There is a point of view that mechatronic technologies include technologies of new materials and composites, microelectronics, photonics, microbionics, laser and other technologies.

However, at the same time, there is a substitution of concepts and, instead of mechatronic technologies, which are implemented based on the use of mechatronic objects, these works deal with the technology of manufacturing and assembling such objects.

Most scientists nowadays believe that mechatronic technologies only form and implement the necessary laws of executive movements of computer-controlled mechanisms, as well as aggregates based on them, or analyze these movements to solve diagnostic and prognostic problems.

In machining, these technologies are aimed at ensuring accuracy and productivity that cannot be achieved without the use of mechatronic objects, the prototypes of which are metal-cutting machines with open CNC systems. In particular, such technologies make it possible to compensate for errors that arise due to oscillation of the tool relative to the workpiece.

However, preliminary it should be noted that mechatronic technologies include the following stages:

Technological problem statement;

Creation of a process model in order to obtain the law of the executive motion;

Development of software and information support for implementation;

Supplementing the information management and design base of a typical mechatronic object that implements the proposed technology, if necessary.

An adaptive method for increasing the vibration resistance of a lathe.

In the conditions of using a variety of cutting tools, machined parts of complex shape and a wide range of both machined and tool materials, the likelihood of self-oscillation and loss of vibration resistance of the machine's technological system increases sharply.

This entails a reduction in processing intensity or additional capital investment in the technological process. A promising way to reduce the level of self-oscillation is to change the cutting speed during processing.

This method is quite simple to implement technically and has an effective impact on the cutting process. Previously, this method was implemented as a priori regulation based on preliminary calculations, which limits its application, since it does not allow taking into account the variety of causes and variability of the conditions for the occurrence of vibrations.

Adaptive systems for controlling the cutting speed with on-line control of the cutting force and its dynamic component are much more effective.

The mechanism for reading the level of self-oscillations during machining with a variable cutting speed can be represented as follows.

Suppose that when processing a part with a cutting speed V 1, the technological system is in conditions of self-oscillation. In this case, the frequency and phase of oscillations on the machined surface coincide with the frequency and phase of oscillations of the cutting force and the cutter itself (these oscillations are expressed as crushing, waviness and roughness).

When switching to the speed V 2, oscillations on the machined surface of the part relative to the cutter during the subsequent revolution (when processing "on the track") occurs with a different frequency and synchronism of oscillations, that is, their phase coincidence is violated. Due to this, in conditions of processing "on the track" the intensity of self-oscillations decreases, and high-frequency harmonics appear in their spectrum.

Over time, natural resonance frequencies begin to dominate in the spectrum and the process of self-oscillations is intensified again, which requires a repeated change in the cutting speed.

It follows from the above that the main parameters of the described method are the amount of change in the cutting speed скоростиV, as well as the sign and frequency of this change. The effectiveness of the effect of changing the cutting speed on the processing performance should be assessed by the duration of the auto-oscillation recovery period. The larger it is, the longer the reduced level of self-oscillations remains.

The development of a method for adaptive control of cutting speed involves the simulation of this process based on a mathematical model of self-oscillations, which should:

Take into account the dynamics of the cutting process;

Take into account tracking processing;

Adequately describe the cutting process under conditions of self-oscillation.

The volume of the world production of mechatronic devices is increasing annually, covering more and more new areas. Today mechatronic modules and systems are widely used in the following areas:

machine tools and equipment for the automation of technological

processes;

robotics (industrial and special);

aviation, space and military equipment;

automotive industry (e.g. anti-lock braking systems,

vehicle motion stabilization and automatic parking systems);

non-traditional vehicles (electric bicycles, cargo

carts, electric rollers, wheelchairs);

office equipment (for example, photocopiers and fax machines);

elements of computing technology (for example, printers, plotters,

floppy drives);

medical equipment (rehabilitation, clinical, service);

household appliances (washing, sewing, dishwashers and other machines);

micromachines (for medicine, biotechnology,

telecommunications);

control and measuring devices and machines;

‑­

photo and video equipment;

simulators for training pilots and operators;

show industry (sound and lighting systems).

One of the main trends in the development of modern mechanical engineering is the introduction of mechatronic technological machines and robots into the production process. The mechatronic approach to the construction of new generation machines is to transfer the functional load from mechanical assemblies to intelligent components that can be easily reprogrammed for a new task and at the same time are relatively cheap.

The mechatronic approach to design does not imply expansion, but precisely the replacement of functions traditionally performed by mechanical elements of the system with electronic and computer units.

Understanding the principles of constructing intelligent elements of mechatronic systems, methods for developing control algorithms and their software implementation is a prerequisite for the creation and implementation of mechatronic technological machines.

The proposed methodological guide refers to the educational process in the specialty "Application of mechatronic systems", are intended to study the principles of development and implementation of control algorithms for mechatronic systems based on electronic and computer units and contain information on three laboratory work. All laboratory work is combined into a single complex, the purpose of which is to create and implement a control algorithm for a mechatronic technological machine.

At the beginning of each laboratory work, a specific goal is indicated, then its theoretical and practical parts follow. All work is carried out at a specialized laboratory complex.

The main trend in the development of modern industry is the intellectualization of production technologies based on the use of mechatronic technological machines and robots. In many areas of industry, mechatronic systems (MS) are replacing traditional mechanical machines that no longer meet modern quality requirements.

The mechatronic approach to the construction of new generation machines consists in transferring the functional load from mechanical units to intelligent components that are easily reprogrammed for a new task and at the same time are relatively cheap. The mechatronic approach to the design of technological machines involves replacing the functions traditionally performed by the mechanical elements of the system with electronic and computer units. Back in the early 90s of the last century, the overwhelming majority of machine functions were implemented mechanically; in the next decade, mechanical components were gradually replaced by electronic and computer units.

Currently, in mechatronic systems, the scope of functions is distributed almost equally among mechanical, electronic and computer components. Qualitatively new requirements are imposed on modern technological machines:

ultra-high speed of movement of working bodies;

ultra-high precision of movements required for the implementation of nanotechnology;

maximum compactness of the design;

intelligent behavior of a machine operating in a changing and uncertain environment;

implementation of the movement of working bodies along complex contours and surfaces;

the ability of the system to reconfigure depending on the specific task or operation being performed;

high reliability and operational safety.

All these requirements can only be met using mechatronic systems. Mechatronic technologies are included among the critical technologies of the Russian Federation.

In recent years, the creation of technological machines of the fourth and fifth generations with mechatronic modules and intelligent control systems has been developed in our country.

These projects include the MC-630 mechatronic machining center, MC-2 machining centers, Hexamekh-1, and the ROST-300 robot machine.

Further development was received by mobile technical robots that can independently move in space and have the ability to perform technological operations. An example of such robots is robots for use in underground communications: RTK-100, RTK-200, RTK "Rokot-3".

The main advantages of mechatronic systems include:

elimination of multi-stage transformation of energy and information, simplification of kinematic chains and, consequently, high accuracy and improved dynamic characteristics of machines and modules;

constructive compactness of modules;

the possibility of combining mechatronic modules into complex mechatronic systems and complexes that allow quick reconfiguration;

relatively low cost of installation, configuration and maintenance of the system due to modular design, unification of hardware and software platforms;

the ability to perform complex movements through the use of adaptive and intelligent control methods.

An example of such a system is the system for regulating the force interaction of the working body with the object of work during machining, control of technological influences (thermal, electrical, electrochemical) on the object of work with combined processing methods; control of auxiliary equipment (conveyors, loading devices).

In the process of movement of a mechanical device, the working body of the system directly affects the object of work and provides quality indicators of the automated operation being performed. Thus, the mechanical part is an object of control in the MS. In the process of MS of functional movement, the external environment has a disturbing effect on the working body, which is the final link of the mechanical part. Examples of such actions are cutting forces in machining operations, contact forces and moments of forces during shaping and assembly, and the reaction force of a liquid jet during hydraulic cutting operations.

In addition to the working body, the MS includes a block of drives, computer control devices, the upper level for which is a human operator, or another computer that is part of a computer network; sensors designed to transmit information about the actual state of the machine blocks and the movement of the MS to the control device.

The computer control device performs the following main functions:

organization of management of functional movements of the MS;

control of the process of mechanical movement of the mechatronic module in real time with processing of sensory information;

interaction with a human operator through a human-machine interface;

organization of data exchange with peripheral devices, sensors and other system devices.

], a field of science and technology, based on the synergistic combination of precision mechanics units with electronic, electrical and computer components, providing the design and production of qualitatively new modules, systems and machines with intelligent control of their functional movements. The term "Mechatronics" was coined by the Japanese company Yaskawa Electric Corp. " in 1969 and registered as a trademark in 1972. Note that in the domestic technical literature back in the 1950s. a similarly formed term was used - "mechatrons" (electronic tubes with movable electrodes, which were used as vibration sensors, etc.). Mechatronic technologies include design, production, information and organizational and economic processes that ensure the full life cycle of mechatronic products.

Subject and method of mechatronics

The main task of mechatronics as a direction of modern science and technology is to create competitive motion control systems for various mechanical objects and intelligent machines that have qualitatively new functions and properties. The mechatronic method consists (in the construction of mechatronic systems) in system integration and the use of knowledge from previously isolated scientific and engineering fields. These include precision mechanics, electrical engineering, hydraulics, pneumatics, computer science, microelectronics and computer control. Mechatronic systems are built through the synergistic integration of structural modules, technologies, energy and information processes, from the design stage to production and operation.

In the 1970s-80s. three basic directions - the axes of mechatronics (precision mechanics, electronics and computer science) were integrated in pairs, forming three hybrid directions (in Fig. 1 are shown by the lateral faces of the pyramid). These are electromechanics (combining mechanical assemblies with electrical products and electronic units), computer control systems (hardware and software integration of electronic and control devices), as well as computer-aided design (CAD) mechanical systems. Then - already at the junction of hybrid areas - mechatronics appears, the formation of which as a new scientific and technical direction begins in the 1990s.

Elements of mechatronic modules and machines have a different physical nature (mechanical motion transducers, motors, information and electronic units, control devices), which determines the interdisciplinary scientific and technical problems of mechatronics. Interdisciplinary tasks also determine the content of educational programs for the training and advanced training of specialists, which are focused on the system integration of devices and processes in mechatronic systems.

Construction principles and development trends

The development of mechatronics is a priority area of \u200b\u200bmodern science and technology all over the world. In our country, mechatronic technologies as the basis for building a new generation of robots are included in the number of critical technologies of the Russian Federation.

Among the urgent requirements for mechatronic modules and systems of the new generation are: performance of qualitatively new service and functional tasks; intelligent behavior in changing and uncertain external environments based on new methods of managing complex systems; ultra-high speeds to achieve a new level of productivity of technological complexes; high-precision movements in order to implement new precision technologies, up to micro- and nanotechnologies; compactness and miniaturization of structures based on the use of micromachines; increasing the efficiency of multi-axis mechatronic systems based on new kinematic structures and structural arrangements.

The construction of mechatronic modules and systems is based on the principles of concurrent engineering, elimination of multistage transformations of energy and information, constructive combination of mechanical units with digital electronic units and controllers into single modules.

A key design principle is the transition from complex mechanical devices to combined solutions based on the close interaction of simpler mechanical elements with electronic, computer, information and intelligent components and technologies. Computer and intelligent devices give the mechatronic system flexibility, since they can be easily reprogrammed for a new task, and they are able to optimize the properties of the system under changing and uncertain factors acting from the external environment. It is important to note that in recent years, the price of such devices has been steadily decreasing, while their functionality has expanded.

Development trends in mechatronics are associated with the emergence of new fundamental approaches and engineering methods for solving problems of technical and technological integration of devices of various physical nature. The layout of the new generation of complex mechatronic systems is formed from intelligent modules (“mechatronic cubes”) that combine executive and intelligent elements in one body. Control of the movement of systems is carried out using information environments to support solutions to mechatronic problems and special software that implements methods of computer and intelligent control.

The classification of mechatronic modules according to structural features is shown in Fig. 2.

A motion module is a structurally and functionally independent electromechanical unit, which includes mechanical and electrical (electrical) parts, which can be used as a separate unit or in various combinations with other modules. The main difference between the motion module and the general industrial electric drive is the use of the motor shaft as one of the elements of the mechanical motion transducer. Examples of motion modules are gear motor, wheel motor, drum motor, machine tool spindle.

Geared motors are historically the first mechatronic modules by the principle of their construction, which began to be mass-produced, and until now are widely used in drives of various machines and mechanisms. In a geared motor, the shaft is a structurally single element for the motor and the motion converter, which eliminates the traditional coupling, thus achieving compactness; at the same time, the number of fittings is significantly reduced, as well as installation, debugging and start-up costs. In geared motors, asynchronous motors with a squirrel cage rotor and an adjustable shaft speed converter, single-phase motors and DC motors are most often used as electric motors. Cylindrical and bevel gear, worm gear, planetary, wave and screw gears are used as motion transducers. To protect against sudden overloads, torque limiters are installed.

A mechatronic movement module is a structurally and functionally independent product, which includes a controlled motor, mechanical and information devices (Fig. 2). As follows from this definition, in comparison with the motion module, an information device is additionally integrated into the mechatronic motion module. The information device includes feedback signal sensors, as well as electronic units for signal processing. Examples of such sensors are photopulse sensors (encoders), optical rulers, rotating transformers, force and torque sensors, etc.

An important stage in the development of mechatronic motion modules was the development of modules of the "engine-working body" type. Such structural modules are of particular importance for technological mechatronic systems, the purpose of the movement of which is to implement the purposeful action of the working body on the object of work. Mechatronic motion modules of the "motor-working body" type are widely used in machine tools called motor-spindles.

An intelligent mechatronic module (IMM) is a structurally and functionally independent product built by synergistic integration of the motor, mechanical, informational, electronic and control parts.

Thus, in comparison with mechatronic motion modules, control and power electronic devices are additionally built into the IMM design, which gives these modules intellectual properties (Fig. 2). The group of such devices includes digital computing devices (microprocessors, signal processors, etc.), electronic power converters, interface and communication devices.

The use of intelligent mechatronic modules gives mechatronic systems and complexes a number of fundamental advantages: the ability of the IMM to perform complex movements independently, without referring to the upper control level, which increases the autonomy of the modules, the flexibility and survivability of mechatronic systems operating in changing and uncertain environmental conditions; simplification of communications between modules and the central control device (up to the transition to wireless communications), which allows achieving increased noise immunity of the mechatronic system and its ability to quickly reconfigure; increasing the reliability and safety of mechatronic systems due to computer diagnostics of malfunctions and automatic protection in emergency and abnormal operating modes; creation of distributed control systems based on IMM using network methods, hardware and software platforms based on personal computers and appropriate software; the use of modern methods of control theory (adaptive, intelligent, optimal) directly at the executive level, which significantly increases the quality of control processes in specific implementations; intellectualization of power converters included in the IMM, for the implementation directly in the mechatronic module of intelligent functions for motion control, protection of the module in emergency modes and diagnostics of malfunctions; Intellectualization of sensors for mechatronic modules allows to achieve a higher measurement accuracy, by programmatically providing noise filtering, calibration, linearization of input / output characteristics, compensation of cross-links, hysteresis and zero drift in the sensor module itself.

Mechatronic systems

Mechatronic systems and modules have entered both professional activity and the daily life of a modern person. Today they are widely used in a wide variety of areas: automotive (automatic transmissions, anti-lock brakes, motor-wheel drive modules, automatic parking systems); industrial and service robotics (mobile, medical, home and other robots); computer peripherals and office equipment: printers, scanners, CD-drives, copiers and facsimile machines; production, technological and measuring equipment; household appliances: washing machines, sewing machines, dishwashers and stand-alone vacuum cleaners; medical systems (for example, equipment for robotic-assisted surgery, wheelchairs and prostheses for the disabled) and exercise equipment; aviation, space and military equipment; microsystems for medicine and biotechnology; elevator and storage equipment, automatic doors in airport hotels, subway and train cars; transport devices (electric cars, electric bicycles, wheelchairs); photo and video equipment (video disc players, camcorder focusing devices); moving devices for the show industry.

The choice of the kinematic structure is the most important task in the conceptual design of new generation machines. The efficiency of its solution is largely determined by the main technical characteristics of the system, its dynamic, speed and accuracy parameters.

It was mechatronics that gave new ideas and methods for the design of moving systems with qualitatively new properties. An effective example of such a solution was the creation of machines with parallel kinematics (MPK) (Fig. 3).

Their design is usually based on the Gew-Stewart platform (a kind of parallel manipulator with 6 degrees of freedom; an octahedral arrangement of struts is used). The machine consists of a fixed base and a movable platform, which are interconnected by several rods of controlled length. The rods are connected to the base and the platform by kinematic pairs, which have respectively two and three degrees of mobility. A working body (for example, a tool or measuring head) is installed on the movable platform. By programmatically adjusting the lengths of the rods using linear drives, you can control the movements and orientation of the moving platform and the working body in space. For universal machines, where it is required to move the working body as a solid body in six degrees of freedom, it is necessary to have six rods. In world literature, such machines are called "hexapods" (from the Greek. Ἔ ξ - six).

The main advantages of machines with parallel kinematics are: high accuracy of execution of movements; high speeds and accelerations of the working body; the absence of traditional guides and a bed (drive mechanisms are used as load-bearing elements of the structure), hence the improved weight and size parameters, and low material consumption; a high degree of unification of mechatronic units, which ensures the manufacturability of the manufacture and assembly of the machine and design flexibility.

The increased accuracy of the IPC is due to the following key factors:

in hexapods, in contrast to kinematic schemes with a sequential chain of links, there is no superposition (overlap) of positioning errors of the links during the transition from the base to the working body;

rod mechanisms have high rigidity, since the rods are not subject to bending moments and work only in tension-compression;

precision feedback sensors and measuring systems (for example, laser) are used, as well as computer methods for correcting the movements of the working body.

Due to the increased accuracy, MPCs can be used not only as processing equipment, but also as measuring machines. The high rigidity of the IPC allows them to be used in power technological operations. So, in fig. 4 shows an example of a hexapod performing bending operations as part of a HexaBend processing complex for the production of complex profiles and pipes.

Computer and intelligent control in mechatronics

The use of computers and microcontrollers that implement computer control of the movement of various objects is a characteristic feature of mechatronic devices and systems. Signals from various sensors, carrying information about the state of the components of the mechatronic system and the influences applied to this system, enter the control computer. The computer processes the information in accordance with the digital control algorithms embedded in it and generates control actions on the executive elements of the system.

The computer plays a leading role in the mechatronic system, since computer control makes it possible to achieve high accuracy and performance, implement complex and effective control algorithms that take into account the nonlinear characteristics of control objects, changes in their parameters and the influence of external factors. As a result, mechatronic systems acquire new qualities while increasing the durability and reducing the size, weight and cost of such systems. Achievement of a new, higher level of quality of systems due to the possibility of implementing highly efficient and complex laws of computer control makes it possible to speak of mechatronics as an emerging computer paradigm of the modern development of technical cybernetics.

A typical example of a computer-controlled mechatronic system is a precision servo drive based on a non-contact multiphase AC electric machine with vector control. The presence of a group of sensors, including a high-precision motor shaft position sensor, digital information processing methods, computer implementation of control laws, transformations based on the use of a mathematical model of an electric machine, and a high-speed controller allows you to build a precision high-speed drive with a service life of up to 30-50 thousand hours or more.

Computer control turns out to be very effective in the construction of multi-axis nonlinear mechatronic systems. In this case, the computer analyzes data on the state of all components and external influences, performs calculations and generates control actions on the executive components of the system, taking into account the features of its mathematical model. As a result, a high quality control is achieved by a coordinated multi-axis movement, for example, of a working body of a mechatronic technological machine or a mobile robot.

Intellectual control plays a special role in mechatronics, which is a higher stage in the development of computer control and implements various artificial intelligence technologies. They enable the mechatronic system to reproduce to some extent the intellectual abilities of a person and, on this basis, make decisions about rational actions to achieve the goal of control. The most effective technologies for intelligent control in mechatronics are fuzzy logic technologies, artificial neural networks and expert systems.

The use of intelligent control makes it possible to ensure high efficiency of the functioning of mechatronic systems in the absence of a detailed mathematical model of the control object, under the action of various uncertain factors and in case of the danger of unforeseen situations in the operation of the system.

The advantage of intelligent control of mechatronic systems lies in the fact that often for the construction of such systems, their detailed mathematical model and knowledge of the laws of change of external influences acting on them are not required, and control is based on the experience of actions of highly qualified experts.

Automobile transport plays an important role in society, the country's transport system, economy. The car is widely used for delivering goods to railways, river and sea berths, servicing industrial trade enterprises, agricultural workers, and providing passenger transportation. The share of road transport accounts for about half of passenger and cargo transportation (Figure 12.1)

Figure 12.1 - Transportation distribution

Literally a little over a hundred years have passed since the first car appeared, and there is practically no sphere of activity in which it would not be used. Therefore, the automotive industry in the economies of developed countries is now the leading branch of mechanical engineering. There are reasons for this:

First, people every day need more and more cars to solve various economic problems;

Secondly, this industry is knowledge-intensive and high-tech. She "pulls" many other industries, whose enterprises fulfill her numerous orders. The innovations introduced in the automotive industry inevitably force these industries to improve their production. Due to the fact that there are a lot of such industries, as a result, there is an increase in the entire industry, and, consequently, the economy as a whole;

Thirdly, the automotive industry in all developed countries is one of the most profitable sectors of the national economy, since it contributes to an increase in trade turnover and brings considerable income to the state treasury through sales in the domestic and world markets;

Fourth, the automotive industry is a strategically important industry. The development of this industry makes the country economically strong and therefore more independent. The widespread use of the best examples of automotive technology in the army undoubtedly increases the country's defensive power.

Now in the automotive industry there are a number of trends that indicate its importance and significance, as well as related industries in the economies of industrialized countries. There is a completely new approach to the technical development of the car, the organization and technology of its production. Scientific and technical trends are to reduce fuel consumption and emissions, develop an ultralight vehicle, improve safety, quality, reliability and durability, as well as develop intelligent road and road systems.

The development of mechatronics in cars (Fig. 12.2) and on production machines has its own characteristics. In automobiles, the expansion of automation, and therefore mechatronics, began primarily in the field of comfort devices. The first of the mechatronic units, as is historically the custom, there was an engine with a fuel supply system and automatic control of it. The second is the Power Attachment Control (EHR), the world leader in the production of which is Bosch. The third is the transmission. Here the process began with the advent of mechanical transmissions with gear shifting under load. They were equipped with hydraulic, then electro-hydraulic switching devices, and then electronic automatic switching control. Western firms (German ZF and others) began to supply automobile plants and produce for sale transmissions in such a complete set

The power and benefit of the mechatronic design of the units is especially clearly visible on the example of transmissions, which, in the presence and absence of automatic control with the same other components of the complex, show a striking contrast in the characteristics of both themselves and the vehicles equipped with them. In mechatronic form, they provide an order of magnitude more favorable characteristics in almost all indicators of machine operation: technical, economic and ergonomic.

Comparing mechatronic complexes with their non-mechatronic prototypes in terms of technical perfection, it is easy to see that the former are significantly superior to the latter, not only in general indicators, but also in the level and quality of design. This is not surprising: the synergistic effect is manifested not only in the final product, but also in the design process due to the new approach to design.

Figure 12.2 - Classification of vehicle mechatronic systems

When controlling the operation of a car engine, various systems are used:

- AVCS (Active Valve Control System) - The variable valve timing system on Subaru vehicles changes the valve lift depending on the instantaneous engine load. Common rail (Nissan) is an injection system that supplies fuel to the cylinders through a common rail at high pressure. Differs in a number of advantages, thanks to which driving brings the driver more pleasure: diesel engines with Common Rail are characterized by both excellent throttle response and low fuel consumption, eliminating the need to often stop at gas stations.

- GDI - Gasoline Direct Injection, which can be translated as "direct fuel injection", that is, fuel on such an engine is injected not into the intake manifold, but directly into the engine cylinders. M-Fire - control system of the combustion process - the smoke of the exhaust gases and the content of nitrogen oxides in them are significantly reduced, while the power is increased and the noise level is reduced.

- MIVEC (Mitsubishi) - optimally controls the moment of opening of the intake valves in accordance with the operating conditions of the engine, which improves the stability of the engine at idle speed, power and torque characteristics for the entire operating range.

- VTEC (Honda) - Variable valve timing system. They are used to improve torque characteristics over a wide rpm range, as well as to improve the economy and environmental performance of the engine. Also applies to Mazda vehicles.

- DPS - Dual Pump System - two oil pumps connected in series (i.e. one after the other). At the same speed of rotation of both oil pumps, there is a "uniform" oil circulation, i.e. there are no areas with high and low pressure (Fig. 12.3).

Figure 12.3 - Dual Pump Sysytem

- Common rail (eng. common highway) is a modern technology of fuel supply systems in diesel engines with direct injection. In the common rail system, the pump pumps fuel under high pressure (250 - 1800 bar, depending on the engine operating mode) into the common rail. Electronically controlled injectors with solenoid or piezoelectric valves inject fuel into the cylinders. Depending on the design, the injectors produce from 2 to 5 injections per cycle. Accurate calculation of the injection angle and the amount of fuel injected allows diesel engines to meet increased environmental and economic requirements. In addition, diesel engines with the common rail system in their power and dynamic characteristics have come very close to, and in some cases have surpassed gasoline engines.

There are different types of mechatronic transmission device:

- CVT - automatic transmission with a variator. It is a mechanism with a gear ratio change range greater than that of a 5-speed manual transmission.

- DAC - Downhill Assist Control - the system controls the behavior of the car on steep slopes. The wheels are equipped with sensors that measure the speed of rotation of the wheels and constantly compare it with the speed of the car. Analyzing the data obtained, the electronics brakes the front wheels in time to a speed of about 5 km / h.

- DDS - Downhill Drive Support - motion control system in Nissan cars on steep slopes. DDS automatically maintains a speed of 7 km / h when descending, preventing the wheels from locking.

- Drive Select 4x4 - All-wheel drive can be switched on and off on the move at speeds up to 100 km / h.

- TSA (Trailer Stability Assist) - vehicle stabilization system while driving with a trailer. When the vehicle loses stability, it usually starts chattering on the road. In this case, the TSA brakes the wheels "diagonally" (front left - rear right or front right - rear left) in antiphase, while simultaneously reducing vehicle speed by reducing the fuel supply to the engine. Used on Honda vehicles.

- Easy Select 4WD - the all-wheel drive system, widely used in Mitsubishi cars, allows you to change 2WD to 4WD, and vice versa, while the car is moving.

- Grade Logic Control - the system of "smart" gear selection, provides uniform traction, which is especially important when going uphill.

- Hypertronic CVT-M6 (Nissan) - Delivers smooth, stepless acceleration without the jerkiness of traditional automatic transmissions. They are also more economical than traditional automatic transmissions. The CVT-M6 is designed for drivers who want to combine the advantages of automatic and manual transmissions with water. By moving the gear lever to the slot farthest from the driver, you get the opportunity to shift six gears with fixed gear ratios.

- INVECS-II - adaptive automatic (Mitsubishi) - automatic transmission with sport mode and the possibility of mechanical control.

- EBA- an electronic pressure control system in the hydraulic brake system, which, in case of emergency braking and insufficient effort on the brake pedal, independently increases the pressure in the brake line, doing it many times faster than a person. And the EBD system evenly distributes braking forces and works in conjunction with ABS - anti-lock braking system.

- ESP + - anti-skid stabilization system ESP - the most complex system using the capabilities of anti-lock, traction control with traction control and electronic throttle control systems. The control unit receives information from the vehicle's angular acceleration and steering wheel angle sensors, information about the vehicle's speed and the rotation of each of the wheels. The system analyzes this data and calculates the trajectory of movement, and if in turns or maneuvers the real speed does not coincide with the calculated one and the car "takes out" outside or inside the corner, corrects the trajectory of movement, braking the wheels and reducing engine thrust.

- HAC - Hill-start Assist Control - the system controls the behavior of the machine on steep inclines. HAC not only prevents wheel spin when starting up a slippery slope, but it can also prevent rolling back if the vehicle speed is too slow and it slides down under the weight of the body.

- Нill Holder - with the help of this device, the car is held on the brakes even after the brake pedal is released, the Нill Holder is disconnected only after the clutch pedal is released. Designed to start moving uphill.

- AIRMATIC Dual Control- active air suspension with electronic control and adaptive damping system ADS II works fully automatically (Fig. 12.4). Compared to traditional steel suspension, it significantly improves ride comfort and safety. AIRMATIC DC works with airbags, which electronics make them harder or softer depending on the road situation. If the sensors, for example, have detected a sporty driving style, the air suspension that is comfortable in normal operation is automatically stiffer. The suspension and damping behavior can also be manually adjusted to Sport or Comfort using a switch.

The electronics work with four different damping modes (ADS II), which adapt automatically on each wheel to the road conditions. Thus, the car rolls smoothly, even on poor roads, without compromising stability.

Figure 12.4 - AIRMATIC Dual Control

The system is also equipped with a vehicle level control function. It provides an almost constant ground clearance even with a loaded vehicle, which gives the vehicle stability. When driving at high speed, the vehicle can automatically lower itself to reduce body tilts. Above 140 km / h, the vehicle is automatically lowered by 15 mm, and below 70 km / h, the normal level is restored again. In addition, for poor road conditions, it is possible to manually raise the vehicle by 25 mm. Continuously driving at a speed of approx. 80 km / h or exceeding the speed of 120 km / h will automatically return to the normal level.

Also in cars, various braking systems are used, which are used to significantly reduce the braking distance, correctly interpret the driver's behavior during braking, and activate the maximum braking force in the event of emergency braking.

- Brake Assist (BAS)standard on all Mercedes-Benz passenger cars, it interprets the driver's behavior during braking and, if emergency braking is detected, generates maximum braking force if the driver himself does not press the brake pedal sufficiently. The development of the brake assist is based on data received by the Mercedes-Benz Accident Research Department: in a critical situation, drivers press the brake pedal quickly, but not hard enough. In this way, the brake assistant can effectively support the driver.

For a better understanding, let's make a brief overview of the technology of modern braking systems: the brake booster, which increases the pressure created by the driver's foot, consists of two chambers, which are separated by a movable membrane. If no braking is performed, then there is a vacuum in both chambers. By pressing the brake pedal in the brake booster, a mechanical control valve is opened, which bypasses air into the rear chamber and changes the pressure ratio in the two chambers. The maximum effort is created when atmospheric pressure reigns in the second chamber. In the brake assist (BAS), a so-called diaphragm movement sensor detects whether the braking is extreme. It detects the movement of the diaphragm between the chambers and transmits the value to the BAS control unit. Constantly comparing the values, the microcomputer recognizes the moment when the speed of pressing the brake pedal (equal to the speed of movement of the diaphragm in the brake booster) exceeds the standard value - this is emergency braking. In this case, the system activates a magnetic valve, through which the rear chamber is instantly filled with air and the maximum braking force is generated. Despite this automatic full braking, the wheels are not locked, because the well-known anti-lock braking system ABS measures the braking force, optimally keeping it on the verge of locking, thereby maintaining the vehicle's handling. If the driver takes his foot off the brake pedal, a special actuation sensor closes the solenoid valve and the automatic brake assist is disabled.

Figure 12.6 - Brake assistant (BAS) Mercedes

- Anti-lock braking system (ABS) (German antiblockiersystem English Anti-lock Brake System (ABS)) - a system that prevents the vehicle wheels from locking when braking. The main purpose of the system is to reduce the braking distance and ensure the vehicle's controllability during hard braking, and to exclude the possibility of its uncontrolled slip.

The ABS consists of the following main components:

Speed \u200b\u200bsensors or acceleration (deceleration) sensors installed on the vehicle wheel hubs.

Control valves, which are elements of the pressure modulator, installed in the line of the main brake system.

A control unit that receives signals from sensors and controls the operation of the valves.

After the start of braking, the ABS begins a constant and fairly accurate determination of the speed of rotation of each wheel. In the event that a wheel starts to rotate much slower than the others (which means that the wheel is close to blocking), a valve in the brake line limits the braking force on that wheel. As soon as the wheel starts to rotate faster than the others, the braking force is restored.

This process is repeated several times (or several tens of times) per second, and usually leads to noticeable pulsation of the brake pedal. The braking force can be limited both in the entire braking system at the same time (single-channel ABS), as well as in the brake system of the bead (two-channel ABS) or even an individual wheel (multi-channel ABS). Single-channel systems provide fairly effective deceleration, but only if the traction conditions of all wheels are more or less the same. Multi-channel systems are more expensive and more complicated than single-channel systems, but they are more effective when braking on uneven surfaces, if, for example, when braking, one or more wheels hit the ice, a wet section of the road, or the side of the road.

Control and navigation systems are becoming widespread in modern cars. .

- System DISTRONIC - carries out electronic regulation of the distance to the vehicle in front using a radar, simple control with the TEMPOMAT lever, provides additional comfort on the autobahns and similar roads, maintains the driver's working condition.

The DISTRONIC distance adjuster maintains the required distance to the vehicle in front. If the distance decreases, the braking system is activated. If there is no vehicle ahead, DISTRONIC maintains the speed set by the driver. DISTRONIC provides additional comfort for driving on the Autobahn and similar roads. The microcomputer processes the signals of the radar, which is installed behind the radiator grill, at a speed of 30 to 180 km / h. The radar pulses are reflected from the vehicle in front, processed and, based on this information, the distance to the front vehicle and its speed are calculated. If a Mercedes-Benz with DISTRONIC comes too close to the front vehicle, DISTRONIC automatically reduces throttle and applies the brake to maintain the set distance. If it is necessary to brake strongly, the driver is informed about this by means of an acoustic signal and a warning light - this means that the driver must press the brake pedal himself. If the distance increases, the DISTRONIC again maintains the required distance and accelerates the vehicle to the set speed. DISTRONIC is a further development of the standard TEMPOMAT function with variable speed limit SPEEDTRONIC

Figure 12.7 - Control and navigation system

Mercedes-Benz has introduced the first mechatronic air suspension, AIR-matic, with ADS damper control as standard on S-Class sedans.

In the AIR-matic system, the strut of the S-class sedan contains a pneumatic elastic element: the role of springs we are used to is compressed air, enclosed under a rubber-cord shell. Also in the rack there is a shock absorber with an unusual "extension" on the side. Naturally, a full-fledged pneumatic system is provided in the car (compressor, receiver, lines, valve devices). And also - a network of sensors and, of course, a processor. How the system works. At the command of the processor, the valves open the air from the pneumatic system to the elastic elements (or bleed air from there). Thus, the level of the floor of the body changes: the system incorporates its dependence on the speed of the vehicle. The driver can also "show will" - to raise the car, say, to move over significant irregularities.

ADS performs more "delicate" work - controls shock absorbers. During the stroke of the shock absorber rod, part of the fluid flows not only through the valves in the piston, but also through the very "extension", inside which the actuator is a valve system that provides four possible modes of operation of the shock absorber. Based on the information received from the sensors and in accordance with the algorithm chosen by the driver ("sport" or "comfortable"), the processor selects for each shock absorber the mode most appropriate to the "current moment" and sends commands to the actuators.

Modern cars are equipped with climate control system... This system is designed to create and automatically maintain a microclimate in the vehicle interior. The system ensures the joint operation of heating, ventilation and air conditioning systems through electronic control.

The use of electronics made it possible to achieve zonal climate control in the passenger compartment. Depending on the number of temperature zones, the following climate control systems are distinguished:

· One-zone climate control;

· Two-zone climate control;

· Three-zone climate control;

· Four-zone climate control.

The climate control system has the following general arrangement:

· Climatic installation;

· control system.

Climatic installation includes structural elements of heating, ventilation and air conditioning systems, including:

· Heater radiator;

Supply air fan;

· An air conditioner consisting of an evaporator, a compressor, a condenser and a receiver.

The main elements climate control systems are:

· Input sensors;

· Control block;

· Executive devices.

Input sensors measure the corresponding physical parameters and convert them into electrical signals. Control system input sensors include:

· Outside air temperature sensor;

· Solar radiation level sensor (photodiode);

· Output temperature sensors;

Flap potentiometers;

· Evaporator temperature sensor;

· Pressure sensor in the air conditioning system.

The number of outlet temperature sensors is determined by the design of the climate control system. A footwell outlet temperature sensor can be added to the outlet temperature sensor. In a two-zone climate control system, the number of output temperature sensors doubles (sensors on the left and right), and in a three-zone climate control system, it triples (left, right and rear).

The damper potentiometers record the current position of the air damper. Evaporator temperature and pressure sensors ensure the operation of the air conditioning system. The electronic control unit receives signals from sensors and, in accordance with the programmed program, generates control actions on the actuators.

Actuators include damper drives and a supply air fan electric motor, with the help of which a given temperature regime is created and maintained. The dampers can be mechanically or electrically driven. The following dampers can be used in the air conditioner design:

· Intake air damper;

· Central flap;

· Temperature control dampers (in systems with 2 or more control zones);

· Recirculation damper;

· Shutters for defrosting glasses.

The climate control system provides automatic temperature control in the vehicle interior within the range of 16-30 ° C.

The desired temperature value is set using the controls on the vehicle dashboard. The signal from the regulator goes to the electronic control unit, where the corresponding program is activated. In accordance with the established algorithm, the control unit processes the signals from the input sensors and activates the necessary actuators. The air conditioner turns on if necessary.

The modern car is a source of increased danger. The steady increase in the power and speed of the car, the density of traffic flows significantly increase the likelihood of an emergency.

To protect passengers in an accident, technical safety devices are being actively developed and implemented. In the late 50s of the last century, seat beltsdesigned to keep passengers in their seats in a collision. In the early 80s were applied airbags.

The set of structural elements used to protect passengers from injury in an accident makes up the vehicle's passive safety system. The system should provide protection not only for passengers and a specific vehicle, but also for other road users.

The most important components of the vehicle passive safety system are:

· seat belts;

· Seat belt tensioners;

· Active head restraints;

· Airbags;

· Car body, resistant to deformation;

· Emergency battery disconnector;

A number of other devices (rollover protection system on a convertible; child safety systems - mountings, seats, seat belts).

The modern system of passive vehicle safety is electronically controlled, which ensures efficient interaction of most of the components.

Control systemincludes:

· Input sensors;

· Control block;

· Executive devices of system components.

Input sensors record the parameters at which an emergency occurs and convert them into electrical signals. The input sensors are:

· Shock sensor;

· Switch of the seat belt buckle;

· Seat occupancy sensor of the front passenger;

· Seat position sensor for driver and front passenger.

On each side of the car, as a rule, two are installed shock sensor... They ensure the operation of the appropriate airbags. At the rear, impact sensors are used when equipping the vehicle with electrically powered active head restraints. The seat belt switch locks in the seat belt.

The seat occupied sensor of the front passenger allows in the event of an emergency and the absence of the passenger in the front seat to keep the corresponding airbag.

Depending on the position of the driver's and front passenger's seat, which is recorded by the corresponding sensors, the order and intensity of use of the system components change.

Based on the comparison of the sensor signals with the control parameters, the control unit recognizes the occurrence of an emergency situation and activates the necessary actuators of the system elements.

The actuators of the elements of the passive safety system are:

· Airbag squib;

· Squib of the seat belt tensioner;

· Squib (relay) of the emergency battery disconnector;

· Squib of the drive mechanism for active head restraints (when using head restraints with electric drive);

· A warning lamp indicating that the seat belts are not fastened.

Actuators are activated in a specific combination in accordance with the installed software.

ISOFIX - Isofix - child seat mounting system. Externally, child seats with this system are distinguished by two compact locks located on the back of the sled. The locks grip a 6mm bar hidden behind plugs in the base of the seat back.

T ermin " mechatronics»Introduced by Tetsuro Moria (Tetsuro Mori) as an engineer of the Japanese company Yaskawa Electric (Yaskawa Electric) in 1969. Term consists of two parts - "fur", from the word mechanic, and "tronika", from the word electronics. In Russia, before the emergence of the term "mechatronics", devices called "mechatrons" were used.

Mechatronics is a progressive direction in the development of science and technology, focused on the creation and operation of automatic and automated machines and systems with computer (microprocessor) control of their movement. The main task of mechatronics is the development and creation of high-precision, highly reliable and multifunctional control systems for complex dynamic objects. The simplest examples of mechatronics are car brakes with ABS (anti-lock braking systems) and industrial CNC machines.

The largest developer and manufacturer of mechatronic devices in the world bearing industry is the company SNR... The company is known as a pioneer in the field of "sensor" bearings, c the technology behind the know-howc using multi-pole magnetic rings and measuring components integrated into mechanical parts. Exactly SNR for the first time proposed the use of wheel bearings with an integrated rotational speed sensor based on a unique magnetic technology - ASB ® (Active Sensor Bearing), which are now a standard recognized and used by almost all major car manufacturers in Europe and Japan. More than 82 million of such devices have already been produced, and by 2010 almost 50% of all wheel bearings in the world produced by various manufacturers will use the technologyASB ®... Such massive use ASB ®once again proves the reliability of these solutions, which ensure high accuracy of measurement and transmission of digital information in the most aggressive environments (vibration, dirt, large temperature differences, etc.).

Illustration : SNR

Bearing structure ASB ®

The main advantages of technology ASB ®used in the automotive industry are:

it is a compact and economical solution, it can also be used on vehicles of the lower price range, and not only on expensive cars, unlike many other competitive technologies,

it is a progressive technology in the study of automotive comfort and safety,

it is the main element in the concept of “total chassis control”,

it is an open standard that minimizes the cost of licensing production to manufacturers of bearings and electronic components.

Technology ASB ® in 1997 at the exhibition EquipAuto in Paris received the firstGrand Prix in the nomination "New technologies for original (conveyor) production".

In 2005 at EquipAuto SNR suggested further development for review ASB ®- a special system with a steering angle sensor ASB ® Steering System, designed to measure the angle of rotation of the steering wheel, which will optimize the operation of the electronic systems of the car and increase the level of safety and comfort. The development of this system began in 2003, through the efforts CONTINENTAL TEVES and SNR Roulements... In 2004, the first prototypes were ready. Field test ASB ® Steering Systemwere held in March 2005 in Sweden in cars Mercedes C -class and showed excellent results. To serial production ASB ® Steering Systemdue in 2008.

Illustration : SNR

ASB ® Steering System

The main advantagesASB ® Steering System will become:

simpler construction,

ensuring a low noise level,

lower cost,

size optimization…

With more than 15 years of experience in the development and manufacture of mechatronic devices, the company offers customers not only from the automotive industry, but also from industry and aerospace - "Mechatronic" bearingsSensor Line... These bearings have inherited unrivaled reliability ASB ®, full integration and compliance with international standards ISO.

Located in the heart of the movement, the sensor Sensor Line transmits information about angular displacement and rotational speed for more than 32 periods per revolution. Thus, the functions of the bearing and the measuring device are combined, which positively affects the compactness of the bearing and the equipment as a whole, while providing a competitive price in relation to standard solutions (based on optical sensors).

Photo : SNR

includes:

Patented multi-track and multi-pole magnetic ring that generates a defined magnetic field;

Special electronic component MPS 32 XF converts information about changes in the magnetic field into a digital signal.

Photo : Torrington

MPS 32 XF component

Sensor Line Encoder can achieve a resolution of 4096 pulses per revolution with a reading radius of only 15 mm, providing a positioning accuracy of more than 0.1 °! In this way,Sensor Line Encoder in many cases can replace the standard optical encoder, while giving additional functions.

Device Sensor Line Encoder can provide the following data with high accuracy and reliability:

angular position,

Speed,

direction of rotation,

Number of revolutions,

Temperature.

Unique properties of the new device SNR were recognized in the world of electronics even at the stage of prototypes. Special sensorMPS 32 XF won the main prize Gold Award at Sensor Expo 2001 in Chicago (USA).

CurrentlySensor Line Encoder finds its application:

in mechanical transmissions;

in conveyors;

in robotics;

in vehicles;

in forklifts;

in control, measurement and positioning systems.

Photo : SNR

One of the further projects to be completed in 2010-11 isASB ® 3 - bearing with an integrated torque sensor based on the use of tunnel magnetoresistance. The use of tunnel magnetoresistance technology makes it possible to provide:

high sensitivity of the sensor,

low energy consumption,

the best signal in relation to the noise level,

wider temperature range.

ASB ® 4, scheduled for release in 2012-15, will complete the opening of the information technology era for bearing construction. For the first time, a self-diagnosis system will be integrated, which will allow, for example, the bearing's condition by the lubrication temperature of the bearing or its vibration.