FunctionalDMU:

towards experiencing behavior of mechatronic systems in DMU

Dr.-Ing. André StorkFraunhofer Institut für Graphische Datenverarbeitung IGD

Fraunhoferstraße 5

64283 Darmstadt

Tel.: +49 (0) 6151 155 – 469

Fax.: +49 (0) 6151 155 – 139

E-Mail: andre.stork@igd.fraunhofer.de

http://www.igd.fraunhofer.de

Video

What is going on behind the scenes?

FunctionalDMU run-time environment

Mastersimulator

Wrapper

Rhapsody

Wrapper

Dymola Simpack

Wrapper

DMU

In DMU multi-CAD data is typically converted into one representation …

… to provide functionality such as …

detecting collisions

checking possibility to assemble / disassemble parts

measuring

annotating

© Siemens AG

FDMU

In addition to geometry models

behavior models of the mechatronic domains:

software

electronics

mechanics

behavior models in diffe-

rent modelling languagesDMU geometry models

integration

So the question arises:

What is the equivalent for geometric integration with respect to behavior

models?

Approaches

mapping of the heterogeneous behavior models into one standard?

no existing standard with full representative power

execution of such an integrated behavior model in a ‚super simulator‘?

Co-simulation matrix

>1=1

integrating

different

simulators

„classic“

simulation=1

co-simulationintegration of

models>1

number of

modeling tools

number of

simulation algorithms

(Prof. Dr.-Ing. Marcus Geimer, Universität Karlsruhe)

We decided to go for a

flexible

open

extensible

vendor-independent

co-simulation framework:

the FDMU framework

Bild

Wrapper Wrapper Wrapper

SimpackRhapsody Dymola

Mastersimulator

We want to use the native behavior models …

as unchanged as possible

but some small adaptations are needed

in / out values

parameters to be changed

native model connector communication-enabled model

FDMU connector library for

Modelica (Dymola)

MAST (Saber)

MATLAB/Simulink

Connectors to map native syntax to standardized syntax

Which standards?

SysML

Modelica

VHDL-AMS

SysML (Systems Modeling Language)

Modeling language for systems engineering

XML base

UML/XML tools exist to create and process SysML

Requirements and systems modeling

Controller (SysML)Unified description

of interface

variables of the

behavior model

Mapping of internal interfaces to a standardized form

Encapsulation of behavior models (example: controller)

native interface of

behavior model

Controller (native)

‚Glueing‘ functional building blocks together to create

a simulation model

and adding geometry models to embed them in an OO way

up

down

f

s

U

I

Next: the simulators

Spice

Dymola

Rhapsody

simulators

DymolaRhapsody SimpackSimpackRhapsody Dymolasimulators

They are as heterogeneous as the behavior models with respect to:

programming languages and APIs

communication schemes

platforms

How to cope with their heterogeniety?

Wrapper Wrapper Wrapper

SimpackRhapsody Dymolasimulators

Solution strategy: Wrapper

controlling the simulator

communicating and mapping data

standardizing interfaces

Wrapper

Rhapsody

Wrapper Wrapper

SimpackDymola

Which information does a wrapper receive?

simulators

behavior models

interface

description

Wrapper

different communication strategies

based on configuration of connectors

Wrapper

simulator control commands, e.g.

configure

initialize

run

start

suspend

resume

stop

terminate

Wrapper

Simulator

control

commands

data

exchange

Wrapper Wrapper Wrapper

SimpackRhapsody Dymola

Mastersimulator

What else do we need?

a master for communication and co-ordination

Which information does the Mastersimulator need?

behavior models

simulator

interface

description

system

behavior model

Mastersimulator

TransferHandler

adapt data communication

Mastersimulator

TransferHandler

support different protocols

constant data flow

constant data flow with upsampling

constant data flow with downsampling

event based input with sampling

event based input /output

To complete the FDMU framework …

Wrapper Wrapper Wrapper

SimpackRhapsody Dymola

Mastersimulator

behavior models

simulator

interface

description

system

behavior model

interactive visualization system behavior model

and geometry models

Video:

SW simulation

with Rhapsody

Wrapper Wrapper Wrapper

SimpackRhapsody Dymola

Mastersimulator

Integration of FE analysis: E-motor example

Demand to integrate and possible couple with

finite element analysis

Challenge: FE known to be slow

A coupling scenario for an E-motor

E-motor with electronic control

Electronics on a PCB mounted at

the backside of the E-motor

The electric behavior of the parts

on the PCB depends on the thermal

conditions (heat)

-> thermo-dynamic simulation

warming of the PCB

(transistors, controller)

heat sources

Integration of FE analysis: E-motor example

General questions that may arise in the design process:

How warm will the transistors get?

What is the contribution of the engine to the temperature of the transistors?

Does the warming have effects on other elements, e.g. the controller?

What kind of cooling to attach to the transistors?

What happens if the distance between motor and PCB is changed?

Etc.

Integration of FE analysis: E-motor example

Physical model

controller

software

electronics

thermo-dynamics

influence

on behavior

mechanics

load

motor (converter)

power loss

time

signaltime

signal

power loss

Integration of FE analysis: E-motor example

Physically-motivated splitting into partial models

TE1: temperature transistor 1

TE2: temperature transistor 2

TM: temperature motor winding

PE1: power loss transistor 1

PE2: power loss transistor 2

PM: power loss motor

Integration of FE analysis: E-motor example

We started to model the thermal behavior within ANSYS

approx. 50.000 nodes (volume mesh)

simulation time in the range of hours

way too slow for interactive simulation

Integration of FE analysis: E-motor example

Reduced model

Model order reduction

reduced systems of equations:

50.00 nodes > 100 nodes

Execution time

almost interactive

little impact on accuracy

(we have not measured

precision yet)

Integration of FE analysis: E-motor example

Mapping of the behavior models to simulators

SaberFeed forward control

- Matlab

- direct user input

Dymosim Dymosim

input file

Reduced thermo-dyn.

Model (Dymosim)

E-motor example

Video

Other applications

Achievements

FunctionalDMU framework

open, extensible, flexible

distributed, service-oriented architecture

unique combination of features

solvers

methodology

visualization features

Wrappers for

Rhapsody, SimPack, Saber, Dymola (Modelica), Matlab/Simulink, …

Methodology for modelling, integrating and running FDMU simulations

Proof-of-concept scenarios

FDMU

visualization

Mastersimulator

Dymola

Simulink

Rhapsody

FDMU-Editor

SimPackSimulink, Visu

Dymola, Mastersim.

FDMU

service

s

Dresden

Berlin

Darmstadt

Saber

Benefits

end-user point of view

earlier multi-domain problem detection

visual insights and communication

integrated 2D/3D interactive visualization

shorter set-up of mechatronic simulations

re-use of behavior models (FBB) in different configurations

no transformation of models

running behavior models as services (without forwarding know-how)

simulation tool provider point of view

re-usable components for simulation coupling and

integrated visualisation

Outlook

Wish list / research issues

fast and flexible simulations, esp. FEM

coupling-in more different FE domains

taking environment conditions and tolerances into account

real-time requirements

‚informed‘ CAD models

data management -> MechatronicPLM

optimization

organizational aspects

IP issues

LTP of behavior models

Das Produkt muss vollständig als Gesamtsystem simulierbar sein.

(Bernd Ehrenberg, Daimler AG)

Contact and consortium

www.functionalDMU.org

for slides and videos see: