Mechatronic Overview

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R. I. TU Darmstadt

2005

MECHATRONISCHE SYSTEME

FÜR KRAFTFAHRZEUGE

(Automotive

Mechatronics

)

Prof. Dr.

-

Ing

. R.

Isermann

Institut für Automatisierungstechnik

Technische Universität Darmstadt

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R. I. TU Darmstadt

AUTOMOTIVE MECHATRONICS

• INTRODUCTION

• DESIGN PROCEDURE

• HISTORICAL DEVELOPMENT

• MECHATRONIC SUSPENSIONS

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

• CONCLUSIONS

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R. I.

TU Darmstadt

Mechatronics: Synergetic integration of different disciplines

MECHATRONICS information technology system theory modeling automation technology software computational intelligence electronics micro electronics power electronics sensors actuators mechanics mechanical elements machines precision mechanics

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R. I.

TU Darmstadt

sensors

measured variables

Mechanical process and information processing develop towards mechatronic systems

mechanics & energy converter mechanical hydraulic thermal electrical energy flow energy supply energy con-sumer monitored variables reference variables manipulated

variables _{information flow}

man/machine interface information processing

actua-tors

auxiliary energy supply

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TU Darmstadt

o Definition

• Many technical processes and products show an increasing

integration of MECHAnics with elecTRONICS and information

processing

• The integration is between the components (hardware) and the

information-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 solutions

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R. I. TU Darmstadt Mechatronic Systems Mechatronic motion generators - integrated electrical servo drives - integrated hydraulic servo drives - integrated pneumatic servo drives - robots (multi-axis, mobile) Mechatronic machine components - semi-active hydraulic dampers - magnetic bearings - automatic gears Mechatronic power producing machines - brushless DC motors - integrated AC drives - mechatronic combustion engines machine tools - integrated multi-axis - integrated hydraulic pumps Mechatronic power consuming machines Mechatronic automobiles - antilock brake (ABS) - electro-hydraulic brake (EHB) - active suspension - active front steering Mechatronic trains - tilting trains - active boogie - magnetic levitated (MAGLEV) trains

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TU Darmstadt

o Functions and integration of mechatronic systems

• Distribution of functions • Operating properties

• New functions • Integration forms

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TU Darmstadt

o Functions and integration of mechatronic systems

• Distribution of functions

• Operating properties

• New functions • Integration forms

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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

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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

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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

integration of components

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R. I.

TU Darmstadt

Mechatronic overall integration

supervision diagnosis

adaptation optimization control

online information processing knowledge base

integration by information processing

mathematical process models performance criteria information gaining - identification - state observer design methods - control - supervision - optimization software-integration

integration of components

hardware-integration

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R. I.

TU Darmstadt

Runge, ATZ 2000

Mechatronic control module for a 6-gear-automatic transmission (ZF 6HP26)

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R. I. TU Darmstadt 1 2 8 k B y te ABS 2 ABS 2 6,2 kg ABS 5.0 ABS 5.0 3,8 kg ABS 5.3 ABS 5.3 2,6 kg ABSR 5.7 ABSR 5.7 2,5 kg ABS 8 ABS 8 1,8 kg Te nd en z ste ige nd ! 4 8 k B y te 2 4 k B y te 1 6 k B y te 8 k B y te 1989 1992 1995 1998 2001 3 6 kg kByte 200 100

History of ABS Systems

Rob. Bosch GmbH

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TU Darmstadt

Quelle:ATZ/MTZ Extra „Der Neue Golf“ Oktober2003

Direct automatic shift gear box with double clutch (2003)

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TU Darmstadt

Q uelle:A TZ/M TZ E xtra „D er N eue G olf“ O ktober2003

Electro-hydraulic control system for DSG

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R. I.

TU Darmstadt

AUTOMOTIVE MECHATRONIC SYSTEMS

• INTRODUCTION

• DESIGN PROCEDURE

• HISTORICAL DEVELOPMENT

• MECHATRONIC SUSPENSIONS

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

• CONCLUSIONS

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R. I.

TU Darmstadt

DESIGN PROCEDURE FOR MECHATRONIC

SYSTEMS

o Mechatronic engineering

o Modelling and simulation

o Software tools

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TU Darmstadt Design procedure for mechatronic systems (iterational steps not indicated) system definition requirements engineering (specification) mechanical & electrical engineering electronic engineering information & control engineering operating engineering process/ component design electronic hardware design inform. proc-cessing &

soft-ware design human-ma-chine inter-face design traditional engineering integration of components (hardware) integration by information processing (software) integrated (concurrent) engineering

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R. I. TU Darmstadt reliability & safety engineering manufacturing engineering mechatronic system

Design procedure for mechatronic systems (iterational steps not indicated) integrated (concurrent) engineering integration of components (hardware) integration by information processing (software)

integrated mechan.electronic system

generation of synergetic

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TU Darmstadt

o Modelling and Simulation for design and integration:

– 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)

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R. Isermann TU Darmstadt

real process real ECU + real actuator

RC P SiL integrated mechatronic system H iL process-model simulation tool θFW n_eng T2,stat T2 p_2,stat p₂ ECU-model high performance real-time computer

(full pass, by pass)

θFW n_eng p_2,Setpoint p 2 control algorithm upwm

Simulations for mechatronic development

real-time

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R. I.

TU Darmstadt

Diesel engines

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R. I.

TU Darmstadt

Hardware-in-the-Loop Simulator für truck engine control

HiL-Simulator, dSpace DSP & Power PC

IAT/DC 1992-1999

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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

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R. I.

TU Darmstadt

AUTOMOTIVE MECHATRONIC SYSTEMS

• INTRODUCTION

• DESIGN PROCEDURE

• HISTORICAL DEVELOPMENT

• MECHATRONIC SUSPENSIONS

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

• CONCLUSIONS

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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. oHG

Collision 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??)

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R. I.

TU Darmstadt

Sensors and

actuators

for

gasoline

engines

Electronic fuel injection (1967, D-Jetronic)

Microelectronic

controlled ignition and injection

(1979, Motronic)

Exhaust gas valve

Tank vent valve

Secundary air valve (1994) Variable geometry manifold Electronic throttle (1997) Variable camshaft timing

Variable valve lift(2001)

Actuators Engine speed (1967), camshaft phase Engine temperature (1967) Manifold pressure manifold 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

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R. I. TU Darmstadt Mechatronic automobiles Mechatronic combustion engines - electrical throttle - mechatronic fuel injection - mechatronic valve trains - variable geo-metry turbo-charger (VGT) - emission control - evaporative emission control - electrical pumps & fans Mechatronic drive trains - automatic hydrodynamic transmission - automatic mechanic shift transm. - continuously variable trans-mission (CVT) - automatic traction control (ATC) - automatic speed and distance control (ACC) Mechatronic steering - parameter-izable power-assisted steering - electro-mechanical power-assisted steering (EPS) - active front steering (AFS) Mechatronic brakes - hydraulic

anti-lock braking (ABS) - electronic stability program (ESP) - electro-hydraulic brake (EHB) - electro-mechanical brake (EMB) - electrical parking brake Mechatronic suspensions - semi-active shock-absorbers - active hydraulic suspension (ABC) - active pneumatic suspension - active anti-roll bars (dynamic drive control (DDC) or roll-control)

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R. I.

TU Darmstadt Control units and data exchange

40 - 75 Electronic Control Units 30 - 150 electrical motors

2- 4 km cables (harness): 40 - 80 kg 4 bussystems

2500 signals

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R. I.

TU Darmstadt

Bordnetz des VW Phaeton

Quelle: ATZ Sonderheft VW Phaeton

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R. I.

TU Darmstadt

AUTOMOTIVE MECHATRONIC SYSTEMS

• INTRODUCTION

• DESIGN PROCEDURE

• HISTORICAL DEVELOPMENT

• MECHATRONIC SUSPENSIONS

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

• CONCLUSIONS

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R. I.

TU Darmstadt Stabilisation through single wheel braking with ESP

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R. I.

TU Darmstadt Electro-Hydraulic Brake System

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R. I.

TU Darmstadt

EHB1 Hydraulic Unit Components

Suction connection

Sealings for pressure sensor modul Contact spring

Pressure sensor modul

ECU

Sealing for ECU Magnet group Valve Medium separator Pump element Accumulator with multilayer diaphragm Electric motor Rob. Bosch GmbH Electrohydraulic brake

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TU Darmstadt

Chassis Systems

Electro Hydraulic Brake System EHB1

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R. I.

TU Darmstadt

Continental Teves (2003)

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R. I.

TU Darmstadt

AUTOMOTIVE MECHATRONIC SYSTEMS

• INTRODUCTION

• DESIGN PROCEDURE

• HISTORICAL DEVELOPMENT

• MECHATRONIC SUSPENSIONS

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

• CONCLUSIONS

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R. I. TU Darmstadt Electrical Power Steering (EPS) Electrical Power Assisted Steering (HPS + EPS) Active Front Steering (AFS)

Mechatronic steering systems

Hydraulic Power Steering (HPS) hydraulic actuator hydraulic pump hydraulic valve Hydraulic Power Steering (HPS) Electrical Power Steering (EPS) electrical actuator electrical actuator in steering column Electrical Power Assisted Steering (HPS + EPS) (larger vehicles) hydraulic actuator hydraulic actuator Active Front Steering (AFS) electrical actuator generates additional steering angles electrical steering torque motor for haptic feedback Steer-by-Wire (SbW) electrical actuator

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R. I. TU Darmstadt Servomotor ECU Steer pinion Torque sensor Torsion rod Servo pinion

Q uelle:ATZ/M TZ Extra „D er N eue Golf“ Oktober2003

Electrical Power Steering (EPS)

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R. I.

TU Darmstadt

Superposition of a steering angle

BMW (2003)

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TU Darmstadt

Development of driver assistance systems

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R. I.

TU Darmstadt

Automotive surrounding sensors

1. Close range: ultra sonic, radar

2. Medium range: lidar, radar, camera

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R. I.

TU Darmstadt

FG Regelungstechnik u. Prozessautomatisierung

Gemeinschaftsforschung mit der Industrie

Arbeitskreise begleiten Forschungsvorhaben: 2-3 Jahre Finanzierung: 50% Industrie – 50% BMBF oder BMWi

Auftragsumfang: 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 Forschungsvereinigung Verbrennungskraftmaschinen FVV

Modellbasierte Telediagnose elektrischer Antriebe und Textilmaschinen

Teleservice Forschungszentrum Karlsruhe Projektträger des BMBF Verbundprojekt OKTEL Intelligente dezentrale elektromechanische Komponenten (1996-1999) Störungsfrüherkennung an oszillierenden Verdrängerpumpen (2002-2004) Mechatronische Systeme Mechatronische Pumpen Deutsche Forschungsgesellschaft für die Anwendung der Mikroelektronik DFAM

Fachgemeinschaft Pumpen VDMA

Einfach anwendbare Diagnoseverfahren für mechatronische Komponenten (2001-2003)

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TU Darmstadt

Forschungskooperationen mit Firmen

Forschungverträge: 1-3 Jahre, Finanzierung: 100% Industrie Auftragsumsatz: ca. € 700.000 pro Jahr

FG Regelungstechnik u. Prozessautomatisierung

Medizintechnik Dialysesysteme (seit 1998) Modellbildung Optimale Regelung Patientenadaption Ottomotoren (seit 1996) Regelung Regelung Brennraumdruck- Abgasrückführungs- Verbrennungsmotoren Verbrennungsaussetzer-Erkennung (1996-2001) Abgasstrang Druckanalyse im Ionenstrommessung Dieselmotoren (seit 1992) Modellbildung Echtzeit-Simulation Regelung Energie-/Produktionstechnik Zementproduktion (1992-1997) Modellbildung, Simulation Strukturvariable Regelung von Mahlanlagen W1 W 2 Heizungssysteme (seit 1986) Modellbildung, Simulation Adaptive Regelung Fuzzy-Regelung Kraftfahrzeuge Brake-by-Wire (seit 1995)

Regelung und Rekonstruktion der Bremskraft einer EMB Intelligentes Bremspedal

Regelung der Horizontaldynamik mit BbW-Aktuatoren (ABS/ESP)

Personenkraftwagen (seit 1990) Geschwindigkeitsregelung On-line Simulationsmodelle Automatische Abstands- und automatisches

Parkassistenzsystem

Aktive Fahrwerke (seit 2001) Zustandserkennung für aktive Fahrwerke

Ottomotoren (seit 2001)

Optimierung der Verbrennung beim Direkteinspritzer

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R. I. TU Darmstadt In Kooperation mit Sensorik Radar Lidar Regelung Notlenken Notbremsen Aktorik Steer-By-Wire Brake-By-Wire

Elektronische Fahrerassistenz für ein unfallvermeidendes Fahrzeug

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R. I.

TU Darmstadt

CONCLUSIONS

• Mechanical, hydraulic and pneumatic components are

integrated 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

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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-FVT

Ausschuss “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 und Motoren - AUTOREG 2004 Aufruf zur Einreichung von Beiträgen

FVT

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TU Darmstadt

END

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R. I.

TU Darmstadt

CONCLUSIONS

• Mechanical, hydraulic and pneumatic components are integrated with microelectronics

• 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?)

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R. I.

TU Darmstadt

CONCLUSIONS

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TU Darmstadt

CONCLUSIONS

and software

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TU Darmstadt

CONCLUSIONS

and software

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TU Darmstadt

CONCLUSIONS

and software

• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)

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R. I.

TU Darmstadt

OUTLOOK

-

Intelligent mechatronic systems

adaptation, learning, decision making

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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)

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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

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R. I.

TU Darmstadt Six-legged walking forest machine (Finland)