simulation data management for the interdisciplinary … · simulation data management for the...

© Siemens AG 2010. All Rights Reserved.

Simulation Data Management for the Interdisciplinary Development of Drive Systems

NAFEMS 2010

Hans-Georg Köpken, Siemens AGIndustry Sector, I DT MC R&D 2

© Siemens AG 2010. All Rights Reserved.Industry Sector 2010-11-05


OverviewIntroduction to Electric Drive SystemsSimulation in the PLM ProcessSales Support with System SimulationValidating Control Software/Motor CombinationsConclusion


Industry SectorDrive Technologies

Drive Technologies portfolio

Com

plet

e dr

ive

unit

Current priorities in the industry

Energy efficiency

Productivity

Reliability

Small Medium

0.12 KW 120 MW

2,3 kNm

0.12 KW

4.700 kNm

100 MW

Large

Drives

Motors

Gears

CNC and motion control systems


Machine tools Production machines

Cranes General Motion Control

Motion Control Systems

Automation solutions for many industries


Simulation in the PLM Process

Electronics

200 257 260

ASIC

Firmware

Mechanics

Lab Samples

Design 270

passed

Systemtest

Typetest

Typetest

other components

Motor Lab Samples

215 Build Lab Samples Typetest Systemtest

local

inter-disciplinary

system level

ConceptDesign

inCAx

PhysicalPrototype

Verificationof

functionalfeatures

Verificationof

functionalfeatures

VirtualProto-type

Verificationof

functionalfeatures

VirtualProto-type

Series

ΔtsimΔtsim

Δtreal > ΔtsimΔtreal > Δtsim

time & costs

FocusReduce time-to-marketMinimize number of HW prototypesShorten test times

Focusimprove system level quality

Enable ad-hoc simulations Allow designers to perform simulations themselves


Simulation Data Management as a Backbone for a Seamless Simulation Workflow

Mechanicaldesign

Electronicssimulation

Fluid/thermosimulation

Magneticssimulation

Controlssimulation

Mechanicssimulation

3Dwork piecesimulation

Digitaltestbench

Augmentedreality

Mat. flow & log.

simulationVirtualcommissioning

Digitalfactory

Shop floorlayout

Costsimulation

Teamcenter


System Simulation for Customer Specific Configurations

WR3Pkt

A&D

WR3Pkt1

ERS

ERS1

QN3Ph

A&D

QN3Ph1C1

C2

TRYy0

A&D

TRYy01LS3Ph

A&D

LS3Ph2

HSE

WR3Pkt

A&D

WR3Pkt2

SYM3ED

A&DSYM3ED1

E1

CustomerLineConnection

CustomerLoad


Automated Workflow Supports Sales Requirements


Benefits of Simulation Workflow Automation and Data Management for Sales Support

Benefits by use of simulation

Benefits by application of SDMCurrent situation

Strong simulation support with large drives proposals (many complex proposals per month)Customers demand for complete analysis of drive impact on grid even in the proposal stageStrong needs for precise and sustainable analysis results to avoid unexpected additional cost in realization phase

Reduction of runtime of proposals leads to

shorter run timesmore simulations for higher accuracy

Improved quality → lower change/rework cost Increasing hit rate of proposals → higher volumeCovering of more specifications by more proposals → higher volume

Simulation process time reduction for new simulation with existing model in the phases:

Product parameter collectionPost processingData management

For re-runs of existing simulations further time reduction in:

Model selection


Adding Value with Simulation

Capability

Capacity

Tc4Sim SPM

Time

Money

Quality

Relieve Experts

SDM: Simulation Data ManagementSPM: Simulation Process Management

X enables Y

SDM

Moremethods & models

Simulation by non-experts

Moresimulation

Less prototypes and tests

More knowledge

Robustness of design

Increase MTBF

Increase first pass yield

CAE Tools

Increase parallelization of development

Increase DurabilityVirtual

validation of all variants

More orders

Increase quality and increase proposal-to-order conversion rate


Virtual testing of control SW working with the entire spread of motor characteristics under realistic loads

Validating Control Software/Motor Combinations

Motor

mod_rst

vol_rst

vol_dc

powerpwm

for

mode

pos

pimech

vol

pos

for

cur

piactor

mode

ref

pos

cur_rst

vol_dc

mod_rst

controldig

[0;1;-1]* u

Gain1

u *[0;1;-1]

[extfor_x_t extfor_x]

[ref_x_t ref_x]

mode_x

mechmode_x

for_ext

S120 control algorithm

Referenzmodell fehlt!

1vol_dq

Selector5

Selector1

Look-UpTable1

Look-UpTable

1s

Integrator

Kpcur

Gain2

KIcur

Gain1

Kpcur

0

1

2cur

1cur_ref

Test casesS120 settingsloadcycles

Resultstracestablespass/fail

RequirementsUse case

analyze motor with Ansys EMAGstore results in Teamcenterconnect Matlab/Simulink toTeamcentermanage Simulations inTeamcenterlink Simulation to Product Datalink Simulation to Use Casesintegrate simulation into the PLM

How do we meet the target ?

Matlab/Simulink

Ansys EMAG

Matlab/Simulink

Target


Representing System Simulation in Teamcenter

Teamcenter PLMXML Engine

TC - MatlabInterface

TeamcenterPLMXML Engine

TeamcenterMathlabInterface


Relating Simulation Revision to Product Revision


Benefits of Simulation Workflow Automation and Data Management for System Testing

Benefits by use of simulation

Benefits by application of SDMCurrent situation

In principle system test has to cover all combinations of motors, drives and SW (e.g. 1PH8: 2x 22 variants; S120: ~6 variants)Many HW prototypes have to be tested for new productsStrong need to reduce time-to-market while maintaining product quality

Performing more simulations due to easier access to CAE data by test personnelReducing time-to-market and additional cost after delivery due to higher quality level of design resultsMinimizing number of HW prototypesReducing test times due to smaller number of real tests required

Reduction of effort to configure simulation models for virtual system testing by

Correlation of CAE and product dataFast access to model parametersEasy management of CAE data (e.g. models, results)

Performing script controlled simulation of large combination matrixes

Motor

mod_rst

vol_rst

vol_dc

powerpwm

for

mode

pos

pimech

vol

pos

for

cur

piactor

mode

ref

pos

cur_rst

vol_dc

mod_rst

controldig

[0;1;-1]* u

Gain1

u *[0;1;-1]


[ref_x_t ref_x]

mode_x

mechmode_x

for_ext

mod_rst

vol_rst

vol_dc

powerpwm

for

mode

pos

pimech

vol

pos

for

cur

piactor

mode

ref

pos

cur_rst

vol_dc

mod_rst

controldig

[0;1;-1]* u

Gain1

u *[0;1;-1]


[ref_x_t ref_x]

mode_x

mechmode_x

for_ext

S120 control algorithm

Referenzmodell fehlt!

1

vol_dq

Selector5

Selector1

Look-UpTable1

Look-UpTable

1s

Integrator

Kpcur

Gain2

KIcur

Gain1

Kpcur

0

1

2cur

1cur_ref

Test cases- S120 settings- load- cycles

Results- traces- tables- pass/fail

RequirementsUse case

Matlab/Simulink

Ansys EMAG

Matlab/Simulink


Conclusion

Electric drive systems address a wide range of applicationsInterdisciplinary optimization leads to higher energy efficiency, productivity and reliabilitySimulation throughout the PLM process reduces time to market while maintaining high product qualityAn automated simulation workflow supports sales for large customer specific drive systemsThe connection of a system simulation tool to the PLM system enables the validation of many combinations of control software and motors

simulation data management for the interdisciplinary … · simulation data management for the...

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