global sales conference 2010

Global Sales Conference 2010

Hardware in the Loop Simulation (HIL)Tom Lee VP Applications Engineering, Paul Goossens Director Applications Engineering

© 2010 Maplesoft, a division of Waterloo Maple Inc.

Without HIL simulation ...

... people can die ...


Key points• HIL testing is a critical process in industry

– Saves money, time, design better products faster

• With MapleSim ...– Dramatically reduce time for HIL development– Fastest real-time execution time for the HIL “plant” – Infeasible systems become feasible– More efficient analysis and design

• Without MapleSim ...– Extremely long development time– Low-fidelity models approximations, guessing

Increasing complexity

Measurements

• Modern cars, aircraft, military equipment, power equipment, and more are controlled by computers

System(plant)

Computer(controller)

Role of simulation

• Simulation prevents costly rework on real systems• Virtually test different cases before building• Software-only simulation is not enough

Numerical Integrator

PlantModel

ControllerModel

Solves the model equations

HIL Variation 1

• Hardware controller + Software plant• Also called MIL (Model in the Loop)


SoftwarePlant Model

Real controller

HIL Simulation

• Test real control strategies witha realistic software model of plant

• Accurate, safe, cost-effective, fast

Software plantmodel

HIL Variation 2

• Software controller + Hardware plant• Also called SIL (Software in the Loop)


HIL Simulation

• Experimental test rig for plant• Virtual analysis of system prior to

full prototype• Better for advanced analysis

Plant test rigSoftwarecontroller

Realtimehardwareplatform

Example toolchain – Plant modeling

Plantmodel

equations

RT Plantmodelcode

Realtimesoftwareplatform

HILVariation

1

Plantmodel

SimulinkSimScape+

DymolaAMESim

Simplorer SimScape+Manual

LabVIEW RTVeristand

Simulink RTWQuanser QUARC

NI PXIDSpace

XPC TargetSpeedgoat

SensorsI/OEtc.

Controllerdesign

RealtimeControllerhardware

Embeddedcode-gensoftware

Simulink RTW-E ETAS ASCET

Simulink/MATLAB BoschMototron


The MapleSim value proposition

Controllerdesign




HILVariation

1

LabVIEW RTVeristand

Simulink RTWQuanser QUARC

NI PXIDSpace

XPC TargetSpeedgoat

Simulink RTW-E ASCET

Simulink/MATLAB

SensorsI/OEtc.

BoschMototron

Plant model equationsPlant model

RT Plant model code

From months to days1

Fast RT: Infeasible Feasible2

Where is CAD?


Plantmodel

equations

RT Plantmodelcode


HILVariation

1

Plantmodel

Controllerdesign



CADDesign

improvement

CADManufacture

CADconcurrent design activities (new opportunities)

HIL markets

Automotive• Vehicle dynamics• Powertrain• Climate control• NVH

Aero/defence• Guidance,

navigation• UAV robotics• Simulators• Command and

control

Power• Wind turbines• New generation

power sources

Space• Space vehicle control• Guidance and nav• Space robotics

Medical• Intelligent

prosthetics• Artificial

organs

Futureopportunities

Global Sales Conference 2010

HIL DemonstrationsTom Lee VP Applications Engineering, Paul Goossens Director Applications Engineering

Derry Crymble, Quanser Consulting


The demonstrationsHIL Variation 1• “Full vehicle” plant model

– Vehicle stability control– MapleSim for multibody plant model– Very fast realtime performance– Mototron controller, NI Veristand

• Effective demonstration to automotive OEMs. Very difficult to achieve with other tools.

HIL Variation 2• Quanser 3 DOF helicopter test rig

– High-fidelity mechatronics model– MapleSim for physical modeling and

controller design– Quanser QUARC + NI realtime

hardware platform

• Ideal platform for research and education in universities

Host PC with…•MapleSim•Full-chassis model•Connectivity Toolbox•LabVIEW•Simulation Module

PXI Chassis•LabVIEW/RT Controller Module

Digital Out

CAN bus Interface

MotoTronStabilityController

Example: Stability Control Test System

Control Output Display

Full vehicle Model

Tire Model

High fidelity full vehicle physical models are rarely deployed for HIL • Difficult to develop• Too slow in realtime

Engineers are forced tomake approximationsand guesses for any HIL

MapleSim offers a better way

With Stability ControllerWithout Stability Controller

63ms cycle time with no loss of fidelity

HIL with full-vehicle physical model becomes feasible!


Demo 1: Stability control

Plantmodel

equations

RT Plantmodelcode


Plantmodel

Controllerdesign



$4595$1895

$995$2995

$10480

Mechatronics research and design

Plant test rigSoftwarecontroller

Mechatronics are at the heart of the most innovative technologies• Computers intelligently control the

movement of complex machines

Advanced controllers are required for demanding mechatronic applications• Impossible to implement without

manual derivation and linearization• Time consuming, error-prone,

natural limitations

MapleSim for controller design• MapleSim plant model

development• MapleSim Control Systems TB

– Standard LQR– Kalman filter– Path control

• Models validated with test rig

• MapleSim advantages– Clean separation between plant

modeling and linearization for control design

– Full access to original non-linear DEs– Parameter studies: eigenvalues,

sensitivity, Monte Carlo


Demo 2: 3 DOF helicopter test rig

Plantmodel

equations

RT Plantmodelcode


Plantmodel

Controllerdesign




Key points• HIL testing is a critical process in industry

– Saves money, time, design better products faster

• With MapleSim ...– Dramatically reduce time for HIL development– Fastest real-time execution time for the HIL “plant” – Infeasible systems become feasible– More efficient analysis and design

• Without MapleSim ...– Extremely long development time– Low-fidelity models approximations, guessing

global sales conference 2010

Documents

vehicle plant

hil plant infeasible

mil model

model equationshil variation

sil software

designwithout maplesim

demonstrationshil variation

division of waterloo