Mechatronic Overview

MECHATRONISCHE SYSTEME
FÜR KRAFTFAHRZEUGE
(Automotive Mechatronics)
Prof. Dr.-Ing. R. Isermann
Institut für Automatisierungstechnik

Technische Universität Darmstadt
R. I.
TU Darmstadt 2005
AUTOMOTIVE MECHATRONICS
• INTRODUCTION
• DESIGN PROCEDURE
• HISTORICAL DEVELOPMENT
• MECHATRONIC SUSPENSIONS
• MECHATRONIC BRAKE SYSTEMS
• MECHATRONIC STEERING SYSTEMS
• ACTIVE FRONT STEERING CONTROL
• CONCLUSIONS
R. I.
TU Darmstadt 2005
system theory
micro electronics
modeling
power electronics information
electronics automation technology
sensors technology software
actuators
computational intelligence
MECHATRONICS
mechanics
mechanical elements
machines
precision mechanics
Mechatronics: Synergetic integration of different disciplines

R. I.
TU Darmstadt
man/machine
interface
reference
monitored
variables
variables
information
processing measured
manipulated
variables
variables information flow
energy flow
actua- mechanics &

sensors
tors energy converter
auxiliary energy
energy con-
energy supply
supply sumer
mechanical
hydraulic
thermal
electrical
R. I.
TU DarmstadtMechanical process and information processing develop towards mechatronic systems
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
IFAC T.C. Mechatronic Systems (2000)
R. I.
TU Darmstadt
Mechatronic
Systems
Mechatronic Mechatronic Mechatronic Mechatronic

power power Mechatronic Mechatronic
machine motion consuming
producing automobiles trains
components generators machines machines
- semi-active - integrated - brushless DC - integrated - antilock brake - tilting trains
hydraulic electrical motors multi-axis (ABS) - active boogie
dampers servo drives - integrated AC machine tools - electro- - magnetic
- automatic - integrated drives - integrated hydraulic levitated
gears hydraulic - mechatronic hydraulic brake (EHB) trains
- magnetic servo drives combustion pumps - active (MAGLEV)
bearings - integrated engines suspension
pneumatic - active front
servo drives steering
- robots
(multi-axis,
mobile)
R. I.
TU Darmstadt
Examples for mechatronic systems
o Functions and integration of mechatronic systems
• Distribution of functions
• Operating properties
• New functions
• Integration forms
R. I.
TU Darmstadt
o Functions and integration of mechatronic systems
• Distribution of functions
• Operating properties
• New functions
R. I.
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
R. I.
TU Darmstadt
- consideration of integrated overall system
- generation of synergetic effects
→ classical mechanical-electronic system:
micro-
actuators process sensors
computer
“addition of available components”

integration of components
R. I.
TU Darmstadt
Spatial integration (integration of the components)
micro- actuators process sensors

computer
“Integration of the components at different places”
actuator and microcomputer

smart actuator
process and microcomputer
sensor and microcomputer
smart sensor
R. I.
TU Darmstadt
Hardware-Integration
integration by information processing
knowledge base software-
mathematical performance integration
process models criteria
information gaining design methods

- identification - control
- state observer - supervision
- optimization
online information processing

supervision adaptation
control
diagnosis optimization
micro- hardware-
actuators process sensors integration
computer
R. I.
TU Darmstadt
Mechatronic overall integration
Runge,
ATZ 2000
R. I. Mechatronic control module for a 6-gear-automatic transmission

TU Darmstadt
(ZF 6HP26)
History of ABS Systems
ABS 2
kg kByte
200
z
d en
nd!
T en
6
ige
st e
ABS 5.0
6,2 kg ABS 8
128kByte
ABS 5.3
ABSR 5.7 100
3
3,8 kg
2,6 kg
2,5 kg
48kByte
1,8 kg
24kByte
16kByte
8kByte
1989 1992 1995 1998 2001
Rob. Bosch GmbH

R. I.
TU Darmstadt Anti-lock braking systems (ABS)
Quelle:ATZ/MTZ Extra „Der Neue Golf“ Oktober2003
Volkswagen
R. I.
TU Darmstadt
Direct automatic shift gear box with double clutch (2003)
Volkswagen Q uelle:A TZ/M TZ E xtra „D er N eue G olf“ O ktober2003
R. I.
TU Darmstadt
Electro-hydraulic control system for DSG
AUTOMOTIVE MECHATRONIC SYSTEMS
• INTRODUCTION
• CONCLUSIONS
R. I.
TU Darmstadt 2005
DESIGN PROCEDURE FOR MECHATRONIC
SYSTEMS
o Mechatronic engineering
o Modelling and simulation
o Software tools
R. I.
TU Darmstadt
system
definition
requirements
engineering
(specification)
traditional mechanical electronic information operating

& electrical engineering & control engineering
engineering engineering engineering
process/ electronic inform. proc- human-ma-

component hardware cessing & soft- chine inter-
design design ware design face design
integrated
(concurrent) integration of components integration by information
(hardware) processing (software)
engineering
R. I.
TU Darmstadt
Design procedure for mechatronic systems (iterational steps not indicated)
integration of components integration by information
(hardware) processing (software)
integrated mechan.electronic system

generation of
integrated synergetic
effects
(concurrent)
engineering reliability &
safety
engineering
manufacturing
engineering
mechatronic
system
R. I.
TU Darmstadt
Design procedure for mechatronic systems (iterational steps not indicated)
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)

• Simulated process and real ECU (real-time)
R. I.
TU Darmstadt
process-model ECU-model
θFW p2,stat p2 SiL p2
θFW control upwm
algorithm
neng
neng T2,stat T2 p2,Setpoint
simulation tool high performance
P
real-time real-time computer
C
iL
R
(full pass, by pass)
real-time
integrated
mechatronic
system
real process real ECU + real actuator
R. Isermann
TU Darmstadt Simulations for mechatronic development
Diesel engines
Truck engine Passenger car engine
R. I.
TU Darmstadt
Hardware-in-the-Loop Simulator für truck engine control
IAT/DC
1992-
1999
R. I.
TU Darmstadt HiL-Simulator, dSpace DSP & Power PC
R. I.
TU Darmstadt HiL-simulation of a single injection pump valve cut off
1 gear shifts
2 drive train oscillations
3 soot limitation
4 speed limitation
5 turbo charger inertness
R. I.
TU Darmstadt HiL-simulation of a full power acceleration of a 40 tons truck
• INTRODUCTION
• CONCLUSIONS
R. I.
TU Darmstadt 2005
Wheel speed sensor Anti-lock brake system
(1979)
Acceleration sensor Anti-skid control (1993)
Electronic stability progr.

Yaw rate sensor (1995)
Brake assist
(1996)
Radar sensor
Adaptive Cruise Control
(1999)
Susp.deflect. Active Body Control

(2000)
Brake-by-Wire (EHB)(2001)
Pedal position
Active front steering (2003 )
EHB-pressure Brake-by wire (20??)
Steer-by-Wire
EMB-force sensor (20??)
Collision Avoidance
Figures: Continental Teves AG & Co. oHG (20??)
R. I.
TU Darmstadt Vehicle dynamics control systems
Sensors and actuators for gasoline engines
Sensors Actuators
Engine speed (1967), Electronic fuel injection
camshaft phase (1967, D-Jetronic)
Engine temperature (1967) Microelectronic
Manifold pressure controlled ignition and
manifold temperature (1967) injection
Knock sensor (1969) (1979, Motronic)
Airmass flap (1973) Exhaust gas valve
Oxygen (lambda) (1976) Tank vent valve
Airmass hot-film (1981)
Secundary air valve
Ambient pressure (1994)
Throttle- and pedal-position
Variable geometry
(1997, E-Gas)
manifold
Tank pressure
ca. 15-25 measurements Electronic throttle (1997)
Ion current (20??)
Combustion pressure (20??) ca. 6-8 manipulation variables Variable camshaft
timing
ca. 80-120 look-up-tables
Variable valve lift(2001)
Abbildung: Adam Opel AG
R. I.
TU Darmstadt
Sensors and actuators for gasoline engines
Mechatronic
automobiles
Mechatronic Mechatronic Mechatronic

combustion drive Mechatronic Mechatronic
suspensions brakes steering
engines trains
- electrical - automatic - semi-active
hydrodynamic - hydraulic anti- - parameter-
throttle shock-absorbers
transmission lock braking (ABS) izable power-
- mechatronic - active hydraulic
- automatic - electronic stability assisted
fuel injection suspension
mechanic program (ESP) steering
- mechatronic (ABC)
shift transm. - electro-hydraulic - electro-
valve trains - active pneumatic
- continuously brake (EHB) mechanical
- variable geo- suspension
variable trans- - electro- power-
metry turbo- - active anti-roll
mission (CVT) mechanical assisted
charger (VGT) bars (dynamic
- automatic traction brake (EMB) steering (EPS)
- emission control drive control
control (ATC) - electrical parking - active front
- evaporative (DDC) or roll-
- automatic speed brake steering (AFS)
emission control control)
- electrical pumps and distance
& fans control (ACC)
R. I.
TU Darmstadt
40 - 75 Electronic Control Units
30 - 150 electrical motors
2- 4 km cables (harness): 40 - 80 kg
4 bussystems
2500 signals
Source: VDA 2001
R. I.
TU Darmstadt Control units and data exchange
Bordnetz des VW Phaeton
Quelle: ATZ Sonderheft VW

Phaeton
R. I.
TU Darmstadt VW Phaeton: Elektrisches Bordnetz
• INTRODUCTION
• CONCLUSIONS
R. I.
TU Darmstadt 2005
VDA 2001
R. I.
TU Darmstadt
Stabilisation through single wheel braking with ESP
VDA 2001
R. I.
TU Darmstadt
Electro-Hydraulic Brake System
EHB1 Hydraulic Unit Components
Suction connection
Electric motor Sealings for pressure sensor modul
Contact spring
Pressure sensor modul
ECU
Valve
Accumulator with
multilayer diaphragm Magnet group
Sealing for ECU
Pump element
Medium separator
Rob. Bosch GmbH
R. I.
TU Darmstadt
Electrohydraulic brake
Chassis Systems
Electro Hydraulic Brake System EHB1
Rob. Bosch GmbH

R. I.
TU Darmstadt
Continental Teves (2003)
R. I.
TU Darmstadt Electro-mechanical brake (prototype)
• INTRODUCTION
• CONCLUSIONS
R. I.
TU Darmstadt 2005
Hydraulic
Active Power
Electrical Front
Electrical
Power
AssistedSteering
PowerSteer-by-
Steering
Steering
(HPS)
(HPS (AFS)
Wire
+ EPS)
(EPS) electrical
(larger(SbW)
vehicles) steering
hydraulic torque motor
pump for haptic
feedback
Hydraulic
Electrical
Active Power
Electrical
Front
Power
Assisted
Power Steering
Steering
Steering
Steering
(HPS)
(HPS + EPS)
(AFS)
(EPS)
electrical
hydraulic
hydraulic
electrical actuator
electrical
electrical
hydraulic hydraulic
actuator generates
actuator
actuator additional
actuator
actuatorsteering
actuator valveangles
in steering column
R. I.
TU Darmstadt Mechatronic steering systems
Servo pinion
Torsion rod
Torque sensor
Steer pinion
Servomotor
ECU
VW Q uelle:ATZ/M TZ Extra „Der Neue Golf“ Oktober2003
R. I.
TU Darmstadt
Electrical Power Steering (EPS)
Superposition of a steering angle
BMW (2003)
R. I.
TU Darmstadt Active front steering
Development of driver assistance systems
R. I.
TU Darmstadt
Automotive surrounding sensors
1. Close range: ultra sonic, radar
2. Medium range: lidar, radar, camera
3. Remote area: radar, camera
R. I.
TU Darmstadt
Gemeinschaftsforschung mit der Industrie
Arbeitskreise begleiten Forschungsvorhaben: 2-3 Jahre
Finanzierung: 50% Industrie – 50% BMBF oder BMWi
Auftragsumfang: 65.000 € pro Jahr und Vorhaben
Verbrennungsmotoren Mechatronische Systeme
Forschungsvereinigung Deutsche Forschungsgesellschaft für
Verbrennungskraftmaschinen die Anwendung der Mikroelektronik
FVV DFAM
Dieselmotoren-Regelung (1992-1995) Intelligente dezentrale
Dieselmotoren-Steuerung (1995-1997) elektromechanische Komponenten (1996-1999)
Nebenaggregate-Management (1995-2000) Einfach anwendbare Diagnoseverfahren für
Fehlerdiagnose an Dieselmotoren (1999-2002) mechatronische Komponenten (2001-2003)
Fehlerdiagnose an Ottomotoren (1999-2002)
DFAM
Mechatronische Pumpen
Fachgemeinschaft Pumpen VDMA
Störungsfrüherkennung an oszillierenden
Teleservice Verdrängerpumpen (2002-2004)
Forschungszentrum Karlsruhe
Projektträger des BMBF
Verbundprojekt OKTEL
Modellbasierte Telediagnose elektrischer
Antriebe und Textilmaschinen
R. I.
TU Darmstadt FG Regelungstechnik u. Prozessautomatisierung
Forschungskooperationen mit Firmen
Forschungverträge: 1-3 Jahre, Finanzierung: 100% Industrie
Auftragsumsatz: ca. € 700.000 pro Jahr
Verbrennungsmotoren Kraftfahrzeuge
Dieselmotoren (seit 1992) Brake-by-Wire (seit 1995)
Modellbildung Regelung und Rekonstruktion
Echtzeit-Simulation der Bremskraft einer EMB
Regelung Intelligentes Bremspedal
Regelung der Horizontaldynamik
Ottomotoren (seit 1996) mit BbW-Aktuatoren (ABS/ESP)
Brennraumdruck-
Regelung Aktive Fahrwerke (seit 2001)
Zustandserkennung für aktive
Abgasrückführungs-
Regelung Fahrwerke
Personenkraftwagen (seit 1990)
Ottomotoren (seit 2001) On-line Simulationsmodelle
Optimierung der Verbrennung Automatische Abstands- und
beim Direkteinspritzer Geschwindigkeitsregelung
Verbrennungsaussetzer- automatisches
Erkennung (1996-2001) Parkassistenzsystem
Druckanalyse im Energie-/Produktionstechnik
Abgasstrang
Heizungssysteme (seit 1986)
Ionenstrommessung
Modellbildung, Simulation
W1 Adaptive Regelung
Medizintechnik W2
Fuzzy-Regelung
Dialysesysteme (seit 1998) Zementproduktion (1992-1997)
Modellbildung Modellbildung, Simulation
Optimale Regelung Strukturvariable Regelung
Patientenadaption von Mahlanlagen
R. I.
TU Darmstadt FG Regelungstechnik u. Prozessautomatisierung
PRORETA Elektronische Fahrerassistenz für ein
unfallvermeidendes Fahrzeug
Regelung
Aktorik
Notlenken Notbremsen
Steer-By-Wire
Sensorik
Brake-By-Wire
Radar Lidar
In Kooperation mit
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
→ Mechatronics: emerging area of innovative engineering
R. I.
TU Darmstadt
AUTOREG 2006
-Steuerung und Regelung von Fahrzeugen und Motoren-
Wiesloch, 7. und 8. März 2006
FVT
Veranstalter: VDI/VDE-GMA und VDI-FVT
Ausschuss “Steuerung und Regelung von Kraftfahrzeugen
GMA
und Verbrennungsmotoren-GMA 7.62”
Steuerung und Regelung
von Fahrzeugen und
Motoren - AUTOREG 2004 AUTOREG 2006 (3.Tagung)
Aufruf zur Einreichung von – 2 Plenarvorträge
Beiträgen
– 64 Einzelvorträge in 3 parallelen Sitzungen
– 15 Posterbeiträge
GMA FVT
www.vdi.de/gma/autoreg2006
R. I.
TU Darmstadt
END
80 Folien: 65 min effektiv benötigt.... Seoul ICCAS: 0.8 min/Folie.
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?)
R. I.
TU Darmstadt
CONCLUSIONS

microelectronics
R. I.
TU Darmstadt
CONCLUSIONS

microelectronics

and software
prototypes
R. I.
TU Darmstadt
CONCLUSIONS

microelectronics
and software
prototypes

R. I.
TU Darmstadt
CONCLUSIONS

microelectronics
and software
prototypes
R. I.
TU Darmstadt
OUTLOOK
- Intelligent mechatronic systems

adaptation, learning, decision making
sensors, actuators, devices (optics, office, medicine)
R. I.
TU Darmstadt
OUTLOOK

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
R. I.
TU Darmstadt
OUTLOOK

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
mobile robots (agriculture, production, home)
R. I.
TU Darmstadt
(S.Niilola,Tekes)
R. I.
TU Darmstadt
Six-legged walking forest machine (Finland)

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MECHATRONISCHE SYSTEME

Prof. Dr.-Ing. R. Isermann

Institut für Automatisierungstechnik

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

Mechatronics: Synergetic integration of different disciplines

actua- mechanics &

• Many technical processes and products show an increasing

Mechatronic Mechatronic Mechatronic Mechatronic

“addition of available components”

micro- actuators process sensors

“Integration of the components at different places”

actuator and microcomputer

information gaining design methods

online information processing

R. I. Mechatronic control module for a 6-gear-automatic transmission

1989 1992 1995 1998 2001

Rob. Bosch GmbH

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

traditional mechanical electronic information operating

process/ electronic inform. proc- human-ma-

integrated mechan.electronic system

– Software-in-the-loop simulation (SiL)

– Hardware-in-the-loop simulation (HiL)

simulation tool high performance

Truck engine Passenger car engine

2 drive train oscillations

5 turbo charger inertness

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

Acceleration sensor Anti-skid control (1993)

Electronic stability progr.

Susp.deflect. Active Body Control

EHB-pressure Brake-by wire (20??)

Mechatronic Mechatronic Mechatronic

Source: VDA 2001

Quelle: ATZ Sonderheft VW

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

Rob. Bosch GmbH

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

VW Q uelle:ATZ/M TZ Extra „Der Neue Golf“ Oktober2003

1. Close range: ultra sonic, radar

2. Medium range: lidar, radar, camera

3. Remote area: radar, camera

• Mechanical, hydraulic and pneumatic components are

→ Mechatronic components change the design of automobiles

→ Mechatronics: emerging area of innovative engineering

80 Folien: 65 min effektiv benötigt.... Seoul ICCAS: 0.8 min/Folie.

• Mechanical, hydraulic and pneumatic components are integrated with

→ Mechatronic components change the design of automobiles

→ Mechatronics: emerging area of innovative engineering

• Mechanical, hydraulic and pneumatic components are integrated with

• Mechanical, hydraulic and pneumatic components are integrated with

• Mechatronic components improve functionality, safety, economy and comfort

• Mechanical, hydraulic and pneumatic components are integrated with

• Same mechatronic development for combustion engines, transmissions