ROBOTIC SYSTEM
DESIGN
Lecture 2: Robotic system design techniques
Course instructor: Nguyễn Duy Ánh
Ho Chi Minh City Univ. of Tech – Mechatronics Department
Robotic System Design
Contents
• Challenges in Design
• Design techniques
- Life cycle design
- Hierarchical design
- V-model design
- Axiomatic design
- Model-based design
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Robotic System Design
Challenges in Design—Hierarchical design models in the mechatronic product
development
Hierarchical design models in the mechatronic product
development process (Hehenberger et al., 2010)
• For any new product, the question is less how to
realize it, than to find a promising superior product
concept. In the traditional linear model of design, the
process flows from synthesis over analysis to
evaluation
• Design methodology at the conceptual level includes
as a mission the creation of innovative concepts,
comprising a description in low detail but with sufficient
relevance for the evaluation of their essential
properties in comparison to other concepts.
• The product’s main properties (e.g. performance,
behavior, function, weight, costs) quantified by
significant parameters are fixed during the conceptual
design phase in the product development process
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Robotic System Design
Challenges in Design—Mechatronic coupling, define mechatronic module
• A mechatronic module utilizes several
different disciplines of mechatronics
(e.g. mechanics, automatic control
techniques etc.). In such a mechatronic
module exclusively domain-specific
components are merged.
• A mechatronic module therefore
designates a mechatronic sub-system at
the lowest hierarchical level of a
mechatronic system and is indivisible
within the set of mechatronic sub-
systems.
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Robotic System Design
Challenges in Design—Mechatronic coupling, define mechatronic module
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Robotic System Design
Challenges in Design—Mechatronic coupling, define mechatronic module
PMSM (permanent magnet synchronous motor) 6
Robotic System Design
Challenges in Design—Mechatronic coupling, define mechatronic module
Mechatronic modules of the PMSM drive system
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Robotic System Design
Challenges in Design—Mechatronic coupling, define mechatronic module
Control of PMSM 8
Robotic System Design
Challenges in Design
• Faster, better, cheaper is the name of the game for
machine builders.
• Intense competition is putting pressure on machine
builders to deliver machines with higher throughput,
reduced operating cost, and increased safety.
• Along with designing the mechanicals, machine
builders now incorporate control logic, human
machine interfaces (HMIs), networking, and machine
condition monitoring systems into their designs.
• The added complexity has created inefficiencies in
the machine design process that lengthen design time
and increase design cost.
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Robotic System Design
Challenges in Design
1. The Machine Design Process Is Serial and Slow
• Challenge: The traditional machine design process is
sequential and slow, involving mechanical design first,
followed by electrical and control design, leading to
potential delays and increased costs.
• Solution: Implement a mechatronics design approach
that integrates mechanical, electrical, and control
design tools. Create a virtual machine prototype before
physical design to test and refine the machine's design
in software.
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Robotic System Design
Challenges in Design
2. Communication with Customers and
among Design Team Members Is Challenging
• Challenge: Understanding customer
requirements and conveying design plans can
be a lengthy and complex process, potentially
leading to misunderstandings and unsuitable
designs.
• Solution: Implement a mechatronics design
approach that integrates mechanical,
electrical, and control design tools. Create a
virtual machine prototype before physical
design to test and refine the machine's design
in software.
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Robotic System Design
Challenges in Design
3. Accurately Sizing Motors Is
Challenging
• Challenge: Selecting the right-sized
motor for an application is challenging,
as it involves factors like cost, weight,
and performance.
• Solution: Use software to determine
the required torque for the machine's
desired motion profile. Simulate motor
performance to select the optimal
motor size for the application.
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Robotic System Design
Challenges in Design
4. Initial PID Tuning Is Difficult to
Determine:
• Challenge: Setting the initial PID
tuning parameters for complex
machines can be challenging and may
result in unexpected machine
movements.
• Solution: Tune PID control algorithms
on a 3D CAD model of the machine
using virtual machine prototyping.
Gain insights into PID tuning
parameters to establish safe starting
points for the physical machine.
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Robotic System Design
Design
techniques
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Robotic System Design
Life cycle design
• Life Cycle Design Approach is a
methodology that considers the
entire life cycle of a product,
system, or technology from its
inception to its end-of-life disposal
or recycling.
• It aims to reduce environmental
impacts, improve sustainability,
minimize resource consumption,
and optimize economic
performance throughout the
product's life.
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Robotic System Design
Life cycle design
Scope of Consideration:
• Life Phases: It encompasses
various phases, including design,
manufacturing, transportation,
usage, maintenance, and end-of-life
disposal or recycling.
• Environmental and Economic
Aspects: It evaluates the
environmental and economic
impacts at each phase, including
energy use, materials, emissions,
waste generation, and costs.
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Robotic System Design
Life cycle design
Principles and Strategies:
• Environmental Impact Reduction: It
aims to minimize negative environmental
effects by reducing energy consumption,
emissions, and resource depletion.
• Sustainability: It considers sustainability
principles, such as reducing waste,
promoting recycling, and using renewable
resources when possible.
• Cost Efficiency: It strives to reduce life-
cycle costs by designing for longevity,
ease of maintenance, and efficient use of
resources.
• Responsibility: It encourages responsible
resource management and adherence to
environmental regulations.
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Robotic System Design
Life cycle design
Design Considerations:
• Material Selection: It focuses on
selecting materials that are
environmentally friendly, durable, and can
be recycled or disposed of responsibly.
• Energy Efficiency: It emphasizes
designing for energy efficiency during both
operation and manufacturing.
• Durability and Reliability: It promotes
the design of products that have longer
lifespans and require fewer repairs or
replacements.
• Ease of Disassembly: It considers the
ease of disassembling products at the end
of their life to facilitate recycling or
responsible disposal.
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Robotic System Design
Life cycle design
Environmental Impact Assessment:
• Life Cycle Assessment (LCA): It often
employs LCA methodologies to evaluate
the environmental impact of a product or
system across its entire life cycle.
• Carbon Footprint: It calculates and
minimizes the carbon footprint of the
product, including emissions associated
with production and usage.
Regulatory Compliance: It ensures that the
design complies with relevant environmental
and safety regulations.
Stakeholder Engagement: It may involve
end-users in the design process to consider
their needs and preferences, as well as to
ensure usability and safety.
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Robotic System Design
Life cycle design
End-of-Life Considerations:
• Recycling and Disposal: It includes
plans for responsible recycling or disposal
at the end of the product's life.
Documentation and Reporting:
• Documentation: It maintains records of
design decisions, material choices, and
environmental assessments.
• Reporting: It may involve reporting on the
product's environmental performance to
stakeholders or regulatory bodies.
Continuous Improvement: It encourages
continuous improvement and refinement of
products and processes based on
environmental and economic performance
data.
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Robotic System Design
Life cycle design
Pros:
• Eco-Friendly: It helps make products and
systems more environmentally friendly by
considering their impact from start to finish.
• Cost Savings: It can save money in the long run
by reducing waste, energy use, and resource
consumption.
• Reduced Risk: It lowers the risk of environmental
or regulatory problems down the line.
• Innovation: It encourages creative solutions and
can make businesses more competitive.
• Good Reputation: It can enhance a company's
image by showing commitment to sustainability.
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Robotic System Design
Life cycle design
Cons:
• Complex: It can be complicated to implement,
especially for big projects.
• Initial Costs: It might require spending more
money upfront for research and development.
• Balancing Act: Sometimes, what's
environmentally friendly may be more expensive.
• Data Needed: It relies on having a lot of data,
which might not always be available.
• Slower Development: It can slow down the
product development process due to extra
planning and analysis.
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Robotic System Design
Hierarchical design
• Hierarchical design principles are
commonly applied in the field of
robotics to structure and organize the
various components, layers, and
subsystems of a robotic system. This
hierarchical structure simplifies the
design, control, and maintenance of
complex robotic systems.
• The concept borrows from traditional
systems engineering and design
philosophies, where complex
systems are decomposed into
smaller, more manageable parts.
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Robotic System Design
Hierarchical design
1. System Level Analysis: Begin by defining the
overall objectives and specifications of the
mechatronic system. Understand the desired
outputs, required inputs, and overall functionalities.
2. Subsystem Decomposition: Divide the system
into smaller subsystems based on functionalities or
disciplines. For example:
• Mechanical subsystem (which may include
structures, actuators, and mechanisms).
• Electronic subsystem (comprising sensors,
circuits, and power supplies).
• Control subsystem (with controllers, software,
and algorithms).
• Communication subsystem (for any networking
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or communication requirements).
Robotic System Design
Hierarchical design
Abstraction layers: Organize
the design tasks into layers with
increasing complexity. Lower
layers focus on physics
fundamentals while higher
layers address system
integration and controls.
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Robotic System Design
Hierarchical design
3. Subsystem Design:
• Each subsystem can be designed more
or less independently, often by experts
in that particular domain.
• Consider how each subsystem will
interact with the others. Interfaces
between subsystems must be clearly
defined to ensure seamless integration
later.
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Robotic System Design
Hierarchical design
4. Component Selection/Design: Within
each subsystem, identify or design specific
components to meet the subsystem's
requirements. For example:
• Choose the right motor for a mechanical
subsystem.
• Decide on a particular sensor for the
electronic subsystem.
• Develop a suitable control algorithm for the
control subsystem.
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Robotic System Design
Hierarchical design
5. Integration & Interfacing: Once individual
subsystems are designed, it's crucial to
integrate them to ensure they work in
harmony. This involves:
• Testing each subsystem individually.
• Ensuring clear and effective communication
between subsystems.
• Managing power distribution and grounding
to prevent interference or noise in signals.
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Robotic System Design
Hierarchical design
6. System-Level Testing & Verification:
After integration, the entire system must be
tested as a whole to ensure it meets the
original objectives and specifications. Any
discrepancies or issues should be traced back
to the relevant subsystem or component and
corrected.
7. Iterative Refinement: As with many design
processes, expect some iteration. You may
find that adjustments in one subsystem
necessitate changes in another. The
hierarchical structure makes it easier to
isolate and resolve such issues.
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Robotic System Design
Hierarchical design
Pros:
• Manages complexity - Breaks down a large, complex system into smaller, more manageable subsystems
and components. This reduces cognitive load.
• Enables specialization - Different teams can focus on particular subsystems allowing expertise to develop
in each area.
• Modularity - Subsystems are relatively independent with defined interfaces enabling easier testing,
maintenance and upgrades.
• Facilitates reuse - Common subsystems can be reused across product families reducing redundant work.
• Parallel development - Subsystems can be designed concurrently accelerating the overall project.
• Reduces integration issues - Well-defined interfaces help identify and resolve integration issues early.
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Robotic System Design
Hierarchical design
Cons:
• Sub-optimal designs - Interfaces between subsystems impose constraints that may limit achieving globally
optimal system-level designs.
• Interface complexity - Excessive hierarchical decomposition can lead to complex interfaces between many
subsystems.
• Communication overhead - Extensive coordination between different subsystem teams may be required.
• Recursive verification - Requirement changes in higher levels affect lower levels, necessitating recursive
verification.
• Skill silos - Engineers may become isolated in their domains and lose sight of the big picture.
• Increased documentation - Hierarchical structure demands detailed interface documentation to enable
integration.
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Robotic System Design
Hierarchical design
• Top-Down Design: In top-down design, the design process starts with a high-level view of the system or
product and gradually breaks it down into smaller, more detailed components. Each component is designed
independently, and their interactions are defined later in the process.
• Bottom-Up Design: Bottom-up design takes the opposite approach. It begins with the smallest components
or modules and gradually assembles them to create larger subsystems and the overall system. This method
is useful for incremental development and for reusing existing components.
• Modular Design: Modular design involves breaking a system into self-contained modules, each responsible
for specific functions or features. These modules can be designed, tested, and maintained independently,
simplifying the development process and facilitating scalability.
• Functional Decomposition: Functional decomposition involves breaking down a system into functions or
tasks. Each function is designed and implemented separately, and they are combined to create the overall
system. This approach is common in control systems and process engineering.
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Robotic System Design
V-Model design
• The V-model (Validation and Verification model)
is a widely accepted systems development lifecycle
model that represents the various phases of a
project from inception to completion in a manner
that allows for detailed system verification and
validation.
• When applying the V-model to the design of a
mechatronics system, it can help ensure that all
system requirements are met and that the system
functions as expected.
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Robotic System Design
V-Model design
1. Left Side of the V: System Definition and Design
• Requirement Analysis:
- Define the overall goals of the mechatronics system.
- Specify the requirements, like speed, accuracy, power consumption, and interface
requirements.
• System Design:
- High-level design of the entire mechatronics system.
- Determine main components such as sensors, actuators, controllers, and
communication systems.
• Architectural Design:
- Develop a detailed system architecture.
- Define the relationship between the components and subsystems.
• Module Design:
- Design individual components and modules in detail.
- For example, decide on the specific sensors, microcontrollers, actuators, and their
interfacing.
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Robotic System Design
V-Model design
2. Bottom of the V: Implementation
• Coding/Physical Construction:
- Develop the embedded software
for the controllers.
- Assemble and build the physical
components of the system.
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Robotic System Design
V-Model design
3. Right Side of the V: System Verification
• Unit Testing:
- Test individual components in isolation.
- For instance, verify if a particular sensor is giving accurate readings.
• Integration Testing:
- Test the interface and interaction between different components.
- For example, check if the sensor data is correctly received and processed by the
microcontroller.
• System Testing:
- Test the entire mechatronics system as a whole.
- Ensure that all components work together seamlessly to meet the defined
requirements.
• Acceptance Testing:
- Confirm that the mechatronics system meets all the customer's requirements and
expectations.
- May involve real-world testing scenarios.
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Robotic System Design
V-Model design
4. Across the V: Validation, Verification, and
Monitoring
• Validation: Ensure that the system fulfills its
intended purpose and meets user needs.
• Verification: Ensure that the system meets the
specified requirements at each stage of
development.
• Monitoring: Continuously monitor the system's
performance during its lifecycle, making adjustments
and updates as necessary.
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Robotic System Design
V-Model design
Pros
• Clear Phases: The V-Model provides distinct development and testing phases, making it clear what tasks
are to be carried out at each stage.
• Systematic Approach: With its step-by-step procedure, the V-Model is systematic, ensuring that validation
and verification occur for every stage of development.
• Early Error Detection: If followed rigorously, errors can be detected in the early stages of the lifecycle,
making them less costly to correct.
• Well-Defined Milestones: Progress is easy to measure, as milestones are clearly defined.
• Discipline: The strict adherence to the model ensures that no phase is skipped.
• Comprehensive Testing: With validation and verification processes paired with each development step,
comprehensive testing is inherent to the V-Model.
• Traceability: The V-Model promotes traceability between design and testing phases, making it easier to link
requirements to their corresponding validation tests. 38
Robotic System Design
V-Model design
Cons
• Rigidity: The V-Model can be seen as rigid and may not be well-suited for projects that require flexibility or
iterative development.
• Complexity: For larger projects, the V-Model can become complex, with numerous requirements and
associated test cases.
• Late User Feedback: User validation occurs relatively late in the process, potentially leading to late-stage
changes and increased costs.
• Not Ideal for Agile: The V-Model is not well-suited for agile development methodologies, which emphasize
flexibility, collaboration, and frequent iterations.
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Robotic System Design
Axiomatic design
• It is a framework used to guide the design of complex systems and products, with a focus on ensuring
that the design meets functional requirements while minimizing unnecessary complexity and ensuring
robustness.
• Axiomatic design is particularly useful in industries where precision and reliability are critical, such as
aerospace, automotive, and manufacturing
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Robotic System Design
Axiomatic design
• The customer domain indicating the needs of the customer.
• The functional domain expressing the desired functions (desired behaviour) of the design object.
• The physical domain representing the physical properties of the design object.
• The process domain illustrating how to achieve or produce the design object.
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Robotic System Design
Axiomatic design
Key Steps in Axiomatic Design:
• Identify Customer Needs: Understand and
document customer's requirements.
• Identify Design Parameters (DPs): Identify
adjustable factors.
• Create the Domain (D) Matrix: Quantify
relationships between DPs and requirements.
• Analyze Independence: Minimize dependencies
and ensure that each FR has a unique set of DPs
associated with it.
• Design Matrix (P) and Standardization: Map
DPs to design solutions.
• Evaluate and Refine: Assess and optimize the
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design.
Robotic System Design
Axiomatic design
Pros:
• Systematic Approach: Axiomatic design provides a structured and systematic approach to design,
ensuring that design decisions are grounded in customer needs and information theory.
• Complexity Reduction: By emphasizing independence and minimizing dependencies, axiomatic
design helps reduce unnecessary complexity in the design, making it more reliable and easier to
manage.
• Robustness: Designs created using axiomatic design principles tend to be more robust and less
sensitive to variations or changes.
• Quality Improvement: Axiomatic design can lead to improved product quality and reliability, which is
crucial in industries like aerospace and automotive.
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Robotic System Design
Axiomatic design
Cons:
• Initial Complexity: Implementing axiomatic design can require additional effort in terms of data
collection and analysis, especially in complex projects.
• Subjectivity: There may be subjectivity in defining customer needs and quantifying relationships in
the D matrix.
• Learning Curve: Team members may need training to effectively apply axiomatic design principles.
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Robotic System Design
Axiomatic design
Example: Design a car's suspension system
Step 1: Identify Customer Needs (Functional Requirements):
• Requirement 1 (FR1): Ensure a smooth ride for passengers.
• Requirement 2 (FR2): Provide stability during cornering.
• Requirement 3 (FR3): Absorb shocks from uneven road surfaces.
Step 2: Identify Design Parameters (DPs):
• Parameter 1 (DP1): Spring stiffness.
• Parameter 2 (DP2): Damper (shock absorber) design.
• Parameter 3 (DP3): Tire selection.
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Robotic System Design
Axiomatic design
Step 3: Create the Domain (D) Matrix:
The D matrix quantifies the relationships between FRs and DPs. In practice, the relationships may be
more complex, but this is a simplified example:
In this simplified matrix:
A "1" indicates a strong relationship between a DP and an FR.
A "0" indicates no relationship.
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Robotic System Design
Axiomatic design
Step 4: Analyze Independence:
Evaluate the D matrix for independence. The goal is to minimize dependencies. In this case, each FR
has a unique set of DPs, indicating good independence.
Step 5: Design Matrix (P) and Standardization:
Now, create a design matrix (P matrix) that maps DPs to specific design solutions:
For DP1 (Spring), there are three design options: High stiffness, Low stiffness, and Medium stiffness.
For DP2 (Damper), there are two design options: Type A and Type B.
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For DP3 (Tire), there are two design options: Performance and Standard.
Robotic System Design
Axiomatic design
Step 6: Evaluate and Refine the Design:
• Assess each design option against the customer's functional requirements. For example, Design 1
(High stiffness springs, Type A dampers, Performance tires) may provide a smooth ride (FR1),
stability during cornering (FR2), and shock absorption (FR3).
• The design can be further refined based on performance, cost, and other factors. For instance, if
Design 1 is too expensive, a compromise might be made by selecting Standard tires instead of
Performance tires.
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Robotic System Design
Model-based design
Model-based design (MBD) is a mathematical and visual method of addressing problems associated with
designing complex control, signal processing, and communication systems.
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Robotic System Design
Model-based design
Key Principles of Model-Based Design: Mathematical Modeling, Simulation and Analysis, and Iterative
Optimization.
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Robotic System Design
Model-based design
Steps in Model-Based Design:
• System or Product Specification: Begin by defining the specifications and requirements of the system or
product. What are the desired functionalities and performance criteria?
• Mathematical Modeling: Create mathematical models that represent the various components and
interactions within the system. These models may include equations, block diagrams, state machines, or
other mathematical representations.
• Simulation: Use specialized software tools to simulate the behavior of the system based on the mathematical
models. Simulations can include dynamic responses, control strategies, and performance analysis.
• Analysis and Optimization: Analyze the simulation results to assess whether the design meets the
specifications. If not, make design modifications and re-simulate. This iterative process continues until the
design meets the desired criteria.
• Validation: Validate the design by comparing simulation results with physical testing or real-world data to
ensure that the model accurately represents the actual system.
• Implementation: Depending on the specific application, the mathematical models can be used to generate
code for embedded systems or serve as blueprints for physical prototypes.
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Robotic System Design
Model-based design
Advantages of Model-Based Design:
• Reduced Development Time: Model-based design allows for rapid prototyping and testing in the virtual
environment, reducing the need for physical prototypes and speeding up the development process.
• Cost Savings: By identifying and addressing design flaws early in the virtual prototyping phase, model-
based design can lead to cost savings by avoiding expensive design changes late in the process.
• Improved Performance: Engineers can fine-tune and optimize designs more effectively using simulations,
leading to improved performance and reliability.
• Complexity Management: Model-based design helps manage the complexity of intricate systems by
providing a structured way to understand and analyze their behavior.
• Documentation: Detailed mathematical models provide comprehensive documentation of the design, aiding
in troubleshooting, maintenance, and future modifications.
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Robotic System Design
Model-based design
Challenges of Model-Based Design:
• Skill and Training: Model-based design often requires specialized software tools and expertise in
mathematical modeling, which may necessitate training for engineering teams.
• Model Verification: Ensuring that the mathematical models accurately represent real-world behavior can be
challenging and requires rigorous validation.
• Resource Intensive: Running complex simulations can be computationally demanding and may require high-
performance computing resources.
• Integration: Integrating model-based design into existing development processes and workflows can be a
complex task.
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