Zhuming Bi

Mechatronics for Complex Products and Systems

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

• Gebundenes Buch

Produktbeschreibung

A project-based approach to designing mechatronic systems with new and emerging technologies In Mechatronics for Complex Products and Systems: Project-Based Design Approaches for Robots, Cyber-Physical Systems, Digital Twins, and Other Emerging Technologies, distinguished researcher Dr. Zhuming Bi delivers an expert discussion of real-world mechatronics skills that students will need in their engineering careers. The book explains the characteristics and innovation principles underlying mechatronic systems, including modularization, adaptability, predictability, sustainability, and concurrent engineering. A mechatronic system is decomposed into a set of mechatronic functional modules such as power systems, actuating systems, sensing systems, systems of signal conditioning and processing, and control systems. The author also offers: * A thorough introduction from classic integration of mechanical, electronic and electrical systems to more complex products and systems, including cyber-physical systems, robotics, human-robot interactions, digital twins, and Internet of Things applications * Insightful project assignments that help reinforce a practical understanding of a learning subject * Practical discussions of real-world engineering problems * Comprehensive guidance on how to select the right type of sensors, motors, and controllers for a variety of mechatronic functional modules Perfect for advanced undergraduate and graduate students of mechatronics, Mechatronics for Complex Products and Systems will also benefit professional engineers working on interdisciplinary projects enabled by digital technologies, Internet of Things (IoT), and Artificial Intelligence (AI).

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Produktdetails

• Verlag: Wiley
• Seitenzahl: 704
• Erscheinungstermin: 18. März 2025
• Englisch
• ISBN-13: 9781394209590
• ISBN-10: 1394209592
• Artikelnr.: 71300862

Autorenporträt

Zhuming Bi, PhD, is a Professor of Mechanical Engineering in the Department of Civil and Mechanical Engineering and Harris Chair in Wireless Communication and Applied Research at Purdue University Fort Wayne. He was a 2023-2024 Fulbright-Nokia Distinguished Chair in Information Communications Technologies (ICT). He has previously held positions at the Nanjing University of Science and Technology (China), Northern Ireland Technology Center (UK), the National Research Council of Canada (Canada), National Institute of Standards and Technology (USA), and Lappeenranta University of Technology (Finland).

Inhaltsangabe

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