Mechatronics simplifies machine design

Mechatronic engineering improves component integration, yielding smaller

machines that perform better and cost less to build and support. Developing a
mechatronic team demands top-down strategies and a synergistic view of
engineering design tools, drive systems, and control design. A traditional
engineering approach taps electrical, mechanical, and software engineers, each
contributing a specific skill set. A mechanical engineer may rework an existing
machine design then forward it to the electrical engineer, who then designs a control
panel based on standard technology.
Then a software engineer is tasked with executing the project. Delays can occur
when problems arise between the machine concept, component
selection, mechanical design, electrical design, program methodology, or even the
end user's intended purpose for the machine. Out of time, the software engineer
might be expected to patch together a mechanical hardware concept with an
imperfect electrical hardware concept, without even fully understanding why they
don't work together.

Breaking away from traditional engineering

By using a mechatronics approach from the onset of a project, electrical, mechanical,
and software engineers can address the actual product a customer wants to handle.
They discuss the operations, or motions, required to form and handle the product,
then make recommendations on how best to perform the operations. The engineers
tap proven modular components and software, knowing precise specifications about
what each can do.
After developing design recommendations, the team collaborates to identify the
implications of its suggestions on how the machine will ultimately perform. More
often than not, the simplicity of modular solutions results in better, stable product
handling and a safer, more efficient machine. Modules are selected and controls
determined based on the features a customer needs. The human-machine interface
is developed using familiar terms, such as product dimensions and machine speed.
Through the collaborative machine building process, the entire team gains valuable
insight into all three engineering disciplines.

Building a productive engineering team

Businesses that are under constant pressure to design and deliver machines don't
always make time for engineers to collaborate or innovate. A simple, yet effective,

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entry ramp can be the rework of an old design taking a cross-discipline approach.
There is a near-constant stream of mechatronic innovation, some of which can vastly
improve the machine design process and product. For example, some vendors now
offer software that combines panel layout with drive sizing and cam design.
It pays to set specific goals when defining the scope of a mechatronics project. There
must be a plan in place to provide detailed project information to each engineer on
the team. A mechanical engineer who understands the potential of a control system
will be more likely to simplify mechanical solutions. An electrical engineer who
understands the five simple machines of physics will be more open to applying an
open-loop system or a smaller controller.
A software engineer who understands the three sides of control can synchronize the
motion of a machine to guarantee the safe movement of products.

Using proven modular technology

Machines today are produced with shorter lead times and are designed to operate
at considerably higher speeds than in the past. In the great race to meet production
deadlines and budgets, innovation must never be an afterthought. Like
mechatronics, innovation results from blending known elements to create something
new. For example, consider the universal smartphone, which combines phone,
camera, music player, lighting, and touchscreen.

By blending the tools based on CPU technology, smartphones become so much

more. The same holds true for machine controls. A single touch panel can combine
HMI, logic, and motion. Servos can be replaced with IP65 closed-loop induction
motor modules for cost savings and better inertia matching.

Use of modular code programming relies on a control system and modular hardware,
but the impact in terms of reducing machine design resources is phenomenal.
Software can be generated much more quickly using code developed for previous
generations of machines in the form of ready-made technology modules, which can
be modified to meet new requirements. An application template provides necessary
basic structures while allowing users to create their own machine modules.

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If not now, when?
Increased demand for automation in broader applications has spurred development
of smarter, more efficient drives, controls, and software tools. Automation products
with embedded mechatronic functionality reduce engineering expenses while taking
up less real estate and offering more dynamic machine performance.
As more OEMs get on board with mechatronics, it becomes imperative that they
manage the process and recognize trends in mechatronics to stay ahead of the
technology curve. By developing a portfolio of mechanical, electrical, and software
modules, it becomes easier to quickly assemble configurable machines to meet
customer requests. Perhaps there's an adjacent industry that could use machines
similar to those one's company builds—driving potential for lucrative new sales.