Virtual Plants in Machine Automation Research and Development
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VTT-R-08126-13 RESEARCH REPORT ReUse-R Virtual plants in machine automation research and development Authors: Juha Kortelainen and Teemu Halmeaho Confidentiality: Public RESEARCH REPORT VTT-R-08126-13 1 (46) Report’s title Virtual plants in machine automation research and development Customer, contact person, address Order reference ReUse-R research project 40234/11 Tekes, Pekka Yrjölä Kyllikinportti 2, P.O. Box 69, FI-00101 Helsinki, Finland Project name Project number/Short name Prosessinhallinnan suunnitteluratkaisujen uudelleenkäyttö 75303/ReUse-R Author(s) Pages Juha Kortelainen and Teemu Halmeaho 47/– Keywords Report identification code Automation, CAD, control system, hydraulic system, model- VTT-R-08126-13 ling, multibody system, simulation Summary Computational product development has become the mainstream methodology in modern product development. The same trend has been visible also in research, where computational methods have gained popularity beside the traditional approach relying on theory and experi- mentations. The objective of this project task was to study and demonstrate a realistic ap- proach for an industrial case to reuse existing mechanical design CAD model as the starting point and the template for mechanical system simulation using multibody system simulation, and to use this MBS model as a virtual test plant for automation and control system testing. In the report, the role of system modelling and simulation in the product process is first dis- cussed and some selected technologies, such as Modelica simulation language and Functional Mock-up Interface specification, are introduced. Then different possible implementations ap- proaches for a test environment of the control and automation system of a multi-technical sys- tem are discussed. The latter part of report focuses on describing the selected approach for a demonstration system and its implementation. The demonstration showed that, at least for the selected case, modelling, simulation and post- processing of a multi-technical simulation system is relatively straightforward and fast with the selected tools. The demonstration gives some understanding of the process for implement- ing one relatively small multi-technical system but does not give realistic feedback about the challenges in industrial-scale process for virtual prototyping of large and complex systems and related data exchange and data management. Confidentiality Public Espoo 12.2.2014 Written by Reviewed by Accepted by Juha Kortelainen, Pekka Rahkola, Johannes Hyrynen, Principal Scientist Senior Scientist Technology Manager VTT’s contact address VTT Technical Research Centre of Finland, P.O. Box 1000, FI-02044 VTT, Finland Distribution (customer and VTT) Pekka Yrjölä, Tekes, 1 copy VTT, 2 copies The use of the name of the VTT Technical Research Centre of Finland (VTT) in advertising or publication in part of this report is only permissible with written authorisation from the VTT Technical Research Centre of Finland. RESEARCH REPORT VTT-R-08126-13 2 (46) Contents 1 Introduction ............................................................................................................. 3 1.1 Objectives ....................................................................................................... 3 2 About modelling and simulation in product process................................................ 4 2.1 General and application-specific approach ..................................................... 5 2.1.1 Product life-cycle data management .................................................... 6 2.2 Modelica simulation language ......................................................................... 7 2.2.1 Requirements-driven development and design, SysML and ModelicaML ........................................................................................ 10 2.3 Functional Mock-up Interface version 1.0 ..................................................... 10 2.3.1 FMI for model exchange .................................................................... 11 2.3.2 FMI for co-simulation ......................................................................... 13 2.3.3 FMI for PLM ....................................................................................... 14 2.4 New features in FMI 2.0 ................................................................................ 15 2.4.1 Merging the documents, schema and header files of Model Exchange and Co-Simulation ............................................................................. 16 2.4.2 New functionalities and flexibility of use ............................................. 17 2.4.3 Performance and reliability upgrades ................................................. 18 2.4.4 Future of FMI usage and progress of the simulation tools ................. 19 3 Virtual automation test environment ..................................................................... 19 3.1 Target system and its subsystems ................................................................ 21 3.2 Approaches for the implementation .............................................................. 23 3.2.1 CATIA V6 environment ...................................................................... 23 3.2.2 CATIA V5 and LMS Virtual.Lab Motion .............................................. 24 3.2.3 General CAD and general MBS ......................................................... 25 3.2.4 A CAD software and MatWorks Simscape/SimMechanics................. 25 4 Implementation ..................................................................................................... 26 4.1 Original approach with CATIA V6 and Modelica ........................................... 26 4.2 Complementary approach with MSC Adams and Simulink ........................... 27 4.2.1 Mechanical system of the test case ................................................... 28 4.2.2 Hydraulic and control system of the test case .................................... 33 4.2.3 Running the overall simulation model ................................................ 37 4.2.4 Simulation results ............................................................................... 38 5 Conclusions .......................................................................................................... 41 6 Summary .............................................................................................................. 41 References ................................................................................................................ 43 APPENDIX A: List of software applications supporting FMI 1.0 ................................ 45 RESEARCH REPORT VTT-R-08126-13 3 (46) 1 Introduction Computational product development, including methods such as computer-aided design (CAD), computer-aided manufacturing (CAM), and computer-aided engi- neering (CAE), has become the mainstream methodology in modern product de- velopment. The same trend has been visible also in research, where computational methods have gained popularity beside the traditional approach relying on theory and experimentations [1]. The reason for this is in many cases the cost savings that can be achieved with computational methods. Utilisation of computational methods enables decreasing the use of physical prototypes in the development process. This can reduce costs in two main sectors: first, the direct savings in de- creasing the number of built prototypes due to savings in material and work, and second, indirect savings due to shortened design time. Another reason to use com- putational methods is often forgotten to mention. Modelling and simulation are good means for the designers and experts in the product process to gain under- standing about the product under development. The modelling phase helps de- signers to understand and structure the product and realise the interactions be- tween subsystems and components. Simulating the overall virtual product or its subsystems helps the designers to understand the dynamics and behaviour of the system. All this can be achieved without physical prototypes already in an early phase of the design process. The use of computational methods in product devel- opment process helps the designers and experts to design the products according to the technical and project schedule requirements. This work does not promote any particular software application or an approach to compose a virtual testing system. The selection of the approach as well as the software applications depends on many things, e.g., the requirements for the de- sign system in use and the use of the selected software applications for other pur- poses. In addition, there can be corporate level policies for using some specific software packages that dictate the selection of tools. Due to this, there is no one optimal solution, but the selection has to be done based on the constraints of the engineering environment. 1.1 Objectives The objective of this project task was to study and demonstrate a realistic ap- proach for an industrial case to reuse existing mechanical design CAD model as the starting point and the template for mechanical system simulation using multi- body system (MBS) simulation, and to use this MBS model as a virtual test plant for automation and control system testing. In the case of the demonstrator, the fo- cus was in modelling, data exchange, and simulation process, and the details and realism of the subsystems, such as the control system, were not emphasised. The emphasis was on modelling