Multidisciplinary development of a badminton robot Model Driven Development Days 2013 April 24
Multidisciplinary development of a badminton robot Model Driven Development Days 2013 April 24th, 2013 Overview + Introduction + Design specification + Conceptual design + Embodiment and detailed design + Conclusions © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p2 Flanders’ Mechatronics Technology Centre + FMTC vzw: Non-profit organization Started in 2003 with support of Agoria In 2011: +4.8 M€ turnover with +35 staff Membership for companies with R&D in Flanders + Our competence: Mechatronics = integration of electronics and software in mechanical systems + Our business: Application oriented research projects + Our market: Machine building and mechatronic component industry © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p3 The FMTC activities are grouped in 4 programs. Model Based Design sensors Smart Sensors energydrivetrain(s) efficient EM drivetrain(s) proces product Self-optimisation environment © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p4 Badminton robot: why? + Build a non-confidential demonstration platform with high PR impact + Integrate and demonstrate key FMTC developed technologies Low latency wireless communication platform Energy efficient control Model based design methodologies Advanced diagnostics © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p5 Challenges + Multidisciplinary design problem Combination of different physical & software components required to fulfill requirements Design team Mechanical designers Specialists on dynamic analyses Control specialists SW specialists Integration of activities crucial © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p6 Model-based development + Models used for Formal representation of Requirements Design solution Link between requirements and design solution SysML Behavioural simulations Matlab Simulink, Modellica, FEM, … © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p7 Overview + Introduction + Design specification + Conceptual design + Embodiment and detailed design + Conclusions © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p8 From informal/uncomplete thoughts… 1. Able to play badminton against a human player in a noncompetition tempo 2. Able to play badminton with standard badminton equipment 3. It covers half badminton field 4. No strings (wires) attached, it can freely move in its half badminton field © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p9 … to a complete list of formal requirements + List of functional and non-functional requirements © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p10 … to a list of technical system specifications + Rationale: Time budget = 1s (realistic average time per shoot) Maximum travel distance = 8m (badminton field in diagonal) Robot waits in the middle of the field Maximum travel distance in 1s = half the field minus 0.5 m the racket length 3.5m Assuming a triangular profile s = 1/4at2 acceleration has to be 14 m/s2 or 1.4g © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p11 Overview + Introduction + Design specification + Conceptual design + Embodiment and detailed design + Conclusions © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p12 Idea generation + Brainstorming by experienced people with mixed background Different working principles identified © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p13 Evaluation of conceptual ideas + Fulfillment of all technical specifications Wireless communication demonstrator H-bridge & cabled robot not OK Acceleration Basic calculations Friction = NormalForce * µ NormalForce = Gravity Gravity = m * g µ ~ 0.4 Max acceleration = µ * g = 0.4 g Wheeled robot on normal field NOT OK NormalForce = Gravity + Magnetic Force Wheeled robot on magnetic field OK Gravity = 3500N Magnetic force @ 4 mm distance = 20000N Magnetic force @ 1 mm distance = 40000N Max acceleration = 3g (theory, in practice will be 2.5 in the best case due to inefficiencies) © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p14 Selected concept © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p15 Overview + Introduction + Design specification + Conceptual design + Embodiment and detailed design + Conclusions © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p16 Embodiment and detailed design + Concretize working principle into a system architecture VISION CONTROL SOFTWARE PHYSICAL DESIGN MECHANICS ELECTRICS MAGNETICS SAFETY Different disciplines involved / working in parallel Coordination by system architect © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p17 Embodiment and detailed design + Central role for system architect ELECTRICS MAGNETICS VISION CONTROL SYSTEM ARCHITECT MECHANICS SOFTWARE SAFETY Coordinate activities of different disciplines Define system architecture Assignment of requirements to different sub-systems Assess effect of design decisions for one sub-systems to another sub-systems Keep overview of complete design © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p18 Multidisciplinary design 1. Definition of system architecture Battery Hitting mechanism Frame Wheels Motors © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p19 Multidisciplinary design 2. Assignment of requirements to different sub-systems Traceability of requirements is important Assignment by system architect (communication among disciplines) Based on experience Weight © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p20 Multidisciplinary design 2. Assign requirements to different disciplines Traceability of requirements is important Assignment by system architect (communication among disciplines) Based on simplified multidisciplinary analysis Ffriction Tmotor 1 M, I Ffriction Power motor Capacity batteries Control performance Tmotor 1 Pmotor = motorTmotor motor © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p21 Multidisciplinary design 3. Fulfill requirements by monodisciplinary design Detailed model-based analyses Magnetic simulations FEM analysis © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p22 Multidisciplinary design 3. Fulfill requirements by monodisciplinary design Models from other disciplines used – dynamic model of the plant used in Simulink © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p23 Multidisciplinary design 3. Fulfill requirements by monodisciplinary design Software: automatic code generation from Simulink Model © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p24 Multidisciplinary design 4. Feedback of monodisciplinary analyses to system architect Holonomic vs. + Simple control - Requires a minimum of 3 driven omnidirectional wheels with uniform friction coefficient Non-holonomic design + Requires only 2 driven wheels - Complex trajectory generation and control Non-holonomic design selected in order to keep total system mass below the 400 kg limit © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p25 Multidisciplinary design 4. Feedback of monodisciplinary analyses to system architect Magnetic simulations Used to optimize the magnetic plate design in order to minimize drag Less powerful motors were needed © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p26 Multidisciplinary design + Iterative process Improved interdisciplinary integration Refinement of design: High abstraction detailed analysis Simplified multidisciplinary analysis Motor selection Detailed CAD design Simplified multibody simulation and optimization Final CAD design M, I © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p27 FMTC’s badminton robot v2 © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p28 Overview + Introduction + Design specification + Conceptual design + Embodiment and detailed design + Conclusions © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p29 Conclusions + Models have been extensively used in the design of the new badminton robot To support design decisions by individual designers To improve communication between designers To keep an overview on the overall design by the system architect + Future challenges Multidisciplinary simulation models (co-simulation) Model-based safety design Model-based testing © FMTC vzw 2010 • STRICTLY CONFIDENTIAL • p30
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