Les produits mécatroniques sont complexes et multidisciplinaires par nature. Les exigences pour les concevoir sont souvent contradictoires et doivent être validées par les différentes équipes d'ingénierie disciplinaire (ID). Pour répondre à cette complexité et réduire le temps de conception, les ingénieurs disciplinaires ont besoin de collaborer dynamiquement, de résoudre les conflits interdisciplinaires et de réutiliser les connaissances de projets antérieurs. De plus, ils ont besoin de collaborer en permanence avec l’équipe d’ingénierie systèmes (IS) pour avoir un accès direct aux exigences et l’équipe d’optimisation multidisciplinaire (OMD) pour valider le système dans sa globalité.Nous proposons d'utiliser des techniques de gestion des connaissances pour structurer les connaissances générées lors des activités de collaboration afin d'harmoniser le cycle de conception. Notre principale contribution est une approche d'unification qui explique comment IS, ID et OMD se complètent et peuvent être utilisés en synergie pour un cycle de conception intégré et continu. Notre méthodologie permet de centraliser les connaissances nécessaires à la collaboration et au suivi des exigences. Elle assure également la traçabilité des échanges entre les ingénieurs grâce à la théorie des graphes. Cette connaissance formalisée du processus de collaboration permet de définir automatiquement un problème OMD. / Mechatronic products are complex and multidisciplinary in nature. The requirements to design them are often contradictory and must be validated by the various disciplinary engineering (DE) teams. To address this complexity and reduce design time, disciplinary engineers need to collaborate dynamically, resolve interdisciplinary conflicts, and reuse knowledge from previous projects. In addition, they need to work seamlessly with the Systems Engineering (SE) team to have direct access to requirements and the Multidisciplinary Design Optimization (MDO) team for global validation. We propose to use Knowledge Management techniques to structure the knowledge generated during collaboration activities and harmonize the overall design cycle. Our primary contribution is a unification approach, elaborating how SE, DE, and MDO complement each-other and can be used in synergy for an integrated and continuous design cycle. Our methodology centralizes the product knowledge necessary for collaboration. It ensures traceability of the exchange between disciplinary engineers using graph theory. This formalized process knowledge facilitates MDO problem definition.

This thesis explores the imperative of intelligent data and potential analysis in the realm of mechatronic product development. The persistent challenges of synchronization and efficiency underscore the need for advanced methodologies. Leveraging the substantial advancements in Artificial Intelligence (AI), particularly in generative AI, presents unprecedented opportunities. However, significant challenges, especially regarding robustness and trustworthiness, remain unaddressed. In response to this critical need, a comprehensive methodology is introduced, examining the entire development process through the illustrative V-Model and striving to establish a robust AI landscape. The methodology explores acquiring suitable and efficient knowledge, along with methodical implementation, addressing diverse requirements for accuracy at various stages of development.  As the landscape of mechatronic product development evolves, integrating intelligent data and harnessing the power of AI not only addresses current challenges but also positions organizations for greater innovation and competitiveness in the dynamic market landscape.

Thesis (MScEng (Mechanical and Mechatronic Engineering))--Stellenbosch University, 2008. / The sustainability and economy of the current South African National Antarctic Expedition IV (SANAE IV) base diesel-electric power system are threatened by the current high fuel prices and the environmental pollution reduction obligations. This thesis presents the potential technical, environmental and economical challenges associated with the integration of small wind energy conversion system (WECS) with the current SANAE IV diesel fuelled power system. Criteria derived from technical, environmental and economic assessments are applied in the evaluation of eight commercially available wind turbines as to determine the most technically and economically feasible candidates. Results of the coastal Dronning Maud Land and the local Vesleskarvet cold climate assessments based on long term meteorological data and field data are presented. Field experiments were performed during the 2007-2008 austral summer. These results are applied in the generation of a wind energy resource map and in the derivation of technical wind turbine evaluation criteria. The SANAE IV energy system and the electrical grid assessments performed are based on long term fuel consumption records and 2008 logged data. Assessment results led to the identification of SANAE IV specific avoidable wind turbine grid integration issues. Furthermore, electro-technical criteria derived from these results are applied in the evaluation of the eight selected wind turbines. Conceptual wind turbine integration options and operation modes are also suggested. Wind turbine micro-siting incorporating Vesleskarvet specific climatological, environmental and technical related issues are performed. Issues focusing on wind turbine visual impact, air traffic interference and the spatial Vesleskarvet wind distribution are analysed. Three potential sites suited for the deployment of a single or, in the near future, a cluster of small wind turbines are specified. Economics of the current SANAE IV power system based on the South African economy (May 2008) are analysed. The life cycle economic impact associated with the integration of a small wind turbine with the current SANAE IV power system is quantified. Results of an economic sensitivity analysis are used to predict the performance of the proposed wind-diesel power systems. All wind turbines initially considered will recover their investment costs within 20 years and will yield desirable saving as a result of diesel fuel savings, once integrated with the SANAE IV diesel fuelled power system. Finally, results of the technical and economical evaluation of the selected commercially available wind turbines indicated that the Proven 6 kWrated, Bergey 10 kWrated and Fortis 10 kWrated wind turbines are the most robust and will yield feasible savings.

La conception des systèmes d'entrainement de bande est étudiée depuis de nombreuses années. Ces systèmes sont très répandus dans l'industrie puisque le conditionnement sous forme de bobines simplifie le traitement de nombreux matériaux tels que le papier, le carton, les polymères, ... Ces systèmes regroupent un grand nombre de difficultés : ils sont de grande dimension, un fort couplage existe entre les grandeurs et de nombreux paramètres varient au cours du temps. La méthode d’optimisation classique consiste à considérer chaque partie du système sans tenir compte des autres. De plus, au sein d'un même sous-ensemble, l’optimisation est réalisée discipline par discipline. Une nouvelle approche est proposée et appliquée à la synthèse de la commande : il s’agit de considérer le système global en prenant en compte la robustesse paramétrique. Ensuite, le choix optimal du tracteur maître et de la technologie d'asservissement de la tension de bane associée sont étudiées. / The design of roll-to-roll systems is studied for several years. This kind of system is very common in industry because the wound roll packaging simplify the treatment of material such as paper, cardboard, polymers, metal ... The studied systems have a high number of difficulties: they are large scale systems, a high coupling between physical values exists and several parameters are time dependent. The classical optimisation method consists in considering separately each subsystem without taking into account interactions. Moreover, the classical optimisation is made for each scientific field. A new approach is developed and applied to controller synthesis: the controllers are synthesized considering the global system with parametric uncertainties. The optimal choice of the master roller position and the technology used to control web tension are then studied.

Shape plays an important role in our everyday life to interpret information about the surroundings whether we are aware or not. Together with visual and auditory information, we are able to obtain and process information for different purposes. Output devices such as monitors and speakers convey visual and auditory information while input devices such as touch screen and microphones receive that information for human machine interaction. Such devices have become commonplace but there has yet to be a fitting input/output device utilizing our haptic perception. Digital Clay is a next generation Human Machine Interface (HMI) device for 2.5D shape input/output via an array of hydraulic actuators. This device potentially has wide applications in the areas of engineering, sciences, medicine, military, entertainment etc. The user can perceive the shape of a computer programmed model in a tangible and concrete manner which means an added realism with the addition of the sense of touch. Conversely, the user can also use Digital Clay as an input device to the computer, by shaping and molding desired shapes on the device, no longer limited to drawing models with a mouse on CAD software. Shape display has been achieved with the current 5x5 prototype at the Georgia Institute of Technology but this research seeks to expand its capability to include haptic feedback and consequently shaping mode. This thesis gives an overview of the current 5x5 prototype and implements 2 commonly used haptic control methods, the admittance control and the impedance control. For implementing the admittance control, actuator displacement and velocity controllers and a proportional integral observer (PIO) are designed. The model-based unknown input observer is a solution for force estimation without added sensors in the actuators. For implementing the impedance control, a novel pressure control technique is designed to provide pressure feedback to the actuators array along with accurate and reliable displacement measurement. Both of the haptic control methods are evaluated, hardware and software limitations are outlined and possible future improvements are suggested.

Today's globally competitive market and its associated environmental and social issues of sustainable development are major challenges for the automobile industry. To meet them, the industry needs to invest in high performance development tools. For improving engine performance in terms of consumption and emission, the interactions between the subsystems of the engine air-path need to be understood. This thesis followed two major axes of research in this context. First, the problems related to the modeling of the global air-path system were studied, which include the airflow characteristics between the different subsystems of the air-path, high frequency combustion modeling and pulsating airflow, and estimation of the exhaust aerodynamic force on the vanes of variable geometry turbochargers (VGT). The detailed modeling study was used for developing an engine air-path simulator, which takes into account these interactions and predicts the influence of subsystems on the global air-path. The second axis of research was focused on modeling of mechatronic actuators of the air-path, taking into account their nonlinear behavior due to friction and changes in operating conditions. A generic nonlinear dynamic model was developed and included in the simulator. This model can be adapted to most commercial actuators. The complete simulator has been implemented using AMESim for engine and air-path modeling, and Simulink for control. It has been parameterized according to the specifications of a commercial diesel engine and validated against experimental data. Finally, robust local controllers were studied for actuator position control, aimed at guaranteeing the performance of the actuators under parametric uncertainty and external disturbances. An advanced controller was developed, which adapts to changes in friction characteristics of the actuator and external load changes. The performance of all controllers has been demonstrated experimentally.

La complexification des produits manufacturés notamment mécatroniques requiert la mise en place d’outils et méthodes pour la gestion de leur processus de conception. Ce processus va du cahier des charges à l’obtention de prototypes satisfaisant les exigences structurelles, fonctionnelles et comportementales. Pour développer des produits performants, sûrs de fonctionnement et à moindre coût tout en respectant les délais ce processus doit être maitrisé. Les travaux menés durant cette thèse ont pour objectif de proposer une démarche générique de conception et de modélisation de produits mécatroniques tout en permettant l’évaluation de leurs performances comportementales. La démarche proposée couvre tout le processus allant de la spécification des besoins à l’identification et l’élaboration de prototypes numériques des produits répondant à ces exigences. Elle est basée essentiellement sur trois étapes successives que sont la conception sémantique conceptuelle (CSC), la modélisation sémantique conceptuelle (MSC) et l’ingénierie de performances comportementales (IPC). Ces contributions théoriques sont ensuite implémentées dans un logiciel nommé Product-BPAS et développé dans cette thèse. / The increasing complexity of manufactured product such mechatronics products requires tools and methods to manage their design process. This process covers the steps going from the requirements specification to the definition of the digital mockup that fulfils the structural, functional and behavioral requirements. To develop high quality products with good performance and low cost while respecting delay this process must be optimized and mastered. The research conducted during this thesis is directed to propose a generic approach for mechatronics products design and behavioural performance assessment. This approach covers the process going from the specification of the requirements to the identification and the design of the digital mockups of the products that meet those requirements. This approach is essentially based on three successive steps that are conceptual semantic design (CSD), conceptual semantic modeling (CSM) and behavioral performance engineering (BPE). These theoretical contributions have been implemented in the Product- BPAS software for test and illustrate purposes.

Dans cette thèse, nous apportons la contribution à la conception de robots médicaux, en proposant une démarche de conception simultanée de la structure mécanique du robot. Par opposition à une vision séquentielle naturelle de la conception, la formalisation du processus créatif permet une simultanéité, ouvrant la voie à des structures innovantes dédiées : en robotique médicale, faible masse et faible compacité de la structure mécanique sont souvent recherchées. A partir d’un descriptif de démarches existantes, nous effectuons la conception d’un robot de télé-échographie et d’un robot de chirurgie mini-invasive. Pour les deux applications, de fortes contraintes sont présentes. En télé-échographie, la portabilité est très recherchée, requérant une faible compacité. Pour la chirurgie mini-invasive, les moto-réducteurs du robot in vivo doivent être dimensionnés au plus juste. Ici, nous avons formalisé l’amélioration de la compacité d’une structure parallèle pour la télé-échographie. Les résultats montrent une amélioration de la compacité de l’ordre de 5%. Dans le même esprit, nous avons formalisé la synthèse dimensionnelle de deux robots 2R-R-R de chirurgie mini-invasive in vivo. Nous réalisons l’optimisation simultanée entre le dimensionnement des moto-réducteurs et des longueurs des corps pour tendre vers une simultanéité totale du processus créatif, ce qui nous permet d’améliorer les performances en termes de force et vitesse à l’effecteur. Ces expériences de conception montrent les limites à une simultanéité stricte. Nous indiquons le besoin d’adapter outils et méthodes de conception mécatronique pour une simultanéité en conception robotique tenant compte de l’aspect imparfait du processus créatif. / In this thesis, we propose a contribution to the design of medical robots, by offering a concurrent design or simultaneous approach. As opposed to a natural sequential view of the design process, the formalization of the creative process allows simultaneity, paving the way for innovative structures, dedicated: in the medical robotic field, low mass and low compactness of the mechanical structure are often sought. From a description of existing approaches, we design a tele-ultrasound robot and a minimally invasive surgery robot. For both applications, high physical integration is required. For tele-ultrasound robots, portability is highly sought, requiring low compactness. For minimally invasive surgery, geared motors of the in vivo robot must be sized correctly. Here, we formalized the improvement of compactness of an existing parallel structure for remote ultrasound application. The results show an improvement of compactness of around 5%. In the same way, we formalize the dimensional synthesis of two robots 2R-R-R for in vivo minimally invasive surgery. The results show the under-sizing of some actuators. We perform simultaneous optimization between the design of geared motors and lengths of the body of a robot 2R-RR, tendering towards full simultaneity of the creative process, allowing to improve minimal force and velocity at the end-effector of the robot. These experiments of design show limits to a strict simultaneity. We indicate the need to adapt the tools and methods of mechatronic design for simultaneous robotics design, taking into account the imperfect aspect of the creative process.

Mechatronic design is an enigma. On the one hand, mechatronic products promise enhanced functionality, and better performance at reduced cost. On the other hand, optimizing mechatronic design concepts is a major challenge to overcome during the design process. In the past, less attention has been paid to the life phases of a mechatronic product, and it was assumed that modifications in electronics and software will ensure that the product performs to expectation throughout its life time. However it has been realized that introducing design changes in mechatronics is not easy, since it is difficult to assess the consequences of a design decision, both during the design process of a new product, and during a design modification. It is also realized that there is a strong need to consider the product's life phases during the early phases of product development. Furthermore, it is rather difficult to perform a design optimization since it requires introducing changes across different domains, which is not well supported by the methods and tools available today. This thesis investigates the topic of mechatronic design and attacks some of the major challenges that have been identified regarding the design of mechatronic products. The goal is to provide support to the designers to facilitate better understanding of the consequences of their design choices as early as possible. The work also aims to provide support for assessing alternative design concepts, and for optimizing a design concept based on requirements, constraints and designer preferences at the time of design. The thesis highlights three main challenges related to mechatronic product development: the need for a common language during conceptual design; the inadequate information transfer between engineering domains; and the difficulty in assessing the properties of competing mechatronic concepts. A model-based integration approach is presented, and these key challenges are considered in relation to an integrated modeling and design infrastructure. The approach is illustrated through the design of two mechatronic systems- a two degrees-of-freedom robot, and a hospital bed propulsion system. Initial results provide evidence of good potential for information transfer across mechatronic domains. Although SysML was used for the case studies, some important questions were raised about its suitability as a common language for mechatronics. Suggestions for future work are: to utilize the developed infrastructure and incorporate a capability to model and assess consequences of competing design concepts; provide support for optimizing these concepts; and evaluate the usefulness of the developed infrastructure in a real-world design setting. These efforts should provide ample information to the designer for making adequate decisions during the design process. / QC 20110629

Driven by the need for automation and autonomy as well as the need to reduce resources and emissions, the automotive industry is currently undergoing a major transformation. Technologically, this transformation is addressing a wide range of challenges and opportunities. The optimal control of all components is significant for the sustainable development and eco-friendly operation of vehicles. Additionally, robust control of the actuators forms the basis for the development of driver assistance systems and functions for autonomous driving. The actuators of the steering system are particularly important, as they enable safe and comfortable lateral vehicle control. Therefore, the model-based development and virtual simulation of an innovative highly robust control approach for modern Steer-by-Wire systems were conducted in this thesis. The approaches and algorithms described in this thesis allow the design of robust Steer-by-Wire systems and offer the opportunity to conduct many investigations in a computer-aided virtual environment at an early stage in the development process. This reduces time- and cost-intensive testing on prototypes, avoids unnecessary iterations in the design and significantly increases the efficiency and quality of the development. The desired high degree of robustness of the steering control also ensures that the parameterization of the steering feel generator can be freely selected for the individual application. This enables safe and comfortable vehicle lateral control.In summary, the research results described in this thesis accelerate the development of new, modern Steer-by-Wire systems whose robust design forms the basis for the realization of functions for highly automated and autonomous driving.