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Many of today s machines and processes, ranging from chemical plants to automobiles, require some form of electronic or computer control for proper operation Computer control of machines and processes is common to the automotive, chemical, aerospace, manufacturing, test and instrumentation, consumer, and industrial electronics industries The extensive use of microelectronics in manufacturing systems and in engineering products and processes has led to a new approach to the design of such engineering systems To use a term coined in Japan and widely adopted in Europe, mechatronic design has surfaced as a new philosophy of design, based on the integration of existing disciplines primarily mechanical, and electrical, electronic, and software engineering1 A very important issue, often neglected in a strictly disciplinary approach to engineering education, is the integrated aspect of engineering practice, which is unavoidable in the design and analysis of large scale and/or complex systems One aim of this book is to give engineering students of different backgrounds exposure to the integration of electrical, electronic, and software engineering into their domain This is accomplished by making use of modern computer-aided tools and by providing relevant examples and references Section 16 describes how some of these goals are accomplished
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1 D
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A Bradley, D Dawson, N C Burd, A J Loader, 1991, Mechatronics, Electronics in Products and Processes, Chapman and Hall, London See also ASME/IEEE Transactions on Mechatronics, Vol 1, No 1, 1996
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Introduction to Electrical Engineering
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Example 12 illustrates some of the thinking behind the mechatronic system design philosophy through a practical example drawn from the design experience of undergraduate students at a number of US universities
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EXAMPLE 12 Mechatronic Systems Design of a Formula Lightning Electric Race Car
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The Formula Lightning electric race car competition is an interuniversity2 competition project that has been active since 1994 This project involves the design, analysis, and testing of an electric open-wheel race car A photo and the generic layout of the car are shown in Figures 13 and 14 The student-designed propulsion and energy storage systems have been tested in interuniversity competitions since 1994 Projects have included vehicle dynamics and race track simulation, motor and battery pack selection, battery pack and loading system design, and transmission and driveline design This is an ongoing competition, and new projects are de ned in advance of each race season The objective of this competitive series is to demonstrate advancement in electric drive technology for propulsion applications using motorsports as a means of extending existing technology to its performance limit This example describes some of the development that has taken place at the Ohio State University The description given below is representative of work done at all of the participating universities
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Instrumentation panel DC-AC converter (electric drive)
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AC motor
+ + + + + + + + 24 V
+ + + + + + + Battery + pack 24 V
Figure 13 The Ohio State University Smokin Buckeye
Figure 14 Block diagram of electric race car
Design Constraints:
The Formula Lightning series is based on a speci cation chassis; thus, extensive modi cations to the frame, suspension, brakes, and body are not permitted The focus of the competition is therefore to optimize the performance of the spec vehicle by selecting a
2 Universities
that have participated in this competition are Arizona State University, Bowling Green State University, Case Western Reserve University, Kettering University, Georgia Institute of Technology, Indiana University Purdue University at Indianapolis, Northern Arizona University, Notre Dame University, Ohio State University, Ohio University, Rennselaer Polytechnic Institute, University of Oklahoma, and Wright State University
Introduction to Electrical Engineering
suitable combination of drivetrain and energy storage components In addition, since the vehicle is intended to compete in a race series, issues such as energy management, quick and ef cient pit stops for battery pack replacement, and the ability to adapt system performance to varying race conditions and different race tracks are also important design constraints
Design Solutions:3
Teams of undergraduate aerospace, electrical, industrial, and mechanical engineering students participate in the design of the all-electric Formula Lightning drivetrain through a special design course, made available especially for student design competitions In a representative course at Ohio State, the student team was divided into four groups: battery system selection, motor and controller selection, transmission and driveline design, and instrumentation and vehicle dynamics Each of these groups was charged with the responsibility of determining the technology that would be best suited to matching the requirements of the competition and result in a highly competitive vehicle Figure 15 illustrates the interdisciplinary mechatronics team approach; it is apparent that, to arrive at an optimal solution, an iterative process had to be followed and that the various iterations required signi cant interaction between different teams To begin the process, a gross vehicle weight was assumed and energy storage limitations were ignored in a dynamic computer simulation of the vehicle on a simulated road course (the Cleveland Grand Prix Burke Lakefront Airport racetrack, site of the rst race in the series) The simulation employed a realistic model of the vehicle and tire dynamics, but a simple model of an electric drive energy storage limitations would be considered later
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