HWPA Program Gateway into Model-Based Design of Mechatronic Systems

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Slide 1 FLUIDON at EHTC 2011

© 2011 FLUIDON

COMPETENCE IN FLUID POWER SYSTEMS SIMULATION

KOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEME

DSHplus

a HWPA Program Gateway

into Model-Based Design of

Mechatronic Systems

Dr. Heiko Baum

FLUIDON GmbH

2011 European HyperWorks Technology Conference




© 2011 FLUIDON

Content

Model Based Design of Mechatronic Systems 1

Application field for DSHplus at a Model Based Design 2

DSHplus - a HWPA Program Gateway into Model-Based Design 3

Summary 4




© 2011 FLUIDON

start product

version A

The Mechatronic Product Development Process according to VDI 2206

refinement of the

specification

... ... ... ... ... ...

product version B

System integration

Model development and analysis

Domain specific design

System design

Feature verification

• The mechatronic product

development process can be

considered as a series of interlocked

V-cycles

• The development of a virtual prototype (a simulation model)

can be one of the innermost of these V-cycles




© 2011 FLUIDON

The Mechatronic Product Development from a Product Point of View

=

Discrete Description

Rigid body

Joining elements

Coordinate systems

Liquids

Hydrolic elements

Compressor

Cylinder

…

Control elements

Voltage sources

Semiconductors

Sensors

…

Circuits

P, D, I Elements

Logical elements

…

• Realizing natural and logical mappings between

disciplinary product structure is a challenge to

consider.

• “… an approach for the integration of different

product models is therefore also fundamental.”

• Model-Based Design is one technique that supports

this development procedure

Source:

Dr. Alain Pfouga

PROSTEP AG

Geometry

Assembly

structure

Feature

Materials




© 2011 FLUIDON

Introduction to 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.

• MDB is used in many motion control, industrial equipment, aerospace, and

automotive applications, where it is applied in designing embedded software.

• MBD provides an efficient approach for establishing a common framework for

communication throughout the design process while supporting the development

cycle ("V" diagram).

• In Model-based design of control systems, development is manifested in these

four steps:

1. modeling a plant,

2. analyzing and synthesizing a controller for the plant

3. simulating the plant and controller

4. integrating all these phases by deploying the controller.

Source: http://en.wikipedia.org/wiki/Model-based_design




© 2011 FLUIDON

Validation

Verification

Rapid Prototyping

Simulation

Method

Example of a V-cycle

for Controller Development

Simulation Methods used for Model-Based Design

„Model-

in-the-Loop“

„Software-

in-the-Loop“

„Hardware-

in-the-Loop“

System

Specification

Function

Specification

Reviews

Program

Specification

Module

Design

Program

Coding

Module Test

Integration

Test

Function

Test

Final Test

Virtual

Proto Type

• 1D system simulation tools such as DSHplus are the mainstream technology to

model and analyze multi-domain, intelligent systems and predict their multi-

disciplinary performance in a Model-Based Design development process.




© 2011 FLUIDON

Content




Summary 4




© 2011 FLUIDON

What is DSHplus ?

DSHplus that is 1D-Simulation for Fluid-Power Mechantronic Systems

DSHplus - comprehensive virtual engineering

functionality in just one simulation tool

Graphic based modeling concept for

dynamic, nonlinear 1D-system simulation

Standard model definitions base on

manufactures data sheets information

Equation based physical model descriptions

for high quality simulations

Intuitive component editor for open

mathematical model description in C++




© 2011 FLUIDON

• With over 10 years experience in co-simulation and mechatronic design

FLUIDON is one of the pioneers in the industrial usage of this technology

How flexible is DSHplus in the context of Mechatronic System Simulation?

1996 1998 2006 2002 2003 2004 2005

FLUIDON

joints MATLAB

partner program

2000 1994 2007

Equation

export

to ACSL

Air-Spring

co-simulation

with SIMPACK

Equation

export

to ADAMS

Co-simulation

with MOBILE

Equation

export

to Simulink

Equation

export

to Opal-RT

Program launch

directly with open

source code

model description Launch of

DSHplus-STC

2008 2009

FLUIDON joints

2011

Current Target List:

-Generic PC Export

-Generic Linux Export

-Simulink

-Altair MotionSolve

-ADAMS

-DADS (PC, SGI)

-SIMPACK

-Virtual.Lab

ADAMS Plug-In for DSHplus-STC

DSHplus-STC

for KIVA

combustion

simulation

DSHplus-STC

for SIEMENS

WinAC Soft PLC DSHplus- Interface

with

DSH program

roots at RWTH

Aachen

1973




© 2011 FLUIDON

DSHplus

plant model

int Regleralgorithmus (...)

{

...

}

Manually programmed

controller source code

µC - simulator

Import Co-Simulation

Co-Simulation

DSHplus Applications for Mil-, SiL- and HiL-Simulation

Model-in-the-loop (MIL)

available interface

Intended or possible interface

Software-in-the-Loop (SiL) covered by DSHplus-STC

NON-RT Hardware-in-the-Loop (HiL)

Export with RTW

S-Function

Export with

DSHplus RTW Target

Import

Code

export

Stand-alone simulation

in DSHplus

DSHplus

plant model

DSHplus

plant model

DSHplus

HIL-Box

Link via

passive

I/O-interface

electronics

Customized

interface

µ-controller based real-time system




© 2011 FLUIDON

Available solution

DSHplus

plant model

DSHplus-RT

export PC based RT-

Linux system

DSHplus

plant model

DSHplus-RT

Export

Export with RTW

and/or Target-Link

Special

RT-Hardware

DSHplus-RT – Real Time Fluid Power Models

DSHplus-RT

export

RT Hardware-in-the-Loop (HiL)

Available solution

µ-Controller hardware

DSHplus

HIL-Box

Link via

passive

I/O-interface

electronics

available interface

Intended or possible interface




© 2011 FLUIDON

Content




Summary 4




© 2011 FLUIDON

HyperGraph Result Analysis

DSHplus a HWPA Program Gateway into Model-Based Design

DSHplus

1D System Simulation

MotionSolve Multi-Body co-simulation

of mechatronic

systems

flexibility of components

RADIOSS Finite Element

data for stress analysis

CAE supported design level

RT export or

PLCI interface

PLC / HMI Controls

PLM supported design level

EPLAN Project Documentation

CAD Geometries for Models

project data exchange

HyperStudy Parameter Optimization

Measurements Validation

validation level




© 2011 FLUIDON

Picture source:

Hans-Dieter Kochs

Faculty of Engineering - Institute for Information Technology

University of Duisburg-Essen / Germany

subsystem-

level

joint

i+1

attachment

i

cantilever i

joint

i AS2

G UM2

G

Z2

Mechanical components

and flexible bodies

MotionSolve & DSHplus-STC

DSHplus 1D System Model

PLC / HMI & DSHplus-PLCI

unit

(arm segment)

AR Computer / PLC / HMI

hydraulic actuator (cylinder) i

D K P W O8

Sensors and actuators

DSHplus - HWPA Integration from a Product Point of View




© 2011 FLUIDON

DSHplus-PLCI – Programmable Logic Controller Interface

Control cabinet E/A-Field bus node

Virtual plant model in DSHplus Soft PLC Visualization

Server

Hardware interface




© 2011 FLUIDON

Advancements in DSHplus - HyperWorks Integration

• MotionView Integration • Macro support for DSHplus

model import into MotionView

• DSHplus labels are now used within MotionView

• The new interface handles 1 to 99 in- and out-put values

• Collaboration with HyperGraph • DSHplus

stores result data in

HyperWorks ABF-file format

• Cooperation with HyperStudy • In a background simulation mode DSHplus

models can be controlled by HyperStudy

• Possible applications are parameter optimization or a sensitivity analysis




© 2011 FLUIDON

DSHplus and HyperStudy: Simple example of a hydraulic cylinder drive Task: Controller parameter optimization of a hydraulic cylinder drive

In order to reach the desired cylinder position as quickly as possible, the controller

parameters KP, KI, and KD have to be optimized.




© 2011 FLUIDON

DSHplus and HyperStudy: Study setup

The template is created from the standard DSHplus

parameter file.

The parameter file includes all design parameters

of the model, the initial values of state variables

and process variables, and the solver parameters.

Create design variables

Of interest for the DSHplus

HyperStudy demo project are

the controller parameters KP,

KI, and KD.




© 2011 FLUIDON

Development of the

quality value during

the optimization study.

DSHplus and HyperStudy: Post processing with HyperStudy

Development of the

controller parameters during

the optimization study.




© 2011 FLUIDON

Result evaluation in DSHplus

Simple example of a hydraulic cylinder drive.

Dotted lines are initial results. Thick lines are results after optimization.




© 2011 FLUIDON

Content




Summary 4




© 2011 FLUIDON

Summary

• Model-Based Design is a technique that supports a CAx-driven

mechatronic development procedure

• 1D system simulation tools, such as DSHplus

, are the mainstream

technology to generate plant models, that are required for the

Model-Based Design approach

• For other HyperWorks products the various DSHplus

interfaces

provide proven gateways into the Model-Based Design

of mechatronic products

• Get more insight into the DSHplus

capabilities at FLUIDON's EHTC

booth

HWPA Program Gateway into Model-Based Design of Mechatronic Systems

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