Abstract

A technical synthesis of three university level proj ects integrating fluid pow er actuation, 3D mechanical assem blies, and robotic kinematics within a unique simulation framework.
 

Introduction

Modern mechatronic systems re quire the integration of mechanical structures, fluid power actuation, and control systems. In engineer ing education, however, these domains are often taught separately, making it difficult for students to understand their interaction. Inte grated simulation environments provide a unified framework where mechanical motion, actuation and control strategies can be analyzed simultaneously. This work explores the use of the Automation Studio simulation en vironment as a support tool for teaching mechatronics engineer ing concepts. Through the devel opment and implementation of three practical projects, the study demonstrates how an integrated simulation platform can help to connect theoretical knowledge with practical system behavior, promoting a deeper understanding of engineering prin ciples related to mechanical motion, fluid power actua tion, and system control. The first project (Figure 1) introduces the Mechanism Manager, a tool that allows the simulation of the kine matic and dynamic behavior of mechanical systems through the definition of joints and constraints be tween rigid bodies. This environment enables the inter action between actuators and mechanical structures to be modeled and analyzed within a two-dimensional multi-body environment.

Fig. 1 - First project - boom lift.

The second project (Figure 2) focuses on the integra tion of three-dimensional mechanical models within the simulation environment. In particular, the study demonstrates the design and simulation of a mobile vertical platform based on a pantograph mechanism, combining 3D modeling with fluid-powered actuation, loads, and mechanical constraints. 

Fig. 2 - Second project - pantograph lift.

Finally, the third project (Figure 3) explores the applica tion of the Denavit–Hartenberg convention for the ki nematic analysis of robotic manipulators. Through the implementation of rotation matrices and coordinate frame transformations, the project provides a visual and interactive representation of robotic arm motion within the simulation environment. By combining mechanical modeling, fluid power sim ulation, and mathematical representations of robotic motion, these projects illustrate how integrated simu lation tools can support the teaching and understand ing of complex mechatronic systems.

Figure 3 - Third project - DH convention.

Methodology

The methodology adopted in this work is based on the use of an integrated simulation environment capable of com bining mechanical modeling, fluid power actuation, and control within a unified framework (Figure 4). Automation Studio enables multi-domain interaction through a consis tent simulation in which mechanical structures, actuators, and control elements are analyzed simultaneously. Mechanical systems are represented as assemblies of rigid bodies connected through kinematic constraints such as revolute and prismatic joints. The Mechanism Manager module defines these constraints and com putes the kinematic and dynamic behavior of articulat ed mechanisms. 

Figure 4 - Automation Studio multi-Technologies.

Fluid power actuators (pneumatic or hydraulic) are di rectly integrated into the mechanical model. The actu ator forces are transmitted through the defined joints, allowing realistic simulation of motion generation un der load. This coupling ensures consistency between actuator dynamics and mechanical constraints. The environment also supports the implementation of external CAD geometries, enabling the construction of three-dimensional assemblies within the same model ling framework. In addition, mathematical models relat ed to robotic kinematics can be implemented through Structured Text and control blocks, allowing dynamic visualization of homogeneous transformation matri ces based on the Denavit–Hartenberg convention. This unified approach provides a direct connection between theoretical formulations, actuator behaviour and mechanical motion. 

Project 1 - Mechanism Manager

The first project (Figure 5) introduces the use of the Mechanism Manager module to demonstrate the coupling between mechanical systems and pneumatic ac tuation within a planar multi-body environment. A boom lift mechanism is modelled, where the rota tion of a rigid arm is driven by a pneumatic cylinder. The system consists of a fixed reference frame, a rigid boom, and an actuator connected through pivot and sliding joints. Mechanical elements are defined using frames, nodes, rigid bodies, and kinematic constraints. When integrated into the mechanism, the pneumatic actuator is automatically represented as a two-body system (cylinder and rod) connected by a sliding joint, ensuring compatibility with the multi-body formula tion. External loads are applied to the boom, and dynamic simulations are performed to evaluate piston displacement, actuator pressure and angular motion. User interaction is enabled through a proportional valve controlled by a joystick interface, allowing re al-time adjustment of pressure limits and observation of the resulting system response. 

Figure 5 - First project – Boom lift and associated pneumatic circuit.

To complement the dynamic analysis, a static equilibrium formulation is introduced (Figure 6). By evaluating torque balance about the boom hinge, the minimum actuator pressure required to lift the system under varying load conditions can be estimated. 

Figure 6 - Static equilibrium formulation.

During the simulation, it is also possible to observe oscil latory behavior caused by the compressibility of the pneu matic fluid. The boom slope can vary between 0 and 80 degrees, as an imposed constraint. A double check can be done through the plotter (Figure 7), which evaluates the extension of the actuator according to the internal pressure. This introductory example provides the modelling foundation required for the more advanced projects presented in the following sections, where the same modelling approach is extended to more complex three-dimensional mechanisms and robotic systems.

Figure 7 - Static equilibrium formulation.

Project 2 – Pantograph Lift

The second project (Figure 8) extends the proposed modelling approach to a three-dimensional mecha tronic system integrating CAD geometry, multi-body mechanics, fluid power actuation, and user interaction. 

Figure 8 - Second project - Pantograph lift.

A pantograph lift mechanism was designed in Solid Works (Figure 9) and imported into the Automation Studio 3D environment. The assembly was completed by defining geometric constraints and kinematic joints (pivot and sliding) to reproduce the  mechanical behaviour of the scissor structure. The 3D model was then linked to the Mechanism Manager, where a simplified rigid-body representation enabled dynamic computation of motion under actuator forces and external loads.

Figure 9 - Drawings made with Solid Works.

Two pneumatic actuators were integrated into the sys tem (Figure 10): one controlling the vertical extension of the pantograph mechanism and the other driving the horizontal translation of the mobile base. 

Figure 10 - Pneumatic actuators.

The actuator strokes are directly converted into me chanical motion through the defined joint constraints. A Human-Machine Interface (HMI) panel was imple mented to allow real-time interaction with the model (Figure 11). The user can modify actuator inputs, vary external load conditions applied to the workbench, and monitor key variables such as platform height and ac tuator pressure. This project demonstrates the capability of the inte grated simulation environment to combine detailed 3D mechanical assemblies with fluid power actuation and control logic, enabling realistic analysis of a multi-de gree-of-freedom mechatronic system.

Figure 11 - Load Knob + Control Panel

Project 3 – Robotic Manipulator and Denavit – Hartenberg Implementation

The third project (Figure 12) focuses on the implementation of robotic kinematics using the Denavit–Harten berg (DH) convention within the same integrated simulation framework. 

Figure 12 - Third project - DH convention.

The kinematic relationships between consecutive frames are described using the homogeneous transformation matrices derived from DH parameters (Figure 13). 

Figure 13 - DH parameters explanation.

A simplified three-dimensional robotic manipulator was modelled to visualize coordinate frames associat ed with each link (Figure 14). 

Figure 14 - Roto-translation matrices + simplified 3D robotic manipulator + DH table.

The elements of the transformation matrices are all computed in real time using Structured Text and Se quential Function Chart (SFC) blocks (Figure 15). 

Figure 15 - Matrices dynamic computation through SFC.

These values are displayed during simulation, enabling direct observation of the relationship between joint variables and the resulting rotation and translation components. Through the HMI interface (Figure 16), the user can modify joint variables either dynamically (cursor mode) or by imposing precise numerical values (display mode). The resulting changes are simultaneously reflected in both the numerical matrix representation and the physical motion of the manipulator in the 3D environment. Different kinematic configurations, including revolute and prismatic joints, can be explored within the same framework. This implementation provides a clear link between mathematical kinematic models and their geometric interpretation, reinforcing the connection between theoretical robotics concepts and observable mechanical behaviour.

Figure 16 - Control panel: Cursor mode on the left, Display mode on the right.

Conclusion

The presented projects demonstrate the effectiveness of integrated simulation environments in supporting mechatronics education. By unifying mechanical mod elling, fluid power actuation, control logic, and robotic kinematics within a single platform, the approach enables consistent analysis of interactions across engi neering domains. The three case studies introduce progressively in creasing complexity, from planar multi-body modelling to three-dimensional fluid-actuated mechanisms and Denavit–Hartenberg-based robotic kinematic anal ysis. This progression highlights the value of linking mathematical models with dynamic system behaviour in a coherent simulation framework. Developed within university-level engineering programs at the Politecnico di Torino and the École de technologie supérieure (ETS) in Montréal, these projects illustrate how integrated simulation tools can enhance training in automation, mechatronics, and robotics.