1. FunctionalDMU:
towards experiencing behavior of mechatronic systems in DMU
Dr.-Ing. André Stork
Fraunhofer Institut für Graphische Datenverarbeitung IGD
Fraunhoferstraße 5
64283 Darmstadt
Tel.: +49 (0) 6151 155 – 469
Fax.: +49 (0) 6151 155 – 139
E-Mail: andre.stork@igd.fraunhofer.de
http://www.igd.fraunhofer.de

2.  Video

3. What is going on behind the scenes?
 FunctionalDMU run-time environment
Mastersimulator
Wrapper Wrapper Wrapper
Rhapsody Dymola Simpack

4. DMU
 In DMU multi-CAD data is typically converted into one representation …
 … to provide functionality such as … © Siemens AG
 detecting collisions
 checking possibility to assemble / disassemble parts
 measuring
 annotating

5. FDMU
 In addition to geometry models
behavior models of the mechatronic domains:
 software
 electronics
 mechanics
integration
behavior models in diffe-
DMU geometry models rent modelling languages

6.  So the question arises:
What is the equivalent for geometric integration with respect to behavior
models?
 Approaches
 mapping of the heterogeneous behavior models into one standard?
 no existing standard with full representative power
 execution of such an integrated behavior model in a ‚super simulator‘?

7.  Co-simulation matrix (Prof. Dr.-Ing. Marcus Geimer, Universität Karlsruhe)
number of
modeling tools
integration of
>1 co-simulation
models
integrating
„classic“
=1 different
simulation
simulators
=1 >1
number of
simulation algorithms

8.  We decided to go for a
 flexible
 open
 extensible
 vendor-independent
 co-simulation framework:
the FDMU framework Mastersimulator
Wrapper Wrapper Wrapper
Rhapsody Bild
Dymola Simpack

9.  We want to use the native behavior models …
 as unchanged as possible
 but some small adaptations are needed
 in / out values
 parameters to be changed
native model connector communication-enabled model

10.  FDMU connector library for
 Modelica (Dymola)
 MAST (Saber)
 MATLAB/Simulink

11.  Connectors to map native syntax to standardized syntax
 Which standards?
 SysML
 Modelica
 VHDL-AMS
 SysML (Systems Modeling Language)
 Modeling language for systems engineering
 XML base
 UML/XML tools exist to create and process SysML
 Requirements and systems modeling

12.  Mapping of internal interfaces to a standardized form
 Encapsulation of behavior models (example: controller)
Controller (SysML)
Unified description
of interface
variables of the
behavior model
Controller (native)
native interface of
behavior model

13.  ‚Glueing‘ functional building blocks together to create
a simulation model
U 
up f
down s
I 
 and adding geometry models to embed them in an OO way

14.  Next: the simulators
Spice
Rhapsody
Dymola
simulators

15.  They are as heterogeneous as the behavior models with respect to:
 programming languages and APIs
 communication schemes
 platforms
simulators Rhapsody Dymola
Dymola Simpack
Simpack
 How to cope with their heterogeniety?

16.  Solution strategy: Wrapper
 controlling the simulator
 communicating and mapping data
 standardizing interfaces
Wrapper Wrapper Wrapper
simulators Rhapsody Dymola Simpack

17.  Which information does a wrapper receive?
interface
Wrapper Wrapper Wrapper
description
simulators Rhapsody Dymola Simpack
behavior models

18.  Wrapper
 different communication strategies
 based on configuration of connectors

19.  Wrapper
 simulator control commands, e.g.
 configure
 initialize
 run Wrapper
 start data
control
commands exchange
 suspend
 resume
 stop Simulator
 terminate

20.  What else do we need?
 a master for communication and co-ordination 
 Which information does the Mastersimulator need?
system
behavior model Mastersimulator
interface
Wrapper Wrapper Wrapper
description
simulator Rhapsody Dymola Simpack
behavior models

21.  Mastersimulator
 TransferHandler
 adapt data communication

22.  Mastersimulator
 TransferHandler
 support different protocols
constant data flow
constant data flow with upsampling
constant data flow with downsampling
event based input with sampling
event based input /output

23.  To complete the FDMU framework …

system behavior model
interactive visualization and geometry models
system
behavior model Mastersimulator
interface
Wrapper Wrapper Wrapper
description
simulator Rhapsody Dymola Simpack
behavior models

24.  Video:
SW simulation
with Rhapsody
Mastersimulator
Wrapper Wrapper Wrapper
Rhapsody Dymola Simpack

25. Integration of FE analysis: E-motor example
 Demand to integrate and possible couple with
finite element analysis
 Challenge: FE known to be slow
 A coupling scenario for an E-motor
 E-motor with electronic control
 Electronics on a PCB mounted at heat sources
the backside of the E-motor
 The electric behavior of the parts
on the PCB depends on the thermal
conditions (heat)
 -> thermo-dynamic simulation
warming of the PCB
(transistors, controller)

26. Integration of FE analysis: E-motor example
 General questions that may arise in the design process:
 How warm will the transistors get?
 What is the contribution of the engine to the temperature of the transistors?
 Does the warming have effects on other elements, e.g. the controller?
 What kind of cooling to attach to the transistors?
 What happens if the distance between motor and PCB is changed?
 Etc.

27. Integration of FE analysis: E-motor example
 Physical model
controller load
software
time
motor (converter) time
signal electronics mechanics
signal
power loss
power loss
influence
on behavior thermo-dynamics

28. Integration of FE analysis: E-motor example
 Physically-motivated splitting into partial models
TE1: temperature transistor 1
TE2: temperature transistor 2
TM: temperature motor winding
PE1: power loss transistor 1
PE2: power loss transistor 2
PM: power loss motor

29. Integration of FE analysis: E-motor example
 We started to model the thermal behavior within ANSYS
 approx. 50.000 nodes (volume mesh)
 simulation time in the range of hours
 way too slow for interactive simulation

30. Integration of FE analysis: E-motor example
 Reduced model
 Model order reduction
 reduced systems of equations:
50.00 nodes > 100 nodes
 Execution time
 almost interactive
 little impact on accuracy
(we have not measured
precision yet)

31. Integration of FE analysis: E-motor example
 Mapping of the behavior models to simulators
Saber Dymosim Dymosim
Feed forward control
- Matlab
- direct user input input file
Reduced thermo-dyn.
Model (Dymosim)

32. E-motor example
 Video

33. Other applications

34. Achievements
 FunctionalDMU framework
 open, extensible, flexible
FDMU
visualization
FDMU
 distributed, service-oriented architecture service
s
Berlin
 unique combination of features Saber
 solvers Dresden
Darmstadt
 methodology
 visualization features
Mastersimulator Rhapsody
FDMU-Editor Simulink, Visu
 Wrappers for
Dymola
Simulink SimPack Dymola, Mastersim.
 Rhapsody, SimPack, Saber, Dymola (Modelica), Matlab/Simulink, …
 Methodology for modelling, integrating and running FDMU simulations
 Proof-of-concept scenarios

35. Benefits
 end-user point of view
 earlier multi-domain problem detection
 visual insights and communication
 integrated 2D/3D interactive visualization
 shorter set-up of mechatronic simulations
 re-use of behavior models (FBB) in different configurations
 no transformation of models
 running behavior models as services (without forwarding know-how)
 simulation tool provider point of view
 re-usable components for simulation coupling and
 integrated visualisation

36. Outlook
 Wish list / research issues
 fast and flexible simulations, esp. FEM
 coupling-in more different FE domains
 taking environment conditions and tolerances into account
 real-time requirements
 ‚informed‘ CAD models
 data management -> MechatronicPLM
 optimization
 organizational aspects
 IP issues
 LTP of behavior models

37. Das Produkt muss vollständig als Gesamtsystem simulierbar sein.
(Bernd Ehrenberg, Daimler AG)

38. Contact and consortium
for slides and videos see:
www.functionalDMU.org