- Email: [email protected]
Mechatronic Systems: Industrial Applications and Modern Design Methodologies
Copyright © IFAC Mechatronic Systems, Sydney, Australia, 2004
ELSEVIER
IFAC PUBLICATIONS www.elsevier.comllocatelifac
Mechatronic Systems: Industrial Applications and Modern Design Methodologies
Dr.-Ing. Werner Dieterle
Robert Bosch GmbH CO/porale Research and Del'e/opment Stlll/gart / Germany
Abstract: Mechatronic systems are used in different fields of apfllicatioll. e.g. industrial goods. consumer products and automotive equipment. Current and future mechatronic as well as mlcro-electromechanical systems are shown on the basis of technological trends and market requirements. e.g. reduced fuel consumption and emission for automotive technology. Special attention will be devoted to the rapidly growing importance 0/ electronics and software. Effective as well as efficient design of mechatronic systems are fundamental prerequisites for competitiveness in a harsh industrial environment. Modern methodologies for interdisciplinary. model-based design of mechatronic systems are presented; the benefits of these new methods are described. Copyright CC) 21111.:1 IFAC I(eywords: mechatronic systems, market requirements, technological trends. complexity and variant handling, design methodology. model-based product life-cycle, role of software. educational aspects.
I. INTRODUCTION ~ lechatronic Systems are based on the tight coupling of different implementation technologies. e.g. hydraulics. mechan ics. pneumatics, electromechanics. electronics and software (Isermann . 2003). The Solhvare content of these systems is growing rapidly. Mechatron ics plays an ever more important role for di fferent business sectors like autolllotive systems. industrial products and consumer goods.
Thi s article reflects future market tow
requirements forthcoming mechatronic is devoted to
Effective and efficient design processes for Illechatronic systems are a prerequisite for competitiveness in an increasignly harsh industrial environment. Th is is especially true for Robert Bosch Gl1lbH . since almost all Bosch products are l11echatronic systems. Fig. 1 shows some examples of l11ecilatronic products. Kev elements of mechatronic systems design are presented. A vision of an over
mechatronic product life-cycle is shown. steps towards implementation of this vision are described.
Exemplary Mechatronic Systems
-"'\
,,1
',,j ....
'!."I
~ ~(ii1~' .. .,. . '
Fig. 1. Bosch Mechatronic Systems
Modern design methodologies should already be addressed in engineering education. Key elements of Mechactronic Systems Engineering education are presented ti'om the viewpoint of industrial req LI irements.
2. GENERAL TRENDS UP TO 2020 Market requirements ("market pull") and technological trends ("technology push") are the main drivers for development of next generation mechatronic products. A comprehensive overview on these drivers cannot be given here. However, some remarkable trends within a time horizon up to 2020 shall be shown in the following (some of these trends are specitic for automotive technology): • New product generations shall always be smaller, cheaper and/o r provide additional functionality. • Softw
Fig. 2 Common Rail Injector Apart from highly-precise manufacturing of components a co-ordinated and accurate interaction of the different parts (e.g. high-pressure fuel pump, solenoid, nozzle etc.) is required, over complete lifecycle of the car. Th is is ensured by sophisticated, software-based algorithms for system control and diagnosis. Apart from solenoid-based systems also piezo-controlled fuel injection systems are used, providing even higher pressure levels (up to 180 MPa) and more flexibility in the injection cycle. A micro-electromechanical yaw-rate sensor is shown as a "micro-mechatronic" product example in fig . 3. It is the core element of the Electronic Stability Program (ESP), stabilizing cars and trucks in critical driving situations, thus reducing the number of accidents.
• The aforementioned trends can be used as a rough orientation for future product marketing and development activities.
:>. EXAMPLES FOR CURRENT AND FUTURE MECHATRONIC PRODUCTS To illustrate the till1ction and design challenges of mechatronic systems two examples shall be given: • Co mmon rail diesel injection systems, I'epresenting the "macro-mechatronic" world. • Micro-electromechanical yaw-rate sensor, representing the "micro-mechatronic" world.
Fig.3 rVlicro-electromechanical yaw-rate sensor
Yaw-rate sensors measure vehicle movement via the vertical axis. The se nsing principle is capacitive and based on Coriolis forces, applied to a rotating mass, the resulting charge flows are detected. A Iso for this mechatronic system apart from manufacturing precision (si Iicon-based process) the high Iy-accurate design of interaction of the respective parts is essential. Micro-electromechanical sensing elements are also used for air-flow, acceleration and rollover sensing, Additional fields of applicmion are outside automotive equipment.
Fig. 2 shows a common rail injector for passenger cars. the new high-pressure diesel injection system in the market. It yields improved power, noise and emission characteristics of diesel combustion systems. A common high-pressure fuel reservoir ("common rail") supplies the injectors with fuel at a pressure level up to 160 MPa. Pressure generation and injection are decoupled .
2
successful supplier of mechatronic systems requires business excellence in two ways: • Innovative Excellence: Yielding of new products with distinctive functionality, better qual ity and/or with a cost advantage ("Iow price by hightech"). • Operational Excellence: Effective and highlydesign. efficient processes for product manufacturing. calibration.
4. CHALLENGES OF MECHATRONIC SYSTEMS DESIGN -l. I Jfas{ering
{he
Future
Increase
of System
('ol1l/)lexily.
For typical mechatronic systems there has been a dramatic increase of complexity during the past few years (doubling every 2-3 years, fig . 4), almost comparable to complexity increase in microelectronics ("moore's law"). System complexity can be measured by different parameters, e .g. number of components and their level of interaction, number of calibration labels. code size of software.
New paradigms for mechatronic system design are needed. that cover both aspects. These will be described in the next chapter.
According to the aforementioned trends (e.g. emission legislation for diesel engines) the complexity increase of mechatronic products will hold on in future. Development. manufacturing and calibration efforts grow accordingly . To illustrate this with an example: For next generation common rail diesel injection systems there will be a sharp increase of the number of calibration labels, at a current level of already 5.000-10.000 calibration labels (independent of supplier).
5. MODERN DESIGN METHODOLOGIES FOR MECHATRONIC SYSTEMS A model-based design methodology for mechatronic systems is a key factor for innovative and operative excellence in product design. In addition, modelbased design can act as a starting point for an overall model-based product li fe-cycle. yielding additional benefits over the complete product li fe-cycle. First steps towards that vision will be outlined.
"Moore's Law" of Mechatronics
5. 1 S:V.l'lel1l.\· Engineering II-/echal/'()nic
To cope with the challenges of system design and complexity handling 80sch started the initiative "Systems Engineering Mechatronic". Targets are high design efficiency (reduction of development time and cost) as well as high design quality (design correctness). New design methodologies and processes are currently established III different business units (automotive equipment, consumer goods, industrial equipment).
~
'x Q)
a..
E
o o
Systems Engineering Mechatronic is based on the well-known V-model for system design. The V -model incorporates different levels for customer, system and components (fig. 5).
time
Fig. 4. Increase of Complexity of Mechatronic Systems
I=R ./.:: .\ /iI.I'/aing h./r ir/ll 1.1'.
Ihe
FUlure
Increase!
EEl
at' Producl
Customer
Another complexity issue is variant handling. Customers require individual solutions with regard to functionality , quality , technology etc. This results in hundreds. often even thousands of product variants to be clealt with at supplier side. adding an additional dilllension of complexity to the system complexity described before. The number of product variants will further increase in future (take for instance the increasing number of car segments, e.g. roadster, SUV. van. mini-van 1.
System
. [] 'I.--....;, IIJ '" ~ ~ .~
~
Component..
Fig. 5. V -Model with Component Level
A Itogether. it must be recognized, that the limits of mastering system complexity and variants are reached. To cope with the challenges described, a
3
,
Customer.
System
and
Key elements of Systems Engineering Mechatronic are: • Use of physical/mathematical models (physical understanding of system and component of behaviour, mathematical description behaviour}. wherever possible. • Appropriate design process in the business units (including organisational structure). • Sound requirements engineering at system and component level. • Virtual system and component test, based on requirements specification. • Provision of an overall computer aided engineering tool infrastructure (commercially available tools that are coupled via scripts for parameter exchange). • Provision of standardised base models for different technologies (hydraulics, mechanics, electronics. control etc.) that allow for fast and virtual rapid prototyping with high reuse of models (" plug and play"). • Fast exchange of models between different tools in horizontal direction (e.g. at a I-dimensional simulation level between tools for hydraulic simulation and electronics simulation). • Fast exchange of models between different tools in vertical direction (e.g. between 3-dimensional and I-dimensional hydraulic simulation tool ).
•
High level of flexibility for system optimisation due to model-based system design description.
5.2 Role olSofiware. Among the implementation technologies for mechatronic systems (e.g. hydraul ics, mechanics, electronics), software has a specific role in a sense that • it has no physical border conditions (e.g. no friction or cavitation effects), • it comprises the complete system complexity since software is used as an integration platform as well as a functional carrier with high flexibility. This means that at a technological level software is easier to deal with. at a system level softvvare is much harder to deal with. Since system complexity handling and also variant handling is very much a software issue, special attention is to be devoted to software engineering methods that provide solutions for mastering the future complexity increases. Software engineering methodologies tor softwareintensive systems of high complexity already exist, e.g. Product Line Approach (PLA) and Capability Maturity Model (CM M), both originally designed at the Software Engineering Institute in Pittsburgh (SEI, 2004). These methodologies are generally accepted and already widely used in industry.
Use of physical/mathematical models is a key issue of Systems Engineering Mechatronic. However, for several reasons, there are still limitations for applicabi Iity of physical/mathematical models: • Some physical effects are still not fully understood and can therefore not been described with physical/mathematical equations. • Physical/mathematical description of some physical processes is still much too complex (e.g. description of combustion processes) and can thus not be used for an efficient product design. • Information systems (lacking energetic interdependencies as well as mass flows) need other methods for modelling; this is also the case for mechatronic products with "high content" of information technology.
However, these software engineering methodologies are not applicable to mechatronic systems since they "classical" mechatronic lack consideration of technologies. Therefore, comprehensive design methodologies are needed, that address both, "classical mechatronics" as well as software aspects. Such an integrated systems engineering concept can be regarded as a future key issue for both basic research and industry. First activities and results on that: • The Software Engineering Institute (SEI) provides CMMi as an extension of the Capability Maturity Model (CtvlM), dedicated to mechatronic systems. • Bosch currently works on an integrated systems engineering concept for software-intensive mechatronic systems.
Systems Engineering Mechatronic has already been applied with high impact in different applications (e.g. wiper systems. power tools, model-based control of turbochargers). Main benefits are: • Better design quality already in early phases by (virtual) rapid prototyping. • Improved design efficiency (e.g . reuse of design models up to 80%). • Reduced number of calibration parameters and therefore reduced calibration eff0l1. • Straightforward variant generation. using a stable hase set of construction elements. • Improved product functionality by use of physical/mathematical models on-board in the electronic control unit (e.g. for model-based control and diagnosis).
5.3 Model-based Prodlfcl Lile-eve/e. So far, considerations have been focussed on svstem design . However, model-based design has an i;npact on the complete product life-cycle, since the physical/mathematical system and component models used in product design can be reused in successive phases of product life-cycle:
4
•
•
•
laying the foundations. Further courses should comprise Reliability and Safety . Quality Management. and Project Management. Lab training should cover Computer Aided Design of Mechatronic Systems and should be organized project-orie nted as teamwork where the students also get a basic knowled ge in project design and management.
Calibration: t\ lodel-based calibration can si!!niticantly reduce calibration effort due to lhvsical know-how of system and component ~eha\'iour. instead of "black-box" behaviour. Operation : Physical/mathematical models can be used on-board (i.e. calculated in real-time in the electronic control unit) for model-based control and diagnosis algorithms. This is especially supported by new controller generations with inte!!rated digital signal processor (DSP). Se~ice: Use of physical/mathematical models can enhance diagnosability of mechatronic products. i.e. improve traceability of faults at component level and reduce diagnosis efforts.
Due to the reuse of the models in the product life-cycle significant be achieved with only minor (models have to he customized phase) .
A Mechatronic Systems Engineering curriculum should be a combined effort of different engineering faculties. It is not necessary to install a newlydesigned Mechatronic Systems Engineering curriculum (maybe then with a tendency "grasp a little bit of everything"). The classical engineering curricula provide a so und basis for Mechatronic Systems Engineering education . Existing courses should be adapted and harmonised. and not be ta ken unchanged from other curricula. to avoid both overloading the students and superficiality. Therefore, it is necessary to link the courses of different faculties in a way to achieve a sy nergetic effect.
different phases of improvements can additional efforts to the respective
The model-based product life-cycle can be seen as a special form of knowledge management: productrelated know-how (physical/mathematical models) is used consistently throughout the organisation. A Ithough overall use of physical/mathematical mockl s in all phases of product life-cycle is still far oft: initial results are very promi sing.
6. CONCLUSION Main challenges of future mechatronic product design are mastering the future system complexity increase as well as mastering further increase o f the number of product variants. Model-based product design and, as an extension. a model-based product life-cycle are appropriate measures to cope with these challenges.
5. EDUCATIONAL ASPECTS
Software is of rapidly growing importance for mechatronic systems design . So far. different design methodologies for software-intensive systems and "c lassical" mechatronic systems have been used . An integrated systems engineering concept can be regarded as a future key issue for both basic research and industry.
The introduction of new design methodologies for mechatronic systems is a big challenge for industry itself. However, to gain broad acceptance and high effectiveness, education of future mechatronic engineers is a key issue (Piwonka, 200 I). General demands on Mechatronic Systems Engineering education from an industrial perspective are: • Basic skills in all relevant disciplines • Engineering methods in control engineering and system analysis • Functional and architectural design techniques • Abstraction methods • Modelling and s imulation method s • Project management • Foreign language skills • Experiencelreadiness in/for international cooperation • Teamwork experience • F:xperience in interdisciplinary work
A broad introduction of new design methodologies in industry requires new educational concepts for Mechatronic Systems Engineering. The "classical" engineering curricula are a sound basis for future engineering education . However. combined efforts of the different engineering faculties are needed. existing courses should be adapted and harmoni sed. to achieve synergetic effects.
REFERENCES Isermann. R. (2003). Mechatronic Systems: Fundamentals. Springer- Verlag. SEI (2004) . http ://www.sei.clllll.edu. Homepage of Software Engineering Institute (SEll. Camegie Mellon Universtity, Pittburgh . Piwonka, F. (2001). Mechatronic Systems Engineering - from methodology to education. n In: 2 " European Workshop on Education in Mechatronics, Proceedings, University of Applied Sciences, Kiel , pp. 53-61.
It is clear that a curriculum in Mechatronic Systems Engineering should not simply offer complete parallel trainings in each Mechanical Engineering, Electrical Engineering and Information Technology. It should rather put emphasis on basic physical understanding of technical systems and on engineering methodologies which are valid for all the different domains of mechatronic systems. This means mode lling and abstraction where system theory is
5
ELSEVIER
IFAC PUBLICATIONS www.elsevier.comllocatelifac
Mechatronic Systems: Industrial Applications and Modern Design Methodologies
Dr.-Ing. Werner Dieterle
Robert Bosch GmbH CO/porale Research and Del'e/opment Stlll/gart / Germany
Abstract: Mechatronic systems are used in different fields of apfllicatioll. e.g. industrial goods. consumer products and automotive equipment. Current and future mechatronic as well as mlcro-electromechanical systems are shown on the basis of technological trends and market requirements. e.g. reduced fuel consumption and emission for automotive technology. Special attention will be devoted to the rapidly growing importance 0/ electronics and software. Effective as well as efficient design of mechatronic systems are fundamental prerequisites for competitiveness in a harsh industrial environment. Modern methodologies for interdisciplinary. model-based design of mechatronic systems are presented; the benefits of these new methods are described. Copyright CC) 21111.:1 IFAC I(eywords: mechatronic systems, market requirements, technological trends. complexity and variant handling, design methodology. model-based product life-cycle, role of software. educational aspects.
I. INTRODUCTION ~ lechatronic Systems are based on the tight coupling of different implementation technologies. e.g. hydraulics. mechan ics. pneumatics, electromechanics. electronics and software (Isermann . 2003). The Solhvare content of these systems is growing rapidly. Mechatron ics plays an ever more important role for di fferent business sectors like autolllotive systems. industrial products and consumer goods.
Thi s article reflects future market tow
requirements forthcoming mechatronic is devoted to
Effective and efficient design processes for Illechatronic systems are a prerequisite for competitiveness in an increasignly harsh industrial environment. Th is is especially true for Robert Bosch Gl1lbH . since almost all Bosch products are l11echatronic systems. Fig. 1 shows some examples of l11ecilatronic products. Kev elements of mechatronic systems design are presented. A vision of an over
mechatronic product life-cycle is shown. steps towards implementation of this vision are described.
Exemplary Mechatronic Systems
-"'\
,,1
',,j ....
'!."I
~ ~(ii1~' .. .,. . '
Fig. 1. Bosch Mechatronic Systems
Modern design methodologies should already be addressed in engineering education. Key elements of Mechactronic Systems Engineering education are presented ti'om the viewpoint of industrial req LI irements.
2. GENERAL TRENDS UP TO 2020 Market requirements ("market pull") and technological trends ("technology push") are the main drivers for development of next generation mechatronic products. A comprehensive overview on these drivers cannot be given here. However, some remarkable trends within a time horizon up to 2020 shall be shown in the following (some of these trends are specitic for automotive technology): • New product generations shall always be smaller, cheaper and/o r provide additional functionality. • Softw
Fig. 2 Common Rail Injector Apart from highly-precise manufacturing of components a co-ordinated and accurate interaction of the different parts (e.g. high-pressure fuel pump, solenoid, nozzle etc.) is required, over complete lifecycle of the car. Th is is ensured by sophisticated, software-based algorithms for system control and diagnosis. Apart from solenoid-based systems also piezo-controlled fuel injection systems are used, providing even higher pressure levels (up to 180 MPa) and more flexibility in the injection cycle. A micro-electromechanical yaw-rate sensor is shown as a "micro-mechatronic" product example in fig . 3. It is the core element of the Electronic Stability Program (ESP), stabilizing cars and trucks in critical driving situations, thus reducing the number of accidents.
• The aforementioned trends can be used as a rough orientation for future product marketing and development activities.
:>. EXAMPLES FOR CURRENT AND FUTURE MECHATRONIC PRODUCTS To illustrate the till1ction and design challenges of mechatronic systems two examples shall be given: • Co mmon rail diesel injection systems, I'epresenting the "macro-mechatronic" world. • Micro-electromechanical yaw-rate sensor, representing the "micro-mechatronic" world.
Fig.3 rVlicro-electromechanical yaw-rate sensor
Yaw-rate sensors measure vehicle movement via the vertical axis. The se nsing principle is capacitive and based on Coriolis forces, applied to a rotating mass, the resulting charge flows are detected. A Iso for this mechatronic system apart from manufacturing precision (si Iicon-based process) the high Iy-accurate design of interaction of the respective parts is essential. Micro-electromechanical sensing elements are also used for air-flow, acceleration and rollover sensing, Additional fields of applicmion are outside automotive equipment.
Fig. 2 shows a common rail injector for passenger cars. the new high-pressure diesel injection system in the market. It yields improved power, noise and emission characteristics of diesel combustion systems. A common high-pressure fuel reservoir ("common rail") supplies the injectors with fuel at a pressure level up to 160 MPa. Pressure generation and injection are decoupled .
2
successful supplier of mechatronic systems requires business excellence in two ways: • Innovative Excellence: Yielding of new products with distinctive functionality, better qual ity and/or with a cost advantage ("Iow price by hightech"). • Operational Excellence: Effective and highlydesign. efficient processes for product manufacturing. calibration.
4. CHALLENGES OF MECHATRONIC SYSTEMS DESIGN -l. I Jfas{ering
{he
Future
Increase
of System
('ol1l/)lexily.
For typical mechatronic systems there has been a dramatic increase of complexity during the past few years (doubling every 2-3 years, fig . 4), almost comparable to complexity increase in microelectronics ("moore's law"). System complexity can be measured by different parameters, e .g. number of components and their level of interaction, number of calibration labels. code size of software.
New paradigms for mechatronic system design are needed. that cover both aspects. These will be described in the next chapter.
According to the aforementioned trends (e.g. emission legislation for diesel engines) the complexity increase of mechatronic products will hold on in future. Development. manufacturing and calibration efforts grow accordingly . To illustrate this with an example: For next generation common rail diesel injection systems there will be a sharp increase of the number of calibration labels, at a current level of already 5.000-10.000 calibration labels (independent of supplier).
5. MODERN DESIGN METHODOLOGIES FOR MECHATRONIC SYSTEMS A model-based design methodology for mechatronic systems is a key factor for innovative and operative excellence in product design. In addition, modelbased design can act as a starting point for an overall model-based product li fe-cycle. yielding additional benefits over the complete product li fe-cycle. First steps towards that vision will be outlined.
"Moore's Law" of Mechatronics
5. 1 S:V.l'lel1l.\· Engineering II-/echal/'()nic
To cope with the challenges of system design and complexity handling 80sch started the initiative "Systems Engineering Mechatronic". Targets are high design efficiency (reduction of development time and cost) as well as high design quality (design correctness). New design methodologies and processes are currently established III different business units (automotive equipment, consumer goods, industrial equipment).
~
'x Q)
a..
E
o o
Systems Engineering Mechatronic is based on the well-known V-model for system design. The V -model incorporates different levels for customer, system and components (fig. 5).
time
Fig. 4. Increase of Complexity of Mechatronic Systems
I=R ./.:: .\ /iI.I'/aing h./r ir/ll 1.1'.
Ihe
FUlure
Increase!
EEl
at' Producl
Customer
Another complexity issue is variant handling. Customers require individual solutions with regard to functionality , quality , technology etc. This results in hundreds. often even thousands of product variants to be clealt with at supplier side. adding an additional dilllension of complexity to the system complexity described before. The number of product variants will further increase in future (take for instance the increasing number of car segments, e.g. roadster, SUV. van. mini-van 1.
System
. [] 'I.--....;, IIJ '" ~ ~ .~
~
Component..
Fig. 5. V -Model with Component Level
A Itogether. it must be recognized, that the limits of mastering system complexity and variants are reached. To cope with the challenges described, a
3
,
Customer.
System
and
Key elements of Systems Engineering Mechatronic are: • Use of physical/mathematical models (physical understanding of system and component of behaviour, mathematical description behaviour}. wherever possible. • Appropriate design process in the business units (including organisational structure). • Sound requirements engineering at system and component level. • Virtual system and component test, based on requirements specification. • Provision of an overall computer aided engineering tool infrastructure (commercially available tools that are coupled via scripts for parameter exchange). • Provision of standardised base models for different technologies (hydraulics, mechanics, electronics. control etc.) that allow for fast and virtual rapid prototyping with high reuse of models (" plug and play"). • Fast exchange of models between different tools in horizontal direction (e.g. at a I-dimensional simulation level between tools for hydraulic simulation and electronics simulation). • Fast exchange of models between different tools in vertical direction (e.g. between 3-dimensional and I-dimensional hydraulic simulation tool ).
•
High level of flexibility for system optimisation due to model-based system design description.
5.2 Role olSofiware. Among the implementation technologies for mechatronic systems (e.g. hydraul ics, mechanics, electronics), software has a specific role in a sense that • it has no physical border conditions (e.g. no friction or cavitation effects), • it comprises the complete system complexity since software is used as an integration platform as well as a functional carrier with high flexibility. This means that at a technological level software is easier to deal with. at a system level softvvare is much harder to deal with. Since system complexity handling and also variant handling is very much a software issue, special attention is to be devoted to software engineering methods that provide solutions for mastering the future complexity increases. Software engineering methodologies tor softwareintensive systems of high complexity already exist, e.g. Product Line Approach (PLA) and Capability Maturity Model (CM M), both originally designed at the Software Engineering Institute in Pittsburgh (SEI, 2004). These methodologies are generally accepted and already widely used in industry.
Use of physical/mathematical models is a key issue of Systems Engineering Mechatronic. However, for several reasons, there are still limitations for applicabi Iity of physical/mathematical models: • Some physical effects are still not fully understood and can therefore not been described with physical/mathematical equations. • Physical/mathematical description of some physical processes is still much too complex (e.g. description of combustion processes) and can thus not be used for an efficient product design. • Information systems (lacking energetic interdependencies as well as mass flows) need other methods for modelling; this is also the case for mechatronic products with "high content" of information technology.
However, these software engineering methodologies are not applicable to mechatronic systems since they "classical" mechatronic lack consideration of technologies. Therefore, comprehensive design methodologies are needed, that address both, "classical mechatronics" as well as software aspects. Such an integrated systems engineering concept can be regarded as a future key issue for both basic research and industry. First activities and results on that: • The Software Engineering Institute (SEI) provides CMMi as an extension of the Capability Maturity Model (CtvlM), dedicated to mechatronic systems. • Bosch currently works on an integrated systems engineering concept for software-intensive mechatronic systems.
Systems Engineering Mechatronic has already been applied with high impact in different applications (e.g. wiper systems. power tools, model-based control of turbochargers). Main benefits are: • Better design quality already in early phases by (virtual) rapid prototyping. • Improved design efficiency (e.g . reuse of design models up to 80%). • Reduced number of calibration parameters and therefore reduced calibration eff0l1. • Straightforward variant generation. using a stable hase set of construction elements. • Improved product functionality by use of physical/mathematical models on-board in the electronic control unit (e.g. for model-based control and diagnosis).
5.3 Model-based Prodlfcl Lile-eve/e. So far, considerations have been focussed on svstem design . However, model-based design has an i;npact on the complete product life-cycle, since the physical/mathematical system and component models used in product design can be reused in successive phases of product life-cycle:
4
•
•
•
laying the foundations. Further courses should comprise Reliability and Safety . Quality Management. and Project Management. Lab training should cover Computer Aided Design of Mechatronic Systems and should be organized project-orie nted as teamwork where the students also get a basic knowled ge in project design and management.
Calibration: t\ lodel-based calibration can si!!niticantly reduce calibration effort due to lhvsical know-how of system and component ~eha\'iour. instead of "black-box" behaviour. Operation : Physical/mathematical models can be used on-board (i.e. calculated in real-time in the electronic control unit) for model-based control and diagnosis algorithms. This is especially supported by new controller generations with inte!!rated digital signal processor (DSP). Se~ice: Use of physical/mathematical models can enhance diagnosability of mechatronic products. i.e. improve traceability of faults at component level and reduce diagnosis efforts.
Due to the reuse of the models in the product life-cycle significant be achieved with only minor (models have to he customized phase) .
A Mechatronic Systems Engineering curriculum should be a combined effort of different engineering faculties. It is not necessary to install a newlydesigned Mechatronic Systems Engineering curriculum (maybe then with a tendency "grasp a little bit of everything"). The classical engineering curricula provide a so und basis for Mechatronic Systems Engineering education . Existing courses should be adapted and harmonised. and not be ta ken unchanged from other curricula. to avoid both overloading the students and superficiality. Therefore, it is necessary to link the courses of different faculties in a way to achieve a sy nergetic effect.
different phases of improvements can additional efforts to the respective
The model-based product life-cycle can be seen as a special form of knowledge management: productrelated know-how (physical/mathematical models) is used consistently throughout the organisation. A Ithough overall use of physical/mathematical mockl s in all phases of product life-cycle is still far oft: initial results are very promi sing.
6. CONCLUSION Main challenges of future mechatronic product design are mastering the future system complexity increase as well as mastering further increase o f the number of product variants. Model-based product design and, as an extension. a model-based product life-cycle are appropriate measures to cope with these challenges.
5. EDUCATIONAL ASPECTS
Software is of rapidly growing importance for mechatronic systems design . So far. different design methodologies for software-intensive systems and "c lassical" mechatronic systems have been used . An integrated systems engineering concept can be regarded as a future key issue for both basic research and industry.
The introduction of new design methodologies for mechatronic systems is a big challenge for industry itself. However, to gain broad acceptance and high effectiveness, education of future mechatronic engineers is a key issue (Piwonka, 200 I). General demands on Mechatronic Systems Engineering education from an industrial perspective are: • Basic skills in all relevant disciplines • Engineering methods in control engineering and system analysis • Functional and architectural design techniques • Abstraction methods • Modelling and s imulation method s • Project management • Foreign language skills • Experiencelreadiness in/for international cooperation • Teamwork experience • F:xperience in interdisciplinary work
A broad introduction of new design methodologies in industry requires new educational concepts for Mechatronic Systems Engineering. The "classical" engineering curricula are a sound basis for future engineering education . However. combined efforts of the different engineering faculties are needed. existing courses should be adapted and harmoni sed. to achieve synergetic effects.
REFERENCES Isermann. R. (2003). Mechatronic Systems: Fundamentals. Springer- Verlag. SEI (2004) . http ://www.sei.clllll.edu. Homepage of Software Engineering Institute (SEll. Camegie Mellon Universtity, Pittburgh . Piwonka, F. (2001). Mechatronic Systems Engineering - from methodology to education. n In: 2 " European Workshop on Education in Mechatronics, Proceedings, University of Applied Sciences, Kiel , pp. 53-61.
It is clear that a curriculum in Mechatronic Systems Engineering should not simply offer complete parallel trainings in each Mechanical Engineering, Electrical Engineering and Information Technology. It should rather put emphasis on basic physical understanding of technical systems and on engineering methodologies which are valid for all the different domains of mechatronic systems. This means mode lling and abstraction where system theory is
5