Innovation Intelligence ® Multi-Physics with MotionSolve Rajiv Rampalli & Keshav Sundaresh, Altair
Sep 12, 2014
Innovation Intelligence®
Multi-Physics with MotionSolveRajiv Rampalli & Keshav Sundaresh, Altair
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
• Need for Multi-Physics simulations
• Case Study: Control of a Wind Turbine
• How other customers are doing Multi-Physics simulations
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Real Models Are Complex
H d li & Fl ibl & N liHydraulics & Control systems
Flexible & Non-linear components
Virtual tires & Virtual driverVirtual tires & digitized roads
Virtual driver models
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Industrial Processes Are Complex
TIRE & ROAD
POSTGMBD POSTFATIGUEMBD
DRIVER
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FEDRIVER FE
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
The Conundrum
Systems Software
Multiple DomainsDiverse Phenomena
Single DomainSingle Formulation
Many Technologies One Integrator
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Introducing MotionSolve…
• A natural environment for multi-disciplinary studies• Open architecture for coupling domains• Many different choices available for coupling
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Model Connection Methodologies
Master
System Equations
S-1 S-2 S-2
Simulator-1 Simulator-2
Co-Simulation (Sharing signals)Sharing Equations
SharedData
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Sharing Linear Models
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Sharing Linear Models: With Simulink
MatlabM ti S l MatlabSimulinkMotionSolve
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MotionSolve exchanges state matrices with Matlab/Simulink
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Sharing Linear Models: With FE
MotionViewHyperMesh MotionViewMotionSolve
HyperMeshRadioss
9MotionSolve shares data with a variety of FE codes
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Sharing Equations: via User Subroutines
ObjectCode
MotionSolveDLL
User Subroutine MotionSolvePython Script
U b ti ll t li k th i ti t MS
DLLSubroutine
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User subroutines allow users to link their own equations to MS
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Sharing Equations: via Code Export
ObjectCode
MotionMotion
“C”MotionSolve
SolveDLL
RTW“C”Code
Co simulation
SimulinkController
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Co-simulation
Native RTW code import from Simulink
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Sharing Signals: MotionSolve + Simulink
System Model
MotionSolveMotionSolvemodel
ControllerS-Function (MS ) Simulink Window
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MotionSolve is an S-Function in Simulink
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Sharing Signals: MotionSolve + DSHplus
System ModelSystem Model
Hydraulic SystemUser Block (MS ) DSHplus Window
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MotionSolve is a user block in DSHplus
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Sharing Signals: MotionSolve + Driver
System Modely
Speed Controller
Controls & Switching Signals
Gearbox ControllerFeedbackSignals
ControllerOutputs
Driver ModelVehicle Model(MS)
Steering Controller
14MotionSolve can include complex driver models via co-simulation
( )
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
• Need for Multi-Physics simulations
• Case Study: Control of a Wind Turbine
• How other customers are doing Multi-Physics simulations
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Co-simulation – Wind Turbine Emergency Stop
“Grid loss” – Sudden drop in generator torqueGrid loss Sudden drop in generator torqueReaction: Immediate blade pitching and activation of the brake disk.
E-stop event• 0-60s Ramp up to full effect, 1MW.
120.0s “Grid loss” 100-0% in 0.1s120.4s Maximum brake pressure & reversing pitch angle135.0s Pitching complete
16Mechanical system, Wind loads – lift and drag forces v/s pitch angle, Tower shadow - %ge drop of wind forces in front of the tower
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Initial Results
• Grid loss and braking generate massive t t i tirotor torque variations
• Large blade vibrations during overshoot• Blades vibrate during initial braking, causing
high frequency variations of rotor torque.
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Control Requirements
• Implement a non-linear braking pressure to:
• Reduce blade deflection
• Eliminate overshoot
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Brake controller: Blade deflection v/s Brake magnifierBrake release: Rotational speed v/s release factorLow pass filter to the braking signal – to avoid rapid vibrations
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Control Model in Simulink
Rotor Velocity C t l P t Flex SensorsRotor Velocity
Flex Sensors
Controller
Control ParameterPlant Outputs
MS Model Sensors
Plant OutputsFlex Sensors
Rotor Velocity
1z
Flex Sensors
1z
Rotor Velocity
Blade Deflection
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Co-Simulation Results
100% Rotor Speed
Simulink Rotor SpeedSimulink Rotor Speed
100% R t S d Si li k R t S d100% Rotor Speed Simulink Rotor Speed100% Rotor Speed
Simulink Rotor Speed
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Brake controller: Blade deflection v/s Brake magnifierBrake release: Rotational speed v/s release factor
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
• Need for Multi-Physics simulations
• Case Study: Control of a Wind Turbine
• How other customers are doing Multi-Physics simulations
21
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Faurecia – Glass guidance simulation
• Challenge: • Find the cable positions to meet requirements
l f f diff t bi ti fon normal forces for different combinations of friction.
• Solution: • Mechanism analysis with MotionSolve to find• Mechanism analysis with MotionSolve to find
the normal forces
• Design optimization with HyperStudy to find the optimal cable positions.
• Benefits:• An optimal design that meets all conflicting
requirements.requirements.• A fast & automated design process leading to
fewer errors & better designs.
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“Co-simulation of window regulator with MotionSolve and Matlab/Simulink gives a full mechatronics model of the system, allowing simultaneous design of both mechanism and
actuator” – Dany Desrus, Leader Product Line EE & Mechatronics, Faurecia Interior Systems
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Summary
• Real systems are complex • A full understanding of these requires multi-disciplinary
simulation• MotionSolve has an architecture that facilitates coupling• MotionSolve has an architecture that facilitates coupling
of different solvers to enable multi-disciplinary simulation• Many different options for coupling are availabley g• The simulation requirements and coupling
difficulty dictate which choice should be used.
Thank You!
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Innovation Intelligence®
Rajiv RampalliKeshav Sundaresh([email protected])