Machinery & Energetics

Synthesis and decomposition of a mechatronic system with hydro-pneumatic automation devices

Oksana Hanpantsurova, Oleksandr Hubarev, Kostyantyn Bielikov, Alyona Murashchenko, Oleh Levchenko
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Abstract

The relevance of this study is driven by the increasing complexity of mechatronic systems with hydropneumatic automation devices and the need to improve the efficiency of their design in the context of Industry 4.0 development. The aim of the study was to substantiate the suitability of the cyclic-modular approach for decomposing a mechatronic system into macromodules, synthesising these modules, and subsequently integrating them without compromising the system’s properties. The research methodology was based on the application of systems analysis, decomposition, and logical synthesis principles for the design and investigation of mechatronic systems with hydropneumatic automation devices. Within the synthesis object, the electronic component was represented by the control algorithm of the system’s actuating devices. The authors consider efficient and competitive technical solutions aimed at introducing new functions and increasing the level of automation in accordance with Industry 4.0 trends. An abstract model of a mechatronic system element, referred to as a macromodule, is proposed. The advantages of autonomous configuration and testing of macromodules are demonstrated, showing a significant reduction in development time and simplification of system design. The consequences of deep fragmentation of a mechatronic system are analysed, and the relationship between module complexity and control architecture is established. The results of the control model analysis demonstrate that excessive decomposition leads to the emergence of a separate hierarchical level responsible for coordinating interactions among simplified elements. It is substantiated that the division of a system into macromodules cannot be arbitrary; rather, it is strictly constrained by the physical properties of the equipment and the functions of the design object. The paper proposes evaluating the quality of decomposition not by the number of elements but by the practical reduction in system development time before and after scaling. The optimal size of macromodules is unique to each specific project because it is determined by the functional and physical content of the components. Effective decomposition achieves a balance between macromodule autonomy and the complexity of coordination links, thereby enabling the rapid implementation of sophisticated automation systems

Keywords

control architecture; macro-module; hydraulic devices; functional decomposition; logical control; modular synthesis; control architecture; Industry 4.0

Suggested citation
Hanpantsurova, O., Hubarev, O., Bielikov, K., Murashchenko, A., & Levchenko, O. (2026). Synthesis and decomposition of a mechatronic system with hydro-pneumatic automation devices. Machinery & Energetics, 17(2), 65-77. https://doi.org/10.31548/machinery/2.2026.5
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