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MODEL BASED DEVELOPMENT OF
MECHATRONIC SYSTEMS
Challenges and opportunities
Dr. Yuan Liu
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
The Old Development Approach
BUILD IT
PAINT IT
ADD CONTROLS
Design errors
Requirement misses
Longer development times
Higher development costs
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Today’s Products are Complex
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Today’s Products are Complex
Clever use of sensors and microprocessors
can significantly reduce energy consumption
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Based Development
Extended V-model according to Eigner et al.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Based Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Based Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Based Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Based Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Challenges
• INTEGRATING VARIOUS USER COMMUNITIES• Math, Signal-, Physical based Modeling
• ENABLING COLLABORATION• Across Departments
• OEM – Suppliers
• 1D vs. 3D Models
• Flexibility and Affordability
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Vision
DRIVING INNOVATION THROUGH SIMULATION
From Concept Design to HIL, SIL Validation
Combining Math, Signal-Based, Physical and 3D Modeling
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HVAC EXAMPLE
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Abstract: model
We have created, using the 1D modeling approach, an easy-to-use/physics-based
model in VisSim™ for managing heating, ventilating , air conditioning (HVAC) and
controls in vehicle cabins to be used as a tool to:
1. Improve the passenger comfort
2. Monitoring the electric consumption due to the A/C usage
3. Improve the concept design of HVAC Systems
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Abstract: objective
The work is about the analysis of the influence of some input variables on the
cabin temperature trend during the cooling down phase. The analysis is carried out
by using HyperStudy®.
Tem
pera
ture
time
AVERAGE AIR TEMPERATURE IN
CABIN ALONG THE SIMULATION
DESIGN VARIABLES
RESPONSES
- System parameters
- Modeling parameters
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Abstract: benefits of the study
• Better understanding of the system
• Identify the most influence parameters on the
studied responses
• If, as design variables, we consider some modeling
parameters, the knowledge of their influence on the
responses is useful during the validation phase
[°C]
• In a second phase, the analysis could be useful to
choose the most important parameters to be used
for optimizing a specific phenomenon of interest
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HVAC System Model
HVAC CABIN
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Fast exploration of the design space:
o Runs are very fast
o No need of modifying 3D CAD or CFD
grids for different configurations
• Valuable insight of the overall system performance
• Easy integration in the simulation environment of the
control algorithms
• Possibility to monitor the humidity variation inside the
cabin
• Easy managing of input parameters
• Useful in the early stages of the product development as
a design tool
Vehicle HVAC: 1D approach strength
WATER VAPOR LOADS
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Vehicle HVAC: 1D approach weakness
• Hard to analyze the flow and temperature
distribution inside the cabin taking into account the
cabin geometry
• Hard to monitor the temperature distribution along
the human body surface
• Not usually used as a verification tool where
experimental tests or CFD analysis are preferred.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Top Level Simulation Interface
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Analysis Results: Final temperature Tf
1. k_hA: The higher is the evaporator cooling capacity (k_hA) the lower is the cabin
regime temperature since temperature of the inlet air in cabin is lower.
2. Xr_envi: If the inlet air humidity to evaporator is high, a big amount of the
evaporator capacity is involved in the water vapor condensation process rather
than in the air cooling so that the temperature of the inlet flow to the cabin and
the final temperature in cabin are higher.
Δ𝑇𝑓Δ𝑇𝑓
For every simulation, all the
other factors are taken at the
middle value.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Best of the Two Worlds
1D World 3D World
Concept studies
Control design
System performance optimization
Controller implementation and testing
Generation of
parameterized 1D-models
Subsystem optimization
Co-simulation with1D
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking
COMPOSE – ACTIVATE – EMBED
Altair‘s Solution for
Model Based Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Compose
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Compose – Data Fitting
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Compose – Algorithm Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Compose – Plotting
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate – Rapid Model Building
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate – Example: Oxygen Mask
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate – Co-simulation with Multibody Dynamics
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate – Example: Optimal Gear Ratios
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Activate – Modelica Example: Heating Control
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Implementation
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Let’s Get Real
IMPLEMEN-
TATION
PLANT
MODELING
CONTROL
DESIGN
&
SIMULATION
CONCEPT REALITY
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Let’s Get Real
• Real-time a must
• Memory restrictions
• Word size restrictions
• Debugging information not easily accessible
• Need to configure A/D, D/A, CAN, PWM, I2C, ….
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Implementation Concerns
EFFICIENCY OF AUTOMATIC CODE GENERATORS
Will it fit into memory?
Will it be fast enough?
Can I read it?
SUPPORT OF ON-CHIP PERIPHERALS
PWM
Quadrature encoder
Event capture
CAN, I2C, serial, SPI, ADC, GPIO, …
ISN’T IT BETTER TO HAND-CODE?
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Code Efficiency
Autogenerated code as efficient as hand-coded
Fixed Point operations are more efficient
4.16 number: 1011.100011011001
vs
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Why Fixed Point?
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Fixed Point: Overflow Detection and AutoScaling
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Debugging in the Real World
Not Needed
• Microcontroller Debugger
• Embed Communication Interface• Plots
• Logging
• Inputs/Disturbances
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Addressing Implementation Concerns
EFFICIENCY OF AUTOMATIC CODE GENERATORS
Will it be fast enough?
Will it fit into memory?
Can I read it?
SUPPORT OF ON-CHIP PERIPHERALS
PWM
Quadrature encoder
Event capture
CAN, I2C, serial, SPI, ADC, GPIO, …
ISN’T IT BETTER TO HAND-CODE? NO
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
solidThinking Embed – Code Generation
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
ROBOTICS DEVELOPMENT
Case Study
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Robotics Development
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Robotics Development - Inverse Kinematics
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Robotics Development - Structural Optimization
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Robotics Development - Control Design
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Robotics Development – Detailed Performance Evaluation
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Best of the Two Worlds
1D World 3D World
Concept studies
Control design
System performance optimization
Controller implementation and testing
Generation of
parameterized 1D-models
Subsystem optimization
Co-simulation with 1D
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Addressing the Challenges
• INTEGRATING VARIOUS USER COMMUNITIES• Math, Signal-, Physical based Modeling
• ENABLING COLLABORATION• Across Departments
• OEM – Suppliers
• 1D vs. 3D Models
• Flexibility and Affordability
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Opportunities for Model Based Development
DRIVING INNOVATION THROUGH SIMULATION
From Concept Design to HIL, SIL Validation
Combining Math, Signal-Based, Physical and 3D Modeling
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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