Produceer met minder energie model based design for ee - wim symens

More efficient machines through model based design

Wim Symens

Seminar « Produceer met minder energie »November 8, 2011, Ghent

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Flanders’ Mechatronics Technology Centre

+ FMTC vzw: Non-profit organization Started in 2003 In 2010: +3.7 M€ income with +30 people Membership for Flemish companies Business outside Flanders as well

+ Our market: Machine building and mechatronic component industry

+ Our competence: Mechatronics= integration of electronics and software in mechanical systemsAnd this way improve the performance/cost ratio of machines

+ Our business: Application oriented research projects


Outline

+ Motivation and needs

+ Model based design approach

+ Example: badminton robot

+ Do it all on your own?

+ Summary and conclusions


Scarcity of energy

+ Societal awareness Consider energetic impact of the things you are doing Be ‘green’ Increasingly stringent legislation

+ Economic angle Increasing prices for energy Contribution of cost of consumed energy during use phase of machine in

Total Cost of Ownership increases

+ As a results Need to reduce energetic footprint machines Energy efficiency (during use phase) becomes a differentiating

performance characteristic

Motivation and needs


Energy Consumption Flanders 2007

19%

53%

3%

16%9%

HouseholdsIndustryAgricultureTransportTrade & Services

Totaal = 1197 PJ (1015J)

OtherIndustry38,4%

1% saving= 2,4 PJ/a= 677 GWh/a= 100,7 million €/a= 35 kton CO2/a

Source: MIRA

Chemistry61,6%

Energy optimization in industry can result in gigantic savings



Reduce energy consumption during the use phase

+ In general Avoid useless energy consumption!

Reduce stand-by losses Use energy efficient components, e.g. energy-efficient motors

If the process generates energy, recuperate it or reuse it Braking energy Waste heat

(Use efficiently generated energy)

+ Applied to (complex) production machines Component level

Use energy efficient components However: might cause performance changes, e.g. electrical motor for dynamic

applications System level

Allows taking into account interaction between components in machine Most opportunities, but less straightforward



Outline







Model based analysis and design

+ Systematic approach necessary to realize optimized design+ Model based approach offers designers the opportunity to

quickly evaluate the impact of design changes Describe energetic behavior components mathematically Combine components Simulate machine behavior

+ Needs to be embedded in design tools for easy use Various (CAE) softwares are already used

during machine design, e.g for Strength and stiffness calculations (FE) Collision avoidance

(Extend) tools with capabilities for energetic analysis Simulate energy flows Identify the (location of) energy losses Evaluate alternatives

Model based design approach


Towards an integrated design environment

+ Describe energetic behavior of components, next to functional behavior Energy and power next to forces, displacements, etc.

+ Softwares exist that provide this functionality E.g. LMS.Amesim, Matlab/Simscape software

+ Efficient and effective visualization of models and results is crucial


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Typically iterative process

+ Unrealistic and unnecessary to model and analyze the whole the machine

+ Understand where energy is used in the machine Existing machine

Can do measurements New machine

Previous experience Stepped approach: from rough

analysis to detailed analysis Analyze various scenarios /

concepts in simulation

Identification of most relevant phenomena

Modeling and analysis of most relevant

components

Identification of losses

Improved design

Energy consumption in operation

Design for energy efficiency


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Outline






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Demonstration application

+ In 2009 FMTC decided to build machine for demonstration purposes+ Machine should include fast dynamics, wireless sensors and interaction

between different systems

+ A badminton playing robot was selected

+ First version realized following a ‘standard’ engineering design approach using off-the-shelf components Design based on maximal forces / stresses Energy considerations not taken into account Linear motor / rotary motors / cameras Time optimal controller implementation

+ First version (2009) has limited work space+ Currently a second version with full work space is being designed

Example: badminton robot

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Badminton robot: system

+ Developed by FMTC in 2009 – see movie


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First attempt to reduce energy consumption

+ Engineering reasoning of main losses Robot is mainly accelerating and decelerating masses Deceleration energy is ‘burned’ in braking resistor

+ Reduce energy consumption? Recuperate braking energy and reuse this energy

+ Capacitors added to system+ Very little reduction in energy consumption (under 5%)!

+ Why is this so?+ More systematic analysis needed!


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Goal of the analysis

+ Analyze energy consumption

+ Identify losses+ Reduce losses

+ How? Modeling of drive components:

Linear Motor 2 Rotary Motors (M1,2) Controller Mechanics

Analyze loss during operational conditions

Improve where possible

Linear Motor

Rot. Motor M1

Rot. Motor M2


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First step: focus on linear motor

+ Analysis for specific situation: robot is on left position of the linear motor guide and has to move to the right position


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Badminton robot: energetic model made

Amax

v/m/s Amax * α

Amax

Trajectory generator / PTOS parameters

• Amax : maximal acceleration, linked to the actuator limitations.

• α: acceleration discount, allows the limitation of the deceleration torque

PlantPosition

ControllerTrajectorygeneratorTarget

position


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Badminton robot: parameter tuning

+ From catalogues e.g. motor

parameters+ Experimentally

e.g. friction parameters (no information available!)


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Badminton robot: energy analysis (I)+ 1: start+ 2: overshoot+ 3: constant

velocity+ 4: stop

Region Region Region Region

Energy flow without additionnal capacitance - Simulation


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Badminton robot: energy analysis (II)

+ Energy flow analysis results Main loss can be attributed to copper losses

and friction losses+ Solution?

Reduce friction losses Other guides? Is being further investigated

Reduce copper loss ~I2; I~F; F~acceleration => reduce

acceleration!+ Current implementation

Time optimal Is it relevant to exploit spare time to improve

efficiency?+ Ad-hoc analysis

Vary parameters of PTOS algorithm Amax: maximum acceleration α: limits the deceleration torque


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Badminton robot: potential of controller improvement

+ Simulation 47% more energy needed for only 14% efficiency improvement

+ Experiment 55 % more energy needed for only 10% efficiency improvement

[s]


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Outline






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How to obtain models?

+ Available libraries + Make them yourself

Measurements Analytically

+ Ask them from third parties Suppliers! Virtual Components!

Do it all on your own?

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Virtual components

+ Co- modeling approach offers formalized framework for interacting with suppliers

+ Various formats information possible Formula’s with parameters Look-up tables Encrypted models

+ Encoding of information might be needed Functionality to be provided by CAE producer

+ Opportunity for supplier to show their products are most efficient

+ Also stimulates interaction with R&D institutions+ Similar developments in other sectors, e.g. automotive


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Example: motor models hitting mechanism badminton robot+ Initially motor-reductor selected

based on max. torque and speed+ Evaluated different alternatives

experimentally (Maxwell, Faul-haber, Smartmotor) Very low overall efficiency Initial selection was not most

efficient (+/- 5% increase of efficiency possible)

+ Discussion with suppliers on-going to provide information on energy consumption motor-reductor combination using Virtual Component concept Should allow calculation application specific energy consumption


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Outline






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More efficient machines through model based design+ Motivation: Energy reduction for environmental and economic reasons

+ Approach Take energy consumption into account on system level Follow mechatronic model based approach Interact with suppliers

+ Application on badminton robot Allowed analyzing the energy ‘sinks’

Copper losses! Friction losses!

(Ad-hoc) Energy-performance trade-off analysis Showed potential of tuning PTOS controller

+ Further actions Extend analysis capabilities, e.g. energy flow analysis dash-board instead of

bars/piecharts

Summary and conclusion

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Energy Flow Visualization

3~

Electrical En. wasteMechanical En. wasteElectrical En. StorageMechanical En. StorageElectrical useful EnergyMechanical useful Energy

Summary and conclusion

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Acknowledgement

+ The research leading to these results has received funding from the European Union Seventh Framework Program (FP7/2007-2013) under grant agreement n°247982– ESTOMAD

+ See www.estomad.org for more info

http://www.estomad.org/�

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Questions