Smart product design for automotive systems

Abstract

Automobiles evolved from primarily mechanical to electro-mechanical, or mechatronic, vehicles. For example, carburetors have been replaced by fuel injection and air-fuel ratio control, leading to order of magnitude improvements in fuel economy and emissions. Mechatronic systems are pervasive in modern automobiles and represent a synergistic integration of mechanics, electronics and computer science. They are smart systems, whose design is more challenging than the separate design of their mechanical, electronic and computer/control components. In this review paper, two recent methods for the design of mechatronic components are summarized and their applications to problems in automotive control are highlighted. First, the combined design, or co-design, of a smart artifact and its controller is considered. It is shown that the combined design of an artifact and its controller can lead to improved performance compared to sequential design. The coupling between the artifact and controller design problems is quantified, and methods for co-design are presented. The control proxy function method, which provides ease of design as in the sequential approach and approximates the performance of the co-design approach, is highlighted with application to the design of a passive/active automotive suspension. Second, the design for component swapping modularity (CSM) of a distributed controller for a smart product is discussed. CSM is realized by employing distributed controllers residing in networked smart components, with bidirectional communication over the network. Approaches to CSM design are presented, as well as applications of the method to a variable-cam-timing engine, and to enable battery swapping in a plug-in hybrid electric vehicle.

Keywords

mechatronics / automotive control / co-design / component swapping modularity / active suspensions / variable camshaft timing engine / plug-in hybrid electric vehicle

References

[1] Board on Manufacturing and Engineering Design. Theoretical Foundations for Decision Making in Engineering Design. Washington, D.C.: National Academies Press, 2001

[2] Tryggvason G, Apelian D. Shaping Our World: Engineering Education for the 21st Century. Hoboken: Wiley, 2012

[3] National Academy of Engineering. Greatest Engineering Achievements of the 20th Century. Retrieved from http://www.greatachievements.org. 2018-08-01

[4] National Academy of Engineering. Grand Challenges for Engineering. Retrieved from http://www.engineeringchallenges.org. 2018-08-01

[5] 10 Emerging Technologies That Will Change the World. MIT Technology Review, 2003

[6] Ulsoy A G, Peng H, Cakmakci M. Automotive Control Systems. Cambridge: Cambridge University Press, 2012

[7] Reyer J A, Fathy H K, Papalambros P Y, Comparison of combined embodiment design and control optimization strategies using optimality conditions. In: Proceedings of the ASME Design Engineering Technical Conference. Pittsburgh, 2001

[8] Fathy H K, Papalambros P Y, Reyer J A, On the coupling between the plant and controller optimization problems. In: Proceedings of the 2001 American Control Conference. Arlington, 2001

[9] Fathy H K, Bortoff S A, Copeland G S, Nested optimization of an elevator and its gain-scheduled LQG controller. In: Proceedings of ASME International Mechanical Engineering Congress and Exposition, Dynamic Systems and Control. New Orleans, 2002, 119–126

[10] Fathy H K. Combined plant and control optimization: Theory strategy and applications. Dissertation for the Doctoral Degree. Ann Arbor: University of Michigan, 2002

[11] Fathy H K, Hrovat D, Papalambros P Y, Nested plant/controller optimization and its application to combined passive/active automotive suspensions. In: Proceedings of the 2003 American Control Conference. Denver, 2003

[12] Fathy H K, Papalambros P Y, Ulsoy A G. Integrated plant, observer and controller optimization with application to combined passive/active automotive suspensions. In: Proceedings of ASME 2003 International Mechanical Engineering Congress and Exposition, Dynamic Systems and Control, Volumes 1 and 2. Washington, D.C., 2003

[13] Alyaqout S F, Papalambros P Y, Ulsoy A G. Quantification and use of system coupling in decomposed design optimization problems. In: Proceedings of ASME 2005 International Mechanical Engineering Congress and Exposition, Computers and Information in Engineering. Orlando, 2005

[14] Alyaqout S F, Papalambros P Y, Ulsoy A G. Combined robust design and robust control of an electric DC motor. In: Proceedings of ASME IMECE. Chicago, 2006

[15] Alyaqout S F. A multi-system optimization approach to coupling in robust design and control. Dissertation for the Doctoral Degree. Ann Arbor: University of Michigan, 2006

[16] Alyaqout S F, Papalambros P Y, Ulsoy A G. Coupling in design and robust control optimization. In: Proceedings of 2007 European Control Conference (ECC). Kos, 2007

[17] Alyaqout S F, Papalambros P Y, Ulsoy A G. Combined design and robust control of vehicle active/passive suspension. In: Proceedings of 2007 European Control Conference (ECC). Kos, 2007

[18] Peters D L, Kurabayashi K, Papalambros P Y, Co-design of a MEMS actuator and its controller using frequency constraints. In: Proceedings of ASME 2008 Dynamic Systems and Control Conference, Parts A and B. Ann Arbor, 2008

[19] Ulsoy A G, Papalambros P Y, Peters D L. Optimal co-design of controlled systems and their controllers. In: Proceedings of NSF CMMI Grantees Conference. Honolulu, 2009

[20] Peters D L, Papalambros P Y, Ulsoy A G. On measures of coupling between the artifact and controller optimal design problems. In: Proceedings of ASME 2009 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, Volume 2: 29th Computers and Information in Engineering Conference, Parts A and B. San Diego, 2009

[21] Peters D L, Papalambros P Y, Ulsoy A G. Relationship between coupling and the controllability Grammian in co-design problems. In: Proceedings of the 2010 American Control Conference. Baltimore, 2010

[22] Peters D L, Papalambros P Y, Ulsoy A G. Sequential co-design of an artifact and its controller via control proxy functions. IFAC Proceedings Volumes, 2010, 43(18): 125–130

[23] Peters D L. Coupling and controllability in optimal design and control. Dissertation for the Doctoral Degree. Ann Arbor: University of Michigan, 2010

[24] Alyaqout S F, Papalambros P Y, Ulsoy A G. Combined robust design and robust control of an electric DC motor. IEEE/ASME Transactions on Mechatronics, 2011, 16(3): 574–582

[25] Alyaqout S F, Peters D L, Papalambros P Y, Generalized coupling management in complex engineering systems optimization. Journal of Mechanical Design, 2011, 133(9): 091005

[26] Peters D L, Papalambros P Y, Ulsoy A G. Control proxy functions for sequential design and control optimization. Journal of Mechani-cal Design, 2011, 133(9): 091007

[27] Alyaqout S F, Papalambros P Y, Ulsoy A G. Combined design and robust control of a vehicle passive/active suspension. International Journal of Vehicle Design, 2012, 59(4): 315–330

[28] Patil R, Filipi Z, Fathy H K. Computationally efficient combined plant design and controller optimization using a coupling measure. Journal of Mechanical Design, 2012, 134(7): 071008

[29] Peters D L, Papalambros P Y, Ulsoy A G. Sequential co-design of an artifact and its controller via control proxy functions. Mechatronics, 2013, 23(4): 409–418

[30] Peters D L, Papalambros P Y, Ulsoy A G. Relationship between coupling and the controllability Gramian in co-design problems. Mechatronics, 2015, 29: 36–45

[31] Peters D L. A procedure for evaluating the applicability of a control proxy function to optimal co-design. Journal of Engineering Design, 2016, 27(8): 515–543

[32] Çakmakcı M, Ulsoy A G. Bi-directional communication among “smart” components in a networked control system. In: Proceedings of the 2005 American Control Conference. Portland, 2005

[33] Çakmakcı M, Ulsoy A G. Improving component swapping modularity using bi-directional communication in networked control systems. In: Proceedings of ISFA 2006 International Symposium on Flexible Automation. Osaka, 2006

[34] Çakmakcı M, Ulsoy A G. Design of modular controllers for systems with smart networked components. In: Proceedings of the 4th International Conference on Design/Production of Machines and Dies/Molds. Çeşme, 2007

[35] Çakmakcı M, Ulsoy A G. Modular discrete optimal MIMO controller for a VCT engine. In: Proceedings of American Control Conference. St. Louis, 2009

[36] Li S, Çakmakcı M, Kolmanovsky I, et al. Throttle actuator swapping modularity design for idle speed control. In: Proceedings of American Control Conference. St. Louis, 2009

[37] Çakmakcı M, Ulsoy A G. Improving component swapping modularity using bi-directional communication in networked control systems. IEEE/ASME Transactions on Mechatronics, 2009, 14(3): 307–316

[38] Çakmakcı M, Ulsoy A G. Combined component swapping modularity for a VCT engine controller. In: Proceedings of ASME 2009 Dynamic Systems and Control Conference, Volume 2. Hollywood, 2009

[39] Çakmakcı M. Mechatronic design for component-swapping modularity using bi-directional communications in networked control systems. Dissertation for the Doctoral Degree. Ann Arbor: University of Michigan, 2009

[40] Li S, Kolmanovsky I V, Ulsoy A G. Direct optimal distributed controller design for component swapping modularity with application to ISC. In: Proceedings of American Control Conference. Baltimore, 2010

[41] Çakmakcı M, Ulsoy A G. Swappable distributed MIMO controller for a VCT engine. IEEE Transactions on Control Systems Technology, 2011, 19(5): 1168–1177

[42] Li S, Kolmanovsky I V, Ulsoy A G. Battery swapping modularity design for HEVs using the augmented Lagrangian decomposition method. In: Proceedings of American Control Conference. San Francisco, 2011, 953–958

[43] Li S, Kolmanovsky I V, Ulsoy A G. Distributed supervisory controller design for battery swapping modularity in plug-in hybrid electric vehicles. Journal of Dynamic Systems, Measurement, and Control, 2012, 134(4): 041013

[44] Li S, Kolmanovsky I V, Ulsoy A G. Direct optimal design for component swapping modularity in control systems. IEEE/ASME Transactions on Mechatronics, 2013, 18(1): 297–306

[45] Li S. Distributed supervisory controller design for battery swapping modularity in plug-in hybrid electric vehicles. Dissertation for the Doctoral Degree. Ann Arbor: University of Michigan, 2011

[46] Ghaffari A, Ulsoy A G. Experimental verification of component swapping modularity for precision contouring. In: Proceedings of American Control Conference. Seattle, 2016

[47] Ghaffari A, Ulsoy A G. Design of distributed controllers for component swapping modularity using linear matrix inequalities. In: Proceedings of IEEE/ASME International Conference on Advanced Intelligent Mechatronics. Banff, 2016

[48] Ulsoy A G. Design for ease of control and estimation. In: Proceedings of ASME Dynamic Systems and Control Conference. Minneapolis, 2016

[49] Ghaffari A, Ulsoy A G. LMI-based design of distributed controllers to achieve component swapping modularity. IEEE Transactions on Control Systems Technology, 2017, PP(99): 1–8

[50] Ghaffari A, Ulsoy A G. Component swapping modularity for distributed precision contouring. IEEE/ASME Transactions on Mechatronics, 2017, 22(6): 2625–2632

[51] Darwin C. On the Origin of Species. London: John Murray, 1859

[52] Koren Y, Heisel U, Jovane F, Reconfigurable manufacturing systems. CIRP Annals, 1999, 48(2): 527–540

[53] Ulrich K, Tung K. Fundamentals of product modularity. In: Proceedings of the 1991 ASME Winter Annual Meeting, ASME DE-Vol. 39. Atlanta, 1991, 73–79

[54] Butts K, Cook J, Davey C, Automotive powertrain controller development using CACSD. In: Samad T, ed. Perspectives in Control: New Concepts and Applications. New York: Wiley-IEEE Press, 2001

Acknowledgements

The author is pleased to acknowledge the collaborators on this research, i.e., Profs. P.Y. Papalambros and I.V. Kolmanovsky, as well as Drs. J. Reyer, H.K. Fathy, S.F. Alyaqout, D.L. Peters, M. Çakmakcı, S. Li and A. Ghaffari. The research featured in this article was sponsored by the National Science Foundation, the U.S.A. Army Automotive Research Center, the Ford Motor Company, and United Technologies, Inc.

Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided the appropriate credit is given to the original author(s) and the source, and a link is provided to the Creative Commons license, indicating if changes were made.

RIGHTS & PERMISSIONS

2019 The Author(s) 2019. This article is published with open access at link.springer.com and journal.hep.com.cn