Model-Based Design for Automation Systems · Model-Based Design for Automation Systems ... RESEARCH...

1© 2012 The MathWorks, Inc.

Model-Based Design for Automation Systems

November 2012

Design and test your designs using simulation and automatically implement it on Allen-Bradley PLCs

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Mechatronic Systems

Robotic arms

Web applications– Printing presses– Steel rolling mills

Machines– Packaging machines

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Mechatronics integrates mechanical, electronic, control, and embedded software systems

Mechatronics

Mechanics Electronics

SoftwareControls

“Mechatronics is really all about design of any physical system, where you integrate controls, electronics, and computers from the very start of the design process.”

Prof. Kevin CraigMechanical Engineering, Marquette University

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Challenges of Designing Mechatronics

Source: System Design: New Product Development for Mechatronics, January 2008, Aberdeen Group

Problems uncovered

late

Multi-discipline

complexity

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As errors propagate through a project they become more expensive to fix in later phases

Requirements Design Coding Integration & Testing

Relative cost to fix an error

Project phase where error is fixed

Type of error: - requirements- design- coding

Source: Return on Investment for Independent Verification & Validation, NASA, 2004

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Engineers struggle to integrate multiple disciplines into mechatronic systems

Development challenges Optimizing the system across multiple

technical disciplines Detecting integration problems before

prototyping electromechanical systems

Integrating more software to provide improved features and performance

Mechatronics

Mechanics Electronics

SoftwareControls

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manroland Develops High-Precision Commercial Printing Press Controller

http://www.mathworks.com/company/user_stories/manroland-Develops-High-Precision-Commercial-Printing-Press-Controller.html

Video:

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Model-Based DesignDesign and test using simulation

DESIGN

RESEARCH REQUIREMENTS Modeled Physical Behavior of paper web

Environmental Models

Control Algorithms

Mechanical Electrical

Supervisory Logic

Designed controller and implemented it

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REAL-TIME TESTING

DESIGN

Control Algorithms

Supervisory Logic

Environmental Models

Mechanical Electrical

RESEARCH REQUIREMENTS

MCU DSP FPGA ASIC

Structured Text

VHDL, VerilogC, C++

PLC

Control Algorithms

Supervisory Logic

Model-Based DesignTest and validate in real-time

Modeled Physical Behavior of paper web

Designed controller and implemented it

Tested the controller in real-time on the press

10INTEGRATION

IMPLEMENTATION

TEST & VER

IFICATIO

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DESIGN

Control Algorithms

Supervisory Logic

Environmental Models

Mechanical Electrical

RESEARCH REQUIREMENTS

MCU DSP FPGA ASIC

Structured Text

VHDL, VerilogC, C++

PLC

Control Algorithms

Supervisory Logic

Model-Based DesignImplement embedded software

Modeled Physical Behavior of paper web

Designed controller and implemented it

Tested the controller in real-time on the press

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Manroland

Overcame 3 challenges:– Modeled Physical Behavior of paper web– Designed controller and implemented it– Tested the controller in real-time on the press

Results:– Shortened development time by 50 percent– Ensured software for customers are error free– Saved time and money

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Problem to Solve

Logic for luggage conveyor belt at an airport

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Problem to Solve

Simplistic representation

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Today’s Workflow

RSLogixLD, FB, SFC, STManual Programming

Control Algorithms

Code compiled to

PLC

Validation is done using hardware

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Model-Based Design WorkflowDesign and test using simulation

Simulink & Stateflow

LD, FB, SFC, STManual Programming

Code compiled to

PLC

RSLogix

Control Algorithms

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Model-Based Design WorkflowTest and validate in real-time

Simulink & Stateflow

LD, FB, SFC, ST

Control Algorithms

Manual Programming

Code compiled to

PLC

Structured Text

Simulink PLC Coder

RSLogix

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Model-Based Design WorkflowTest and validate in real-time

Simulink & Stateflow

LD, FB, SFC, ST

Control Algorithms

Manual Programming

Code compiled to

PLC

Structured Text

ANSIC-Code

Simulink Coder

Hardware-in-the-Loop

Simulink PLC Coder

RSLogix

Real-TimeSystem

Machine Model

Validation is done using real-time

simulation

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Model-Based Design WorkflowImplement embedded software

Simulink & Stateflow

LD, FB, SFC, ST

Control Algorithms

Manual Programming

Code compiled to

PLC

Structured Text

Simulink PLC Coder

RSLogix

Machine Model

Final validation is done using hardware