steering
(EPS)
electricalactuator
electricalactuator
in steering column
Electrical PowerAssisted Steering
(HPS + EPS)(larger vehicles)
hydraulicactuator
hydraulicactuator
Active FrontSteering
(AFS)
electricalactuator
generates additionalsteering angles
electricalsteering
torque motorfor hapticfeedback
Steer-by-Wire
(SbW)
electricalactuator
R. I.TU Darmstadt
Servomotor
ECU
Steer pinion
Torque sensor
Torsion rodServo pinion
Quelle:ATZ/MTZ Extra „Der Neue Golf“ Oktober2003
Electrical Power Steering (EPS)
VW
R. I.TU Darmstadt
Superposition of a steering angle
BMW (2003)
Active front steering
R. I.TU Darmstadt
Development of driver assistance systemsDevelopment of driver assistance systems
R. I.TU Darmstadt
Automotive surrounding sensors
1. Close range: ultra sonic, radar
2. Medium range: lidar, radar, camera
3. Remote area: radar, camera
R. I.TU Darmstadt FG Regelungstechnik u. Prozessautomatisierung
Gemeinschaftsforschung mit der IndustrieArbeitskreise begleiten Forschungsvorhaben: 2-3 Jahre
Finanzierung: 50% Industrie – 50% BMBF oder BMWiAuftragsumfang: 65.000 € pro Jahr und Vorhaben
Dieselmotoren-Regelung (1992-1995)
Nebenaggregate-Management (1995-2000)Fehlerdiagnose an Dieselmotoren (1999-2002)Fehlerdiagnose an Ottomotoren (1999-2002)
Dieselmotoren-Steuerung (1995-1997)
Verbrennungsmotoren
ForschungsvereinigungVerbrennungskraftmaschinenFVV
Modellbasierte Telediagnose elektrischer Antriebe und Textilmaschinen
TeleserviceForschungszentrum KarlsruheProjektträger des BMBFVerbundprojekt OKTEL
Intelligente dezentraleelektromechanische Komponenten (1996-1999)
Störungsfrüherkennung an oszillierendenVerdrängerpumpen (2002-2004)
Mechatronische Systeme
Mechatronische Pumpen
Deutsche Forschungsgesellschaft fürdie Anwendung der MikroelektronikDFAM
Fachgemeinschaft Pumpen VDMA
Einfach anwendbare Diagnoseverfahren fürmechatronische Komponenten (2001-2003)
DFAM
R. I.TU Darmstadt
Forschungskooperationen mit FirmenForschungverträge: 1-3 Jahre, Finanzierung: 100% In dustrie
Auftragsumsatz: ca. € 700.000 pro Jahr
FG Regelungstechnik u. Prozessautomatisierung
MedizintechnikDialysesysteme (seit 1998)
ModellbildungOptimale RegelungPatientenadaption
�
��
Ottomotoren (seit 1996)
Regelung
Regelung
Brennraumdruck-
Abgasrückführungs-
�
�
Verbrennungsmotoren
Verbrennungsaussetzer-Erkennung (1996-2001)
AbgasstrangDruckanalyse im
Ionenstrommessung
�
�
Dieselmotoren (seit 1992)Modellbildung�
Echtzeit-SimulationRegelung
��
Energie-/Produktionstechnik
Zementproduktion (1992-1997)Modellbildung, SimulationStrukturvariable Regelung von Mahlanlagen
�
�
W1
W2
Heizungssysteme (seit 1986)Modellbildung, SimulationAdaptive RegelungFuzzy-Regelung
�
��
KraftfahrzeugeBrake-by-Wire (seit 1995)
Regelung und Rekonstruktionder Bremskraft einer EMBIntelligentes BremspedalRegelung der Horizontaldynamikmit BbW-Aktuatoren (ABS/ESP)
�
��
Personenkraftwagen (seit 1990)
Geschwindigkeitsregelung
On-line Simulationsmodelle Automatische Abstands- und
automatischesParkassistenzsystem
�
�
�
Aktive Fahrwerke (seit 2001)Zustandserkennung für aktiveFahrwerke
�
Ottomotoren (seit 2001)Optimierung der Verbrennungbeim Direkteinspritzer
�
R. I.TU Darmstadt
In Kooperation mit
Sensorik
Radar Lidar
Regelung
Notlenken Notbremsen
Aktorik
Steer-By-Wire
Brake-By-Wire
Elektronische Fahrerassistenz für einunfallvermeidendes FahrzeugPRORETA
R. I.TU Darmstadt
CONCLUSIONS
• Mechanical, hydraulic and pneumatic components areintegrated with microelectronics
• Software determines functions• Mechatronic components improve functionality, safety,
economy and comfort• Modelling and simulation tools allow simultaneous
engineering and fewer prototypes• Same mechatronic development for combustion engines,
transmissions
→ Mechatronic components change the design of automobiles
→ Mechatronics: emerging area of innovative engineering
R. I.TU Darmstadt
AUTOREG 2006-Steuerung und Regelung von Fahrzeugen und Motoren-
Wiesloch, 7. und 8. März 2006
Veranstalter: VDI/VDE-GMA und VDI-FVTAusschuss “Steuerung und Regelung von Kraftfahrzeugen
und Verbrennungsmotoren-GMA 7.62”
AUTOREG 2006 (3.Tagung)– 2 Plenarvorträge
– 64 Einzelvorträge in 3 parallelen Sitzungen
– 15 Posterbeiträge
FVT
GMA
Steuerung und Regelung von Fahrzeugen undMotoren - AUTOREG 2004
Aufruf zur Einreichung von Beiträgen
FVTGMAwww.vdi.de/gma/autoreg2006
R. I.TU Darmstadt
END
80 Folien: 65 min effektiv benötigt.... Seoul ICCAS: 0.8 min/Folie.
R. I.TU Darmstadt
CONCLUSIONS
• Mechanical, hydraulic and pneumatic components are integrated withmicroelectronics
• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions• Mechatronic components improve functionality, safety, economy and comfort• Mechatronic design allows parallel development of hardware , electronics
and software• Modelling and simulation tools allow simultaneous engineering and fewer
prototypes• Same mechatronic development for combustion engines, transmissions• Next steps: surrounding sensors, collision avoidance, drive-by-wire• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)
→ Mechatronic components change the design of automobiles
→ Mechatronics: emerging area of innovative engineering
R. I.TU Darmstadt
CONCLUSIONS
• Mechanical, hydraulic and pneumatic components are integrated withmicroelectronics
• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions
R. I.TU Darmstadt
CONCLUSIONS
• Mechanical, hydraulic and pneumatic components are integrated withmicroelectronics
• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions
• Mechatronic components improve functionality, safety, economy and comfort• Mechatronic design allows parallel development of hardware , electronics
and software• Modelling and simulation tools allow simultaneous engineering and fewer
prototypes
R. I.TU Darmstadt
CONCLUSIONS
• Mechanical, hydraulic and pneumatic components are integrated withmicroelectronics
• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions• Mechatronic components improve functionality, safety, economy and comfort• Mechatronic design allows parallel development of hardware , electronics
and software• Modelling and simulation tools allow simultaneous engineering and fewer
prototypes
• Same mechatronic development for combustion engines, transmissions• Next steps: surrounding sensors, collision avoidance, drive-by-wire• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)
R. I.TU Darmstadt
CONCLUSIONS
• Mechanical, hydraulic and pneumatic components are integrated withmicroelectronics
• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions• Mechatronic components improve functionality, safety, economy and comfort• Mechatronic design allows parallel development of hardware , electronics
and software• Modelling and simulation tools allow simultaneous engineering and fewer
prototypes• Same mechatronic development for combustion engines, transmissions• Next steps: surrounding sensors, collision avoidance, drive-by-wire• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)
→ Mechatronic components change the design of automobiles
→ Mechatronics: emerging area of innovative engineering
R. I.TU Darmstadt
OUTLOOK
- Intelligent mechatronic systems� adaptation, learning, decision making � sensors, actuators, devices (optics, office, medicine)
R. I.TU Darmstadt
OUTLOOK
- Intelligent mechatronic systems� adaptation, learning, decision making � sensors, actuators, devices (optics, office, medicine)
- Fault- tolerant mechatronic systems� highly reliable and safe systems (vehicles,
engines, drive systems, production machinery)� Medical devices (operation robots, implants)� Aero-space systems
R. I.TU Darmstadt
OUTLOOK
- Intelligent mechatronic systems� adaptation, learning, decision making� sensors, actuators, devices (optics,office, medicine)
- Fault- tolerant mechatronic systems� highly reliable and safe systems (vehicles,
engines, drive systems, production machinery)� Medical devices (operation robots, implants)� Aero-space systems
- x-by-wire mobile systems� brake-by wire, steer-by wire, drive-by wire� autopilot-driver assistance, auto-navigation� mobile robots (agriculture, production, home)
R. I.TU Darmstadt
Six-legged walking forest machine (Finland)
(S.Niilola,Tekes)