The Mechatronic System Design Process provides an environment that is rich with numerical and graphical analysis tools that stimulate innovation, integration, communication, and collaboration within design teams. It aims to reduce the risk of not meeting the functional requirements by enabling early and continuous verification throughout the entire design workflow.

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The Mechatronic System Design Process results in the creation of a system virtual prototype, complete with models of the plant, sensors, actuators and all supporting electronics, as well as the real-time computer control code. The process involves control-oriented physical modeling, mathematical modeling using the laws of nature, dynamic response prediction by simulation, experimental validation of prediction, control system design, and evaluation of both system design and control system together to meet dynamic performance requirements.

Once the mechatronic system virtual prototype has been created and successfully simulated with as much real-world detail as is possible, a hardware real prototype is created. This hardware prototype should work the first time the power is turned on.

Mechatronic Machine Design Principles are followed in the creation of the actual prototype. These include mechanism analysis and synthesis, exact constraint design, material selection for strength, stiffness, fatigue, friction, wear, and manufacturing process, geometry selection, failure prevention static and fatigue design, and power transmission selection and sizing.

This module presents in detail the Mechatronic System Design Process together with several real-world case studies.