Bidirectional Integration Of Geometric And Dynamic Simulation Tools Chah´eAdourian Supervisor: Prof. Hans Vangheluwe School of Computer Science McGill University, Montr´eal,Canada A thesis submitted to the Faculty of Graduate Studies and Research in partial fulfilment of the requirements of the degree of Master of Science in Computer Science and Engineering (CSE program) Copyright c 2011 by Chah´eAdourian All rights reserved ii ABSTRACT Mechanisms to share information from Mechanical Computer Assisted Design (MCAD) to simulation model have been demonstrated using various approaches. However, in all cases the information shar- ing is unidirectional - from the MCAD to Multi-Body Systems (MBS) simulation - which lacks the bidirectional mapping required in a concurrent engineering context where both models need to develop in parallel while remaining consistent. We present a modelling library and a model mapping that permits and encourages parallel development of the mechanical assembly in both the MBS simulation and MCAD environments while supporting both bidirectional initial full transfer and incremental updates. Furthermore, with the adopted ap- proach and with a careful selection of the simulation language, MCAD parts can be extended with non-mechanical behaviour in the simulation tool. iii iv ABREG´ E´ Des m´ecanismespour partager l'information entre un mod`eleCAD et un mod`elede simulation ont ´et´ed´emontr´esutilisant divers approches. Pourtant, dans tous les cas, le partage d'information ´etait unidirectionnel - allant du mod`eleCAD vers le mod`elede simulation - donc ne poss´edant pas les qualit´es bidirectionnelles n´ecessairesdans le contexte de l'ing´enieriecollaborative ou les mod`elesdoivent rester consistants en permanence. Nous pr´esentons notre librairie de mod´elisationet notre d´eveloppement des transformations entre mod`elesqui permettent et encouragent le d´eveloppement parall`elede l'assemblage m´ecaniquedans les deux environnements de simulation et de conception CAD. Notre approche supporte le partage et la synchronisation des mod`elesdans les deux sens et de faon incr´ementale si n´ecessaire.En compl´ement, avec l'approche adopt´e,les mod`elesm´ecaniquespeuvent tre associ´esa des mod`elescomportementales non m´ecaniquedans l'outil de simulation. v vi DEDICATION This document is dedicated to the graduate students of the McGill University and all of those that pursue science and technology for the betterment of their fellow people and the planet. vii viii ACKNOWLEDGEMENTS I would like to thank my supervisor Hans Vangheluwe who introduced me to the Modelica language and the fascinating subject of Modelling and Simulation many years ago. His obvious fascination and interest in the subject inspired me to start and complete this thesis. It is thanks to the efforts of dedicated people like Hans and others that the field of modelling and simulation will be making great progress in years to come. I am thankful for the opportunity and appreciated the patience and advice that I was given over the course of this thesis. I would also like to thank Florence St-Amand and Leo Hartman, colleagues from the Canadian Space Agency, for proof-reading and providing valuable comments on the document. Finally, I would like to thank the CSA for granting me a leave of absence and partial funding for the completion of the course requirements. Without it, this would have been a much longer process. ix x Contents ABSTRACT iii ABREG´ E´ v DEDICATION vii ACKNOWLEDGEMENTS ix 1 CONCURRENT ENGINEERING 3 1.1 Introduction . 3 1.2 Unidirectional Versus Bidirectional Tool Integration . 3 1.2.1 Model integration and evolution . 4 1.2.2 Manual Versus Automated Consistency Recovery . 5 1.2.3 Multi-model Integration And Consistency . 5 1.3 Mechatronics . 6 1.4 Mechatronics and Concurrent Engineering . 7 2 MODELLING AND SIMULATION OF THE DYNAMICS OF SYSTEMS 9 2.1 Overview . 9 2.2 Continuous, Discrete and Hybrid Systems . 9 2.2.1 Continuous Systems Simulation . 10 2.2.1.1 Differential and Ordinary Differential Equations . 10 2.2.1.2 Differential Algebraic Equations . 11 2.2.2 Discrete Events Simulation . 13 2.2.3 Hybrid systems simulation . 13 2.3 Causal and A-causal modelling . 14 2.3.1 Causal modelling . 14 2.3.2 A-Causal modelling . 15 2.4 Simulation Languages and Tools . 17 2.4.1 Numerical Simulation Tools . 19 2.4.1.1 ACSL . 20 2.4.1.2 GAUSS . 20 2.4.1.3 O-Matrix . 20 2.4.1.4 MATLAB . 20 2.4.2 Computer Algebra Systems . 20 2.4.3 Component-Based A-causal Simulation Tools . 21 xi 2.4.3.1 Simscape . 22 2.4.3.2 20-Sim . 22 2.4.3.3 AMESim 1D-Lab . 22 2.4.3.4 Dymola . 22 2.4.3.5 MapleSim . 22 2.4.3.6 SimulationX . 22 2.4.3.7 Easy5 . 23 2.4.3.8 Ecosimpro . 23 2.4.3.9 Mathematica-based tools . 23 2.4.4 Tools and Features . 24 2.4.5 Modelica Language . 25 3 MECHANICAL MODELLING AND SIMULATION 27 3.1 Current State of the Art . 27 3.2 Multi-body Simulation Tools . 29 3.2.1 ADAMS . 29 3.2.2 LINKAGEDESIGNER . 29 3.2.3 LMS Virtual.Lab Motion . 29 3.2.4 Modelica.Mechanics.MultiBody . 30 3.2.5 ODE (Open Dynamics Engine) . 30 3.2.6 SimMechanics . 30 3.2.7 SIMPACK . 31 3.3 CAD tools, joints and mates . 31 3.3.1 Generalised Geometric features . 32 3.3.2 Constraints in Solid Works 2010 . 32 3.3.2.1 Simple Mates . 32 3.3.2.2 Advanced Mates . 33 3.3.2.3 Mechanism Mates . 33 3.3.3 Constraints in CATIA v6 . 34 3.3.4 Constraints in Solid Edge v100 . 34 3.3.5 Constraints in Autodesk Inventor 2010 . 34 3.3.5.1 Assembly Constraints . 35 3.3.5.2 Motion Constraints . 35 3.3.5.3 Transitional Constraint . 35 3.3.5.4 Constraint Set . 38 3.3.6 Constraints Comparison . 38 3.4 Mechanical Interference and Collision detection . 41 3.4.1 Interference detection . 41 3.4.2 Collision detection and contact dynamics . 41 xii 3.5 Connecting Geometry With Simulation . 42 3.5.1 Solid Works To Modelica . 43 3.5.2 Other references . 43 3.5.2.1 Working Model 3D . 43 3.5.2.2 ADAMS to EASY5 . 44 3.5.2.3 Solid Works to SimMechanics . 44 3.5.2.4 CATIA to Modelica Multi-body . 45 3.6 Selected MCAD Tool: Solid Edge . 45 3.6.1 Part Model . 46 3.6.1.1 Part Physical Properties . 46 3.6.1.2 Part Dimensioning Parameters . 47 3.6.1.3 Geometric Features . 47 3.6.2 Assemblies . 48 3.6.3 Assembly Relations . 49 3.6.3.1 Match Coordinate Systems . 49 3.6.3.2 Planar Align . 49 3.6.3.3 Mate . 50 3.6.3.4 Angle . 50 3.6.3.5 Axial Align . 51 3.6.3.6 Insert . 52 3.6.3.7 Connect . 52 3.6.3.8 Tangent . 53 3.6.3.9 Gear . 54 3.6.3.10 CAM . ..