Optimization of design for mechatronic system based on virtual prototyping technology

According to the traditional design method, in order to manufacture a mechatronic system, from the initial idea, the designer designs the mechanical system by CAD (Computer-Aided-Design), this system is then fabricated, finally, the system will be tested on the working condition. If the system does not work properly, the design of the system will be changed, and hardware is re-manufactured. This method is more time-consuming and cost for repairing and manufacturing hardware repeatedly. To save design time and reduce the cost of the manufacturing hardware as well as to optimize the design process of a mechatronics system, this paper introduces an engineering model it is called a virtual prototyping technology which allows optimizing the designs on the computer before manufacturing the test-bed system. Based on the concept of the system working, the mechatronics system is designed on SOLIDWORKS and then exported to the ADAMS software (Automated Dynamic Analysis of Mechanical System). The flexible element is also modeling and analysis in ANSYS software then exported to ADAMS. The integrated simulation in ADAMS environment is executed to investigate the dynamic behaviors of the mechanical system and design will be adjusted. Virtual prototyping model will then be exported to MATLAB/Simulink to develop the control strategies. Co-simulation results in some contexts to evaluate the effectiveness of the proposed mechatronic system before implementing on test-bed

Development of a Servo-Based Broaching Machine Using Virtual Prototyping Technology

Predicting machine tool performance at the design stage is one way to resolve the time issue and achieve cost savings. The objective of this paper was to develop a new non-hydraulic broaching machine using a servo motor, ball screw, and roll element linear guide using virtual prototyping technology. First, we developed a multi-body simulation model (MBS) of a servo-based broaching machine to investigate its dynamic behaviour. Then, an adaptive sliding mode proportional-integral-derivative (PID)-based controller (ASMPID) was proposed to conduct the broaching process. We then performed a co-simulation between the mechanical structure and virtual controller to investigate the ram body trajectory and identify the optimal control parameters. Finally, we manufactured a prototype machine to evaluate the simulation results and determine the benefits of the new system. Our results indicated that the proposed model, which includes a mechanical structure and intelligent controller, effectively improved broaching machine design. Therefore, this work is expected to improve the prototyping efficiency of new broaching machines.