The advances of mechatronic system design and system integration have shown improvements in functionality, performance and energy efficiency in many applications across industries, from autonomous ground vehicles and drones to conveyor belts. This trend has been adopted in some industries more than others. The design of equipment to handle granular or bulk material is commonly based on traditional approaches. Therefore, introducing mechatronic concepts in the design procedure can enable new possibilities, such as sensor integration and data analyses, adaptability and control. The efficiency of bulk material handling equipment in ports, agriculture and food processing is heavily influenced by the operational conditions. Typically, a piece of equipment is designed for defined operational conditions when the maximum performance can be achieved. In this work the concept of adaptability to varying operational conditions is explored by understanding the technologies implemented in other industries and the feasibility to be implemented in the bulk handling equipment design. Sensing technology, actuation and adaptability are systematically presented in this work to support the design process of the next generation of bulk handling equipment. This will pave the way for incorporating the technological trends in the design, such as: sustainability, “smartness”, Internet of Things, Industry 4.0, digital twin and machine learning. Adaptive mechatronic solutions will play a crucial role in generating and implementing innovative sustainable solutions for bulk handling equipment.@en

The shared autonomous vehicle (SAV) is a new concept that meets the upcoming trends of autonomous driving and changing demands in urban transportation. SAVs can carry passengers and parcels simultaneously, making use of dedicated passenger and parcel modules on board. A fleet of SAVs could partly take over private transport, taxi, and last-mile delivery services. A reduced fleet size compared to conventional transportation modes would lead to less traffic congestion in urban centres. This paper presents a method to estimate the optimal capacity for the passenger and parcel compartments of SAVs. The problem is presented as a vehicle routing problem and is named variable capacity share-a-ride-problem (VCSARP). The model has a MILP formulation and is solved using a commercial solver. It seeks to create the optimal routing schedule between a randomly generated set of pick-up and drop-off requests of passengers and parcels. The objective function aims to minimize the total energy costs of each schedule, which is a trade-off between travelled distance and vehicle capacity. Different scenarios are composed by altering parameters, representing travel demand at different times of the day. The model results show the optimized cost of each simulation along with associated routes and vehicle capacities.

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Floating cranes have shown their benefits in port operations and in offshore tasks. With the increase of offshore wind farms, installation and maintenance of the wind turbines require crane vessels for multiple tasks. In order to operate in open sea regardless the ocean waves, active heave compensation system is necessary to be installed. In this work an electric drive is proposed for active heave compensation of a floating crane, as more sustainable solution among other benefits. Dynamic model of a floating crane was derived for model based control. Different control algorithms were developed and numerically tested for efficiency.

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The digitalization of the product design process has become the new norm in the engineering design with the development of different CAD software, design analyses tools, and rapid prototyping techniques. More holistic approaches in the product design analyses include modeling of the manufacturing technologies and the entire logistics regarding the product life-cycle. Advanced design techniques have paved the way for engineers and designers to create new innovative products with unique functionalities or entirely change the shape of an existing traditional product. Generative and parametric design methods have established themselves in the recent years with benefits regarding material use and sustainability, but mostly with the development of the additive manufacturing technologies. They enable concepts like application driven design to become feasible, in this case lightweight structures while still maintaining structural integrity. In this work, an application driven design of non-homogeneous structure with tailored response to different external load conditions is presented. The structure design constraints in size and expected load capacity result in nonhomogeneous structure with optimal material distribution and structure mechanical response.

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This paper discusses an elastic metamaterial for filtering energy from certain frequencies of an incoming wave. The unit cell, which is composed by a single material, is built to obtain a local resonance band gap. Since Bloch-Floquet's periodic condition is enforced to the unit cell, the dynamic characteristics of the metamaterial is obtained by only evaluating such structure. The attenuation mechanism is guaranteed by visualizing bandwidths in which the wave propagation is prohibited. Such bandwidths, denoted as band gaps, are observed in the band structure diagram of the unit cell and in the transmissibility loss over the metamaterial. The assemble of unit cells with different internal geometries results in a filtering mechanism. The proposed single-phase metamaterial could be applied in structures requiring vibration control for selective frequencies.

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Online shops are responsible for a significant increase in the total volume of parcels which have to be transported. Due to the increase in volume there are more vehicles required to meet this enormous demand. This has a negative impact on the traffic flow on the infrastructure. A possible solution can be found in ride-sharing, as sharing resources paves the way to more sustainable designs. Public transport often operates with occupancy rates below the maximum, and a way to optimize it to combine it with parcel transport. A multi-functional vehicle which combines public and cargo transport in variable ratios could lower the impact of parcel vehicles on the traffic flow. The designing steps for a multi-functional vehicle are presented which lead to a more detailed case design. This case zooms in on small public transport vehicles which are often active between small towns. The multi-functional case design consists of an innovative solution based on reconfigurable chairs which enables a more efficient use of vehicle space. Multiple options to implement the multi-functional vehicles in the transport system are also discussed.

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The design of machinery for handling granular materials relies mainly on empirical methods and in-house engineering knowledge. This traditional approach provides incremental improvements that are often limited. Advancements in simulation and optimization can offer a promising alternative approach. Most of the research involved in improving or optimizing equipment design does not include the realistic performance of the new prototype and as such it is uncertain that the predicted performance is also guaranteed in practice. In this study, a design framework for a new generation of machinery handling granular materials, grabs, has been established that includes a full-scale validation step. This has been proven to lead to a breakthrough in equipment design. This design framework uses a co-simulation between Discrete Element Method (DEM) and Multi Body Dynamics (MBD), thus, capturing operational conditions in full-scale. The DEM simulation supported design step integrated as the main step to generate new prototypes. The performance of the prototype is evaluated by conducting full-scale experiments, thus validating the adequacy of the new design as well as the accuracy of the co-simulation. Through this a full design cycle has been fulfilled and a validated model has been achieved that is independent of specific design configurations.

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As machines and robots become a increasingly larger part of society, it is important that they are fully accepted. If the machines are not utilized as intended, it is not only a waste of time and energy, but also of valuable resources. This acceptance by humans of robots is based on how well the interaction with robots is trusted. Trust of robots can be based on three approaches: physical safety, operational understanding, and the social aspect of training. It is important to also consider these aspects when designing machines that will interact with humans, since acceptance by the people is key for the correct utilization of the machines. A possible approach to solve the issues around trust are soft robots. These machines are adaptable to a situation by either a physical flexibility or a digital anticipation due to sensing and control. This adaptiveness to humans in different ways makes Soft Robotics easier to accept then regular rigid machines. With their reduced or prevented effect if collided with humans they are safer. Because of the reduced operational complexity and digital simulations they are therefore easier to understand. Training becomes also easier as operator can experience the flexible nature of soft material themselves as well have augmented reality or virtual reality to assist them in training and operating. All these benefits of Soft Robotics will eventually lead to better acceptance of robots and should therefore be taken into account when designing robots to enable a flourishing automatized society.

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With the shift from traditionally manufactured rigid-body mechanisms to lightweight compliant mechanisms (CMs) in additive manufacturing, researchers have become interested in modeling the behavior of CMs with high flexibility. Due to the large deformations that can be achieved, the use of CMs has expanded into applications such as energy absorption, and in the case of cellular contact-aided compliant mechanisms (C3Ms), stress-relief through self-contact. Although CMs provide greater design freedom in terms of geometry, size, and functionality than their rigid-link mechanism counterparts, there are notable challenges in modeling their complexity. This complexity arises not only from the nonuniform geometry of CMs, but also from variable material properties such as effective modulus. Current research in this area has been primarily limited to the study of linear elastic materials. Thus, there is a need to develop a model that describes CMs with nonlinear material behavior. The focus of this work is on a low-fidelity model using nonlinear, superelastic materials. In order to account for both geometric nonlinearity and superelasticity, the use of a new pseudo-rigid body model is proposed. The model incorporates the mechanics of shape memory alloy (SMA) behavior in a folding C3M design. The combined application of pseudo-rigid body modeling and SMAs allows for the prediction of large recoverable deformations through superelasticity. In previous work, a segmented pseudo-rigid body model was used to account for the nonlinear behavior of a folding C3M. A mathematical model of the superelastic SMA material is derived based on 2D beam flexure equations. The development of these equations allows for an analysis of the deflection under an applied force. As a part of this study, the results of the SMA model will be compared to high-fidelity finite element simulations as a judge of the accuracy of the analytical model.

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Smart material graspers have shown potential for different applications in terms of functionality and actuation, especially in handling arbitrary shapes, fragile objects and complex 3D geometries. However, to take these initial designs further towards real applications, the challenge remains to determine the optimal size, shape, and passive and smart material location. Virtual reality can be beneficial in the early concept generation as it can help visualize and understand the grasping process. The access to suitable hardware and the development of virtual reality (VR) software has resulted in increased use of this technology. The 3D visualization offered by VR especially in the early stages of the design process assists engineers in making appropriate and efficient decisions, and it can also support the interaction with the end user to iterate on potential design improvements. The conceptual phase is often overlooked and rushed by the other departments involved in the design and development process although it is of great importance for successful outcome. It is important to make the most of it in order to assure quality result. In order to ensure short conceptual phase that will not reflect on the products' quality we propose introduction of the VR in the early stages of the design process. In this paper we show how the use of VR can be beneficial in new product development. In this case we focus on the design of smart material grasper.

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This research explores the possibility of upscaling bio-inspired designed soft robots in transport engineering application with the focus on grabbing and manipulating break bulk such as windmill blades or rolls of steel. Upscaling current state soft robotic systems includes challenges regarding the structural strength of the robot. Also certain actuation methods could be affected by upscaling the actuators as well. The design of the proposed bio-inspired soft robot is determined by analysing the functions and constraints of the design as well as evaluating different types of gripping solutions based on the different types of shapes of the object. In this research the claw gripping is selected to be applied in break bulk manipulation. This gripping solution could potentially be combined with the vacuum gripping solution to be able to manipulate more types of objects. The three fingers of the claw are designed based on the trunk of an elephant as the trunk of an elephant can lift heavy loads and can therefore be seen as a good starting point to design a high load capacity gripper.

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Floating structures have raised interest in the recent years for different applications, from living and farming at sea to renewable energy production. To support the logistics on the float- ing structures, floating cranes are necessary and their designs are constantly improved. In- creasing developments in the automation industry paved the way for automated crane opera- tions. In this work, motion control of a smart crane is presented with particular attention to the performance under wave motion. In this research, a scaled down, two-dimensional math- ematical model of a gantry crane is derived using Lagrangian mechanics and DC motors dy- namics. This results in a nonlinear system that is capable of simultaneous traversing and hoist- ing a container. The system is simulated in MATLAB Simulink environment and a proportional-derivative control and a state feedback control are designed and implemented. Their robustness is explored by modelling sensor behavior, external disturbances and floating platform dynamics. Both control strategies were able to keep stability in a disturbed system. During simulation, the sway angles never exceed 10 degrees. Smaller oscillations occurred us- ing the state feedback control. Therefore, it creates a smoother response compared to the pro- portional derivative control, which ultimately translates to increased safety, turnover rate and durability of the crane.@en

Large scale structures can benefit from the design of compliant joints that can provide flexibility and adaptability. A high level of deformation is achieved locally with the design of flexures in compliant mechanisms. Additionally, by introducing contact-aided compliant mechanisms, nonlinear bending stiffness is achieved to make the joints flexible in one direction and stiff in the opposite one. All these concepts have been explored in small scale engineering design, but they have not been applied to large scale structures. In this paper the design of a large scale compliant mechanism is proposed for novel design of a foldable shipping container. The superelasticity of nickel titanium is shown to be beneficial in designing the joints of the compliant mechanism.

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The space exploration activities are merging new technologies in order to develop systems challenged to achieve capabilities for high mission experience. Inspired by the numerous applications in space exploration, with the integration of shape memory alloys (SMAs), a 3D printed continuous All Terrain Grasper Transport (AT-GT) vehicle with implemented multi-locomotion grasper was created. In order to reduce failure of the mechanical system, the vehicle is equipped with SMA suspension and SMA tensioner of a pulley system with adaptable height able to achieve movement on a given trajectory and adjust to any terrain. SMA actuators provide controllable actuation based on the simplicity of their design and the shape memory effect. By using the advantages of the origami engineering, soft robotics and smart material implementation, a bio-inspired autonomous grasper was integrated on the AT-GT, capable of leaving the vehicle, grabbing an object and bringing it back to the vehicle. The concept development, the analytical models and the prototype including the benefits of the combined work of the vehicle and the grasper are presented.

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Design of floating terminals requires integrated approach as it requires multi-machine systems. Master students in mechanical engineering from Multi-ma-chine engineering track at TU Delft were assigned design of floating terminals as part of their Integration Project course. Each of seven student groups designed a specific piece of port equipment that was later integrated in the floating terminal design. This required different design approaches: a detailed one for the equipment design (structure and functionality), and conceptual one for the floating terminal (overall layout and operational strategy). This encouraged the students to develop skills needed in real working environment, managing the design process and deci-sion making within their own group and discussing setup, basic designs and dimen-sions together with the other groups. Owning their design throughout the entire pro-cess was in particularly important to the students, as they wanted other groups to use their equipment design. For the terminal design they needed to make a case for the feasibility of the floating terminal, including logistics simulations and cost. This paper shows the benefits of integrated design project course, the methods used for its implementation, as well as addressing current challenges of online group design work and supervision. Being part of European Horizon 2020 project motivated the students even more to contribute to an overall bigger objective.@en

The future of technology lies in the diverse characteristics and capabilities of autonomous machines and devices and their application in many technical challenge. Rapid technology development, market globalization and availability of affordable electronics and controllers, have recently resulted in increased scientific and technical interest in drones as autonomous solutions for professional, as well as, amateur applications. On the other hand, researchers have been improving how manmade machines move through air by attempting to replicate animals motion by mimicking their aerial abilities. In this paper, we propose a development of a bio-inspired modular drone concept motivated by the bats agility, wingspan and wings folding into various shapes. The drone can be tailored for different applications, from sea port mapping, surveying, tank inspection and port traffic control to pollution monitoring and detection of illegal activities. The aerial performances of the drone allow it to be able to conduct windmills monitoring by connecting to their local monitoring units and send alerts to officials in real-time. This small bat-inspired drone is proposed to have an ability of performing flights with precisely defined trajectories. The accent will be put on the interchangeable wings, analysis of their dynamic attributes and transformation possibilities as a crucial segment of the overall drone performance. The design and fabrication process and the flight characteristics of the various wing configurations of the drone are discussed in details. Limitations of the drone, proposed solutions for further development and recommendations are also presented.

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Energy harvesting as a concept of “catching” the energy which is wasted due to inevitable processes is a very promising technology for energy collection and its transformation into a type of energy suitable to power wireless devices. Energy can be harvested by using different materials properties, such as piezoelectrics, in order to produce electricity when being exposed to mechanical vibrations. This paper focuses on achieving energy harvesting by one’s walk or run, by incorporating shoes piezoelectric “smart soles” capable of transforming generated mechanical vibrations into electricity. Using the smallest amount of energy of one or more energy sources, accumulate that energy or even use it right away, is a new and effective way of dealing with the devices which need a constant power supply such as Wi-Fi modules, IoT devices or even personal gadgets. Therefore, the goal is to make energy harvesting devices easy to use by people in their everyday life, and yet inexpensive in order. In this paper, a model and design of a shoesole which uses the property of the piezoelectric materials to generate electric voltage as a result of mechanical vibrations is developed. The aspect of person’s walk is used as mechanical stress that indicates vibrations in the sole which is collected in the piezoelectric placed in the shoe. The dynamics of movement of person’s feet with different dynamic variables and other physical parameters that affect the process are discussed. An analytical model of the shoe-sole is built and experimental measurement results are explained. As proof of concept, a functional prototype is presented.@en

Inspired by the movement of a turtle in nature, a low-budget turtle-like robot was designed and developed to operate on natural terrain. Applying affordable additive manufacturing (3D printing) leads into creating unique 3-D structure with potential of flexibility, multi-functionality and multi-movement. By implementing solar panels, the energy from the sun is used, which makes the robot self-sustainable. The robot is controlled remotely with an android application designed for the need of this work. The bio-inspired robot can play an interesting role in real-life applications, such as monitoring in hardly accessible terrain, video and data collection for environmental friendly application, animals’ observation and others. The main application of the robot is for animal observation in the zoo, so it will often need to move across not even landscape in order to allow surveillance of that area. By implementing smart materials, the movement of the turtle can be improved. This paper presents the design concepts and functionality, together with CAD model of the robot, the prototyping (hardware, control and application design) and the results from the measurements.

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