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: [email protected]
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: