Mechatronics Education and Research

Mechatronics Education and Research at the Brno University of Technology

Institute of Solid Mechanics, Mechatronics and BiomechanicsFaculty of Mechanical Engineering, Brno University of Technology

2009-2015

Outline

About Mechlab

– about FME, Brno University of Technology

– about Mechatronics

– teaching Mechatronics at FME BUT

Our laboratory equipment – RCP & HIL

– list of our equipment

Projects– selected R&D projects

– selected bachelor/master thesis

Possible cooperation

www.mechlab.czISMMB, Faculty of Mechanical Engineering, Brno University of Technology

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Brno

About the Brno University of Technology

Brno University of Technology founded in 1899

second largest and oldest technical university in the CR

8 faculties

about 20.000 students

Faculty of Mechanical Engineering founded in 1900

about 4.000 students, 500 employees

Institute of Solid Mechanics, Mechatronics and Biomechanics about 30 employees

Mechatronics laboratory (MechLab) founded in 2009


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What is Mechatronics?

Definition from http://www.mcgs.ch/mechatronics_definition.html:

Mechatronics is an interdisciplinary area of engineering that combines mechanical and electrical engineering and computer science. A typical mechatronic system picks up signals from the environment, processes them to generate output signals, transforming them for example into forces, motions and actions.

http://www.mcgs.ch/mechatronics_definition.html


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Teaching Mechatronics at FME, BUT

Academic degrees: Bachelor degree (3 years)

Master degree (2 years)

Doctoral degree – PhD (4 years)

Curriculum general courses (the same as standard mechanical engin. study)

about 25% of courses taught by Faculty of Electrical Engineering and Communication

hands-on trainings in MechLab


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About MechLab – Mechatronics Laboratory

MechLab is one of several laboratories at Institute of Solid Mechanics, Mechatronics and Biomechanics

Faculty of Mechanical Engineering, Brno University of Technology

Founded in 2009 as a result of project FRVS (Ministry of Education, Youth and Sport)

Continues with previous activities of „Laboratory of mechatronics and robotics“ (2002-2008, joint research centre of BUT and IT, Czech Academy of Science)


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MechLab – Objective/mission

to improve the quality of regular educationin 3. and 4. and 5. year of bachelor/master study regular exercises on computers

with I/O multifunction card – e.g. control of DC motor

to enable the working on high quality bachelor/master thesis with relation to real mechatronic system students generally prefer assignment related to real world instead of

simulation

to provide good environment for research and development for the most motivated PhD students

to successfully realize the projects/cooperation with industry


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MechLab: Experiences and competences

modelling of dynamical systems kinematics, dynamics of MBS, app. in robotics

tools Simulink, SimScape, SimMechanics

microcontrollers programming

design and production of PCBs

applications

measurement and control in real-time Simulink (RealTime toolbox, RT Win Target, Code generation)

NI LabVIEW (PC, FPGA apps.) – several successfully completed industrial projects

Hardware-In-the-Loop, Rapid Control Prototyping

FPGA System Generator (Xilinx)

applications for dSPACE I/O card

R&D of industrial testing devices applications for Bosch, Skoda Auto, Alucast

MechLab: Team


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Outline

About Mechlab– about FME, Brno University of Technology



Our laboratory equipment

– RCP & HIL






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Experimental equipment in MechLab ::

Rapid Control Prototyping & Hardware In the Loop


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12+1 computers with I/O multifunction card MF 624 Matlab/Simulink supported

(Real-Time Toolbox, Real-Time Windows Target)

8x ADC, DAC, DOUT, DIN, 4x incremental encoder, 4x PWM generator/counter, PCI

12+1 EduKit based on dsPIC33 microcontroller

2 professional educational models(Helicopter 2 dof, Magnetic Levitation)

12+1 „Double DC drive“ edu model 2x DC motor with encoder + current sensors

connection to MF624 / dsPIC

many other “students-made” educational models

laboratory power sources, oscilloscopes, sign. gen.,…

Experimental equipment in MechLab :: Educational tools


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Rapid Control Prototyping HW :: MF 624

I/O 8x 14bit A/D (+-10V, 1.6(1 ch.)-3.7(8ch.)us

conversion time)

8x 14bit D/A (+-10V, 10mA max., 31us settling time)

8x Dout, 8x Din (TTL compatible)

4x timer (32-bit, PWM)

4x encoder input

power on board +5V (100mA / 250mA max.)

+12V (150mA max.)

connectors Canon (2 x DB-37 F)

RealTime Toolbox – directly I/O to/from Simulink (without compilation – approx. up to 1kHz)

RealTime Windows Target – 10 kHz


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Experimental equipment in MechLab ::

RealTime measurement & control with Simulink

Long-time experience with Matlab/Simulink

RealTime Toolbox

RealTime Windows Target

RealTime Workshop

RTI, Control Desk (dSPACE)

model based development environment for 16- and 32-bits microcontrollers PIC RT Workshop + RTW Embedded Coder + Simulink Fixed Point


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Rapid Control Prototyping and HIL equipment

dSPACE single board 1103 with AutoBox many peripherals including RS232, CAN

professional tool

dSPACE modular system DS1006 processor board

DS2202 HIL I/O board

DS5203 FPGA board

NI cRIO (several chassis, modules) real-time computer, FPGA, modular I/O

programming in NI LabView

NI PXI several I/O cards (incl. FPGA)

laboratory power sources (>8)

oscilloscopes (>10)

others...


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Hardware: dSPACE DS1103, AutoBox

Hardware: dSPACE modular system with DS1006

DS1006 – processor board

DS2202 HIL IO board

DS5203 programmable FPGA board

DS814 link board

Our applications: – Simulation of BLDC motor for aircraft fuel pump

– Development of advanced control techniques for BLDC motor


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Hardware: NI Compact RIO

NI cRIO-9073 (Integrated 266 MHz Real-Time Controllerand 2M Gate FPGA)

NI 9401 (8 Ch, 5 V/TTL High-Speed Bidirectional Digital I/O Module)

NI 9215 (4-Channel, 100 kS/s, 16-bit, ±10 V Simultaneous Sampling Analog Input Module

NI 9411 (6-Channel, 500 ns, ±5 to 24 V Digital Input Module)

NI 9221 (8-Channel, ±60 V, 800 kS/s, 12-Bit Analog Input Module)

NI 9211 (4-Channel, 14 S/s, 24-Bit, ±80 mV Thermocouple Input Module)

NI 9263 (4-Channel, 100 kS/s, 16-bit, ±10 V, Analog Output Module)

Outline






Projects

– selected R&D projects

– selected bachelor/master thesis Possible cooperation


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List of selected projects 1/2

2009 – Laboratory of mechatronics – educational project (approx. 60 kEUR)

2009 – 2012 – Human resources training for team cooperation in research and development (VUT is partner, approx. 80 kEUR)

2011 – Microcontroller PIC kits into regular education (6 kEUR) 2011 – Automotive Hydraulic Power Steering stand (5 kEUR) 2011 – New lab and powerful equipment (modular dSPACE, PXI NI,

oscilloscopes, power sources,…) (approx. 116 kEUR for Mechlab) 2011-2015 – ESPOSA = Efficient Systems and Propulsion for Small

Aircraft, European 7FP (VUT is partner, approx. 329 kEUR) 2012 – Introduction of FPGAs into regular education (9 kEUR) 2012 – HIL simulator for parking ECU – ŠKODA Auto (6 kEUR) 2013 – HIL simulator for parking ECU II. (mobile version)– ŠKODA Auto

(6 kEUR) 2013 – Testing stand for detection of DC fuel pump rotation direction

(Bosch Č.B., 5kEUR)


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List of selected projects 2/2

2014 HIL simulator for parking ECU III. (ŠKODA Auto, 4kEUR) Training (Honeywell, Knorr-Bremse DE, 3kEUR) Acceleration simulator for testing of DNOX

tanks/modules (BOSCH ČB, 28kEUR) Training „Advanced Simulink“ (Danfoss, SK) GelPicker – manipulator for medical research (MUNI,

2kEUR) Wireless data acquisition module for ball bearing

diagnostics (ZKL, 4kEUR) Stand for loading of linear actuators for automatical

boot opening (ŠKODA Auto, in progress)

2D Acceleration Simulator for DNOX tank testing

Application: industrial motion simulator

2DOF rotating platform Working range: ±40 deg.

Max. load 50 kg

Platform size: 1000x1000 mm

Electronics 240W DC brushed motors

Position controlled by dsPIC

Customer: Robert Bosch, České Budějovice

video


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../../videos/BOSCH_Naklanec

Wireless data acquisition module (2014)

application: crankshaft vibro-analysis

Long term monitoring module Piezoelectric sensor, temp. sensor

Variable acc sensitivity (10-1000g)

Sample rate: 20-100kHz

Range: 30m

Outputs raw data for advanced analysis

Lifetime: 1,7y (measure 3 times a day)

Dimension (d=50mm, h=120mm)

User software included (LabView)

Customer: ZKL Brno


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Wireless measurement of deformation (2014)

application: gear-wheel strainmeasurement

Straingauge wireless module 120Ω quarter bridge

24 channel bridge measurement

Sample rate: 700 Hz

Range: 30m

Outputs raw data for further analysis

Dimension (d=110mm, h=40mm)

Experimental software (LabView)

Customer: IG Watteeuw


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Car4: four-wheel steering experimental vehicle

Used for research and educational purposes

Two main fields of reseach: Dynamics and traction control

Autonomous navigation

Sensors ACU

Xtion

Stereovision cameras

…

Electronics dsPIC units

Regular PC for harder task (stereovision)

Electronics:


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2D and 3D laser scanners

application: project Car4 obstacle detection, navigation (SLAM),

autonomous movement

Hokuyo URG – 2D laser scanner Rotating head

240° detection area

Resolution 0.36° @ 10 Hz

ASUS Xtion (Kinect) – 3D depth map Laser projector + CMOS sensor

58° x 45° detection area

Resolution 640×480 pixels @ 33 Hz

USB connection, data processing in MATLAB


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BOSCH Hall: Rotation Direction Detector

Application: Production quality control

Aimed at fuel pumps Uses Hall sensors

Measure changes in magnetic flux density

Can detect the rotation directionfor both DC and BLDC pumps

Controlled by two Microchip PIC24

Digital I/O and RS232 for communication

Customer: Robert Bosch, spol. s.r.o.


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GelPicker: manipulator for picking gel (2014)

application: medical research

3DOF manipulator X,Y axes: stepping motor controlled

Z axes: solenoid

Working range: 350 x 350mm (x,y)

stroke 20mm (z)

Electronics: Stepper motor driver

controlled by the dsPIC

Customer: MUNI Brno

video


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../../videos/GelPicker/gelpicker.mp4


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7FP project ESPOSA (2011-2015)

ESPOSA = Efficient Systems and Propulsion for Small Aircraft, European 7FP, http://www.esposa-project.eu/

39 partners (9 universities, 11 research est.)

role of BUT: modelling, HIL, support for code generation for FADEC, TEGs

http://www.esposa-project.eu/


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Embedded HIL simulator for parking ECU (2013)

Task: create embedded version

of HIL simulator for parking ECUs

Requirements: capable of testing PDC and

PLA 3/4/7/8/12 ch

uC based solution

user interface on PC

Implementation: dsPIC microcontroller

with signal conditioning and UART-USB interface

GUI and obstacle model programmed in LabView

Customer: ŠKODA Auto


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Power HIL simulation of DC motor (2014)

Goal: extension of classical HIL simulationto the ability to test power electronics

Application: testing control units for fuel pumps


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Advanced control / HIL simulation for BLDC motor (2012-2014)

test stand with encoder,torque meter and load

algorithms for – sensorless control

– control with one of the hallsensor fault

HIL simulation– very fast execution

implemented on FPGA


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HIL simulator for parking ECU (2012)

task: „hack“ and simulate parking sensors for parking ECU (Valeo)

requirements: prepared for 3, 4 and up to 8 sensors

EtherCAT communication with other HIL „boxes“

implementation:– signal conditioning (sensor uses 1 wire bi-directional communication)

– experiments, understanding of basic sensor behavior

– NI hardware & software


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Students project: Self balancing vehicle (2011)

Vehicle properties:

robust mechanical construction (CNC machining of aluminium), direct connection of DC motors to wheel shaft (without chain)

all electronics developed in MechLab (dsPICmodule, h-bridge, battery charger)

implementation of PID control with Complementary filter

Generalization: intensive use od Matlab/Simulink tools in development process

modelling using Simulink/SimMechnics

Simulink Parameter Estimation

Real Time Toolbox with MF624

code generation with RTW,RTWEC, Kerhuel(cheap and easy to use dsPIC target)

[video]

../../videos/Keywatko/Keywatko_3_Hummer/hummer_honza_MicrosoftVideo1.AVI


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Testing stand for DNOX jet (2010)

object: solenoid jet for Ad-Blue application for diesel engines (reduction of NOx)

task: test of opening/closing time, voltage

HW: NI USB DAQ

SW: LabVIEW

customer: Bosch CB


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commercially available module: important features/parts are external

(crystal, reset, prog. connector)

our module: 44-pin dsPIC33FJ128MC804

20MHz crystal

programming connector for ICD2/3

reset

3.3V regulator

Universal dsPIC module (2010)


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Universal dsPIC module (2010) - Code generation

C code is automatically generatedfrom Simulink

tools: Simulink Coder

(formerly Real-Time Workshop)

Embedded Coder (formerly RT Workshop Embedded Coder)

Kerhuel blockset- support of the subset of the Microchip 16,32-bit devices[http://www.kerhuel.eu/]

MPLAB compiler and bootloader.


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Universal dsPIC module (2010) - Code generation

Setting signal data types

Setting signal storage classes (interface with hand writtenmodules – global variables)

Generating reusable functions

Customized signal object class


39www.mechlab.czÚstav mechaniky těles, mechatroniky a biomechaniky, FSI, VUT v Brně

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Integrating automatically generated code from Simulink coder

User

code

Generated C code

Simulink model

Setting signal data types

Setting signal storage classes (interface with hand written modules – globalvariables)

Generating reusable functions

Customized signal object class


40www.mechlab.czÚstav mechaniky těles, mechatroniky a biomechaniky, FSI, VUT v Brně

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Fully generated C code directly from Simulink

Blocks for peripherals handing (reusable in other projects)

Custom code generation (Target specifics main.cfile)

„Direct code generation for nonsupportedtargets from Simulink“

Generated executable code

Simulink model


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Code generation: Support for complex peripherals

Block for display units Advanced GUI compared to masked blocks.

Design display layout

Automatically generates TLC and MEX files…

4DOF robotic platform for education (2013,2014)

our own mechanical, electronics and control design

full access to all sensor signals, ideal for teaching

very fast dynamics

controlled by I/O card (MF624) fromMatlab/Simulink

safety electronics imlemented

Examples of use:

teaching kinematics and dynamics

edu applications for image processing

Playing Tic Tac Toe

video


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../../videos/Robot_TicTacToe/manipulator_tic_tac_toe.mp4


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Grepl, Lee (2008,2009):

Projects: Electronic throttle control

conventional “bowden” handling

mechatronic solution = pedal sensor

DC motor

angle sensor

controller

motivation better fuel economy, emissions

possibility to implement advanced tracking control

improvement of the whole system performance

Research @ Keimyung University, Daegu, Korea

video

../../videos/throttle/throttle_control.avi

Projects: Electronic throttle control Grepl, Lee (2008,2009)


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Grepl, Čoupek, Konvičný, Krejčiřík (2009):

Projects: Mobile robot with hybrid undercarriage

hybrid undercarriage = robot can ride on wheels and also walk using legs

4 DC motors with enkoders

7 servos

6 ECUs NXP ARM @ 43MHz

production using Rapid Prototyping Technology(Laser sintering)


46www.mechlab.czISMMB, Faculty of Mechanical Engineering, Brno University of Technology

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Grepl, Čoupek, Konvičný, Krejčiřík, Radoš (2009): Mobile robot with hybrid undercarriage - RobotX

hybrid undercarriage = robot

can ride on wheels and also

walk using legs

4 DC motors with enkoders

7 servos

6 ECUs NXP ARM @ 43MHz

production using Rapid Prototyping Technology(Laser sintering)


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Grepl, Švehlák, Bezdíček, Sztwiertnia (2003,2006):

Four legged walking robot

12 dof actuated with Hitec servos

microcontroller Atmel AVR Atmega 128(8bit @ 18MHz)

gait on flat terrain controlled by artificial neural network

Bluetooth communication with PC

video 1

video 2

../../videos/robot_Jaromir/01_basic_gait_and_test/robot_Jaromir_BrnoUT_Grepl_divX.avi

../../videos/robot_Jaromir/03_balancing/robot_Jaromir_3D_balancing_hq.avi


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Anti-sway Crane (Grepl, Veselý: 2000)

motivation = transport without swinging

simple dynamic model (constant r)

assume x is “kinematic excitation”(we control the motor by x(t) )

goal = travel given Δx asap without swinging

with the motor and system limits

tancos

rg x

video

../../videos/crane/crane_Grepl_BrnoUT.avi



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František Zouhar (B 2009) : Design, production and testing of education model „Helicopter with two rotors“

Motivation, Aim of work Design of helicopter and electronic

Parameter’s estimation

PID control for 3 degrees of freedom

Results Function model with autonomous electronic

Simullink model of helicopter

Reliable PID control

Good education instrument

video

../../_video/BP_DP/2009_BP_Zouhar_Helicopter__1dof_control__P1050651-xvid.avi



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Ondřej Klusáček (M 2009): Modelling, identification and control of rotary pendulum

Nonlinear model created and parameters identified

Use of LMD18245 H-Bridge for power electronics to

provide momentum based control

LQR stabilizing state-space controller designed

Swing-up controller and switching algorithm designed

and tested

Zero steady-state error obtained with use of

additional input

integrator

video

../../_video/RotPend/RotPend_2009_Klusacek.avi



51ISMMB, Faculty of Mechanical Engineering, Brno University of Technology

Jan Štěpánek & Tomáš Trnkócy (B 2009) : Design, production and testing Data Glove

Motivation, Aim of work Glove with bend sensors and accelerometer

Creation VRML model of human hand

Real-time projection users hand in Virtual Reality

Results Functional prototype

Communication with PC via Bluetooth

Rechargeable battery power

Controlled using GUI



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Šuranský, (B 2011): Electronical safety valve for hydraulic liquids

goal: design and implementation of safety valve with DC motor (modification of manual valve)

prototype developed using MF624 and Simulink.



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Sova (B 2011): Development of testing unit for hydraulic proportional valves

goal: design, implementation and testing of electronic test unit for hydraulics valves

MCU PIC32 used, programming from Simulink

Outline










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Possible cooperation with universities/industrial partners

We have long term experience with cooperation with industrial partners:

– Škoda Auto– Bosch Č.B.– ŽĎAS a.s.– UNIS– Alucast

... as well as with partners from universities:– Keimyung University, Daegu, Korea– University of Malta– Warsaw Technical University.


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We can offer our services/cooperation in all areas of ourcompetence:

modelling of dynamical systems (kinematics, dynamics of MBS, app. in robotics, tools Simulink, SimScape, SimMechanics)

design of embedded system (PCB design, electronics, mechanical parts, programming, case, testing).

measurement, control in real-time and HIL (Simulink (RealTime toolbox, RT Win Target, Code generation), NI LabVIEW (PC, FPGA apps.) – several successfully completed industrial projects, Hardware-In-the-Loop, Rapid Control Prototyping)

applications of FPGAs system identification and parameter estimation automatical code generation from MATLAB/Simulink


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We are looking for cooperation with universities in following areas:

– R&D projects– staff/students exchange, research fellowship – Erasmus exchange

We are looking for cooperation with industry in following areas:– R&D projects– engineering solutions in field of Mechatronics– trainings, consultancy

If you have any idea of possible

cooperation, CONTACT US!

assoc. prof. Robert Grepl, [email protected]

[email protected].: +420 732 542 500

www.mechlab.czInstitute of Solid Mechanics, Mechatronics and Biomechanics

Faculty of Mechanical EngineeringBrno University of Technology

Documents

Mechatronics Education and Research