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ASME Webinar: Model-Driven Innovation in Machine Design
- 1. © 2015 Maplesoft, a division of Waterloo Maple Inc. Model-Driven Innovation Simplifying Machine Design with System-Level Modeling Willem Fourie, Development Manager, FL Smidth Paul Goossens, VP, Engineering Solutions, Maplesoft Orang Vahid, Director, Application Engineering, Maplesoft
- 2. © 2015 Maplesoft, a division of Waterloo Maple Inc. 2 The Engineering Challenge System Complexity Time to Market Budget Constraints
- 3. © 2015 Maplesoft, a division of Waterloo Maple Inc. 3 Control Design Mechanical Design Electrical Machine Design Hydraulic Circuit Design Structural DesignMultiple Subsystems Multiple Design Groups Multiple Engineering Domains Disparate Tools in Each Domain Subsystem interactions are key to overall performance Problems arise at system integration time! Challenges of Design Complexity Many Concepts, Components, Variants and Strategies
- 4. © 2015 Maplesoft, a division of Waterloo Maple Inc. System-Level, Multidomain Model - Virtual Prototyping - Dynamic Behavior - Design Validation - Multi-Domain - Forces, Loads, Heat, … - 3D Visualization - Scenario Exploration Model-Driven Innovation Modeling & Simulation - Inverse Kinematics - Inverse Dynamics - Symbolic Jacobians - System Equations - CAD/PLM - Control Design - Operator Training - V&V - HIL/SIL Tool Integration & Solution Deployment - Parameter Tuning - Optimization - Monte Carlo - Sensitivity - Vibration Design-space Exploration & Optimization
- 5. © 2015 Maplesoft, a division of Waterloo Maple Inc. Modeling & Simulation Model-Driven Innovation System-Level, Multidomain Model Design-space Exploration & Optimization Tool Integration & Solution Deployment Professional Services
- 6. © 2015 Maplesoft, a division of Waterloo Maple Inc. 6 System-Level Simulation Explore Simulation Results Parameterized Models Multidomain Component Libraries Mechanical Thermal Magnetics Control Hydraulics Batteries Multibody Easy Model Construction 3-D Visualization Incorporate CAD Data
- 7. © 2015 Maplesoft, a division of Waterloo Maple Inc. 7 Dynamic Load Analysis Parameter Sweeps/Optimization Vibration Analysis Inverse Kinematics and Dynamics Motor Sizing Design-space Exploration
- 8. © 2015 Maplesoft, a division of Waterloo Maple Inc. Willem Fourie Development Manager, FLSmidth Orang Vahid Director of Application Engineering, Maplesoft Dual-Truck Mobile Sizer 8
- 9. © 2015 Maplesoft, a division of Waterloo Maple Inc. 9 Why work with Maplesoft? • Appeal of MapleSim for virtual prototyping of the proposed design • Shortage of resources to develop the models and analyses in-house • Readily available, highly skilled developers through Maplesoft • Excellent service: depth of knowledge, rapid turnaround, fast return on investment
- 10. © 2015 Maplesoft, a division of Waterloo Maple Inc. 10 Scope of Work – DTMS Project Maplesoft In close collaboration with FLSmidith’s designers and engineers, Maplesoft’s Application Engineering team contributed to the follow areas: • Initial Design Evaluations • Mechanical Design Tools for the Skip System • DTMS Dynamics Chassis Model • System Safety Simulations
- 11. © 2015 Maplesoft, a division of Waterloo Maple Inc. Block Diagram Illustrating the Model Concept Interconnectivity MapleSim Model Left and right skips, mechanical and hydraulic actuation Hydraulic Energy Storage System Hydraulic Circuit Hydraulic Linear Actuation Mechanical Fixed Frame Mechanical Skip Model Payload Offload Model Controller DTMS: Initial Investigations Dynamic Model Concept
- 12. © 2015 Maplesoft, a division of Waterloo Maple Inc. Geometrical Structure of the Skip and the Limiting Mechanism Fully Parameterized Model Easy access to key geometry features Easy access to key dynamic properties Automatic inertia properties extraction from CAD DTMS: Initial Investigations MapleSim Model
- 13. © 2015 Maplesoft, a division of Waterloo Maple Inc. DTMS: Initial Investigations MapleSim Model
- 14. © 2015 Maplesoft, a division of Waterloo Maple Inc. 14 The Skip system model was linearized at key operating points… Hydraulic Circuit Skip Mechanism DTMS: Initial Investigations Hydraulic System Stability
- 15. © 2015 Maplesoft, a division of Waterloo Maple Inc. Eigenvalue Plots Feedback Velocity: Instability Stability DTMS: Initial Investigations Hydraulic System Stability
- 16. © 2015 Maplesoft, a division of Waterloo Maple Inc. Stable System System with high Vibration DTMS: Initial Investigations Hydraulic System Stability
- 17. © 2015 Maplesoft, a division of Waterloo Maple Inc. • Skip model examines the skip actuation and material loading characteristics • Parametric Model for easy model adjustments • Calculation of Hinge Forces • Variable material loading • Footings Geometry/Configuration • Speed Profile • Hydraulic System Requirements Skip System Modeling Overview
- 18. © 2015 Maplesoft, a division of Waterloo Maple Inc. • Parameter Sweep tool provides multiple simulation variation to be plotted again one another • View results in time domain or vs skip angle Results vs Time Results vs Skip Angle Skip System Modeling Design Tool: Parameter Sweep
- 19. © 2015 Maplesoft, a division of Waterloo Maple Inc. Skip System Modeling Design Tool: Speed Profile Design • Interactive worksheet to determine required operating speed and position of skip cylinder • Utilizes inverse kinematics of the lifting mechanism
- 20. © 2015 Maplesoft, a division of Waterloo Maple Inc. Accumulator Sizing Calculation Skip System Modeling Hydraulic Accumulator Sizing Pressure in accumulator and cylinder
- 21. © 2015 Maplesoft, a division of Waterloo Maple Inc. Center Loading Off-Center Loading Skip System Modeling Off-Center Skip Loading
- 22. © 2015 Maplesoft, a division of Waterloo Maple Inc. Upper Hinge Skip System Modeling Skip Hinge Forces Calculation: Upper Hinges
- 23. © 2015 Maplesoft, a division of Waterloo Maple Inc. Lower Hinge Skip System Modeling Skip Hinge Forces Calculation: Lower Hinges
- 24. © 2015 Maplesoft, a division of Waterloo Maple Inc. Full DTMS Chassis System Modeling Initial Concept…
- 25. © 2015 Maplesoft, a division of Waterloo Maple Inc. Full DTMS System Modeling Flexible Frame Modal Analysis: First Mode ANSYS Mode: #1 1.91Hz MapleSim Mode: #1 1.93Hz Matching Mode Shapes
- 26. © 2015 Maplesoft, a division of Waterloo Maple Inc. Full DTMS System Modeling DTMS System In Action Playback at 20x speed
- 27. © 2015 Maplesoft, a division of Waterloo Maple Inc. Full DTMS System Modeling DTMS Model Full DTMS model consists of: • Frame structure (rigid or flexible) • Two skip system • Frame and skip footings • And soil interaction models Main Frame Soil Skip Footings
- 28. © 2015 Maplesoft, a division of Waterloo Maple Inc. Full DTMS System Modeling DTMS Vertical Footing Displacement
- 29. © 2015 Maplesoft, a division of Waterloo Maple Inc. Truck/Chock Modeling Impact Simulation
- 30. © 2015 Maplesoft, a division of Waterloo Maple Inc. Paul Goossens Wrap-up 30
- 31. © 2015 Maplesoft, a division of Waterloo Maple Inc. 31 NEW! Painless CAD Model Import SolidWorks, Autodesk, NX, Catia V5, SolidEdge, ProE, Parasolid, STEP and IGES Easy Model Preparation Component grouping and hiding Feature detection Easy identification of constraint coordinates (revolute, prismatic, weld) Rapid Virtual Prototyping Dynamic simulation of mechanism Add other engineering domains • electrical, hydraulic, batteries, thermal… System-level functional validation • “Will it work?” Analysis and Optimization • “Can we make it work better?”
- 32. © 2015 Maplesoft, a division of Waterloo Maple Inc. Overview 32 - Design Explorations - Live Mathematical Documents - Parametric Analysis and Optimization - System-level Modeling and Simulation - Multidomain models - Fast HIL/SIL code generation Driveline Battery HydraulicsTires Global OptimizationControlVertical Add-ons MATLAB®/Simulink® LabVIEW™ Code Generation CAD Systems FMI/FMU B&R VI-gradedSPACE®NI VeriStand™ JMAG®-RT Web Deployment Toolchain Connectors Professional Services Model Development Design Validation MPC / Motion Control HIL Training Simulink is a registered trademark of the The MathWorks Inc. All other trademarks are properties of their respective owners.
- 33. © 2015 Maplesoft, a division of Waterloo Maple Inc. Overview 33 - Design Explorations - Live Mathematical Documents - Parametric Analysis and Optimization - System-level Modeling and Simulation - Multidomain models - Fast HIL/SIL code generation Driveline Battery HydraulicsTires Global OptimizationControlVertical Add-ons MATLAB®/Simulink® LabVIEW™ Code Generation CAD Systems FMI/FMU B&R VI-gradedSPACE®NI VeriStand™ JMAG®-RT Web Deployment Toolchain Connectors Professional Services Model Development Design Validation MPC / Motion Control HIL Training Simulink is a registered trademark of the The MathWorks Inc. All other trademarks are properties of their respective owners. Our Mission: Make You Successful! Reduce project risk Produce better products Get to market faster
- 34. © 2015 Maplesoft, a division of Waterloo Maple Inc. Thank You Questions? 34
Hinweis der Redaktion
- Many engineering organizations today are facing major challenges when designing and delivering new products. - Time to market as well as cost control are critical in an ever more competitive and global market. - At the same time, system complexity is rising to accommodate growing customer expectations and increased regulatory constraints. - However, key, sometimes fundamental design issues are often discovered late in the development process. - This results in budget overruns and project delays, especially if issues are not discovered until hardware prototyping or even integration - Moreover, once a system has been delivered and installed, failures and on-site service calls, can become very expensive and hurt your company’s bottom line.
- Why is this so hard? Many of these issues come about because design of a complex system involves several distinct groups, each focused on the development of one subsystem, using dedicated tools and methods to determine if their design will comply with the specifications for that system. Once these subsystems are integrated during prototyping, or even final assembly, problems arise. For example, a stress analysis of a mechanical setup will provide us with data on structural integrity and failure points. However, in isolation, such an analysis can’t answer system-level questions on optimal sizing of actuators, stability of the selected control strategy or the impact of thermal management on the hydraulics.
- MapleSim is our product for system-level simulation It allows you to quickly build complex simulation models, by selecting and connecting components from a large library of pre-built components, covering a variety of domains like Mechanical, multibody, control, thermal, magnetics and hydraulics. We also offer specialized libraries for battery, driveline, advanced hydraulics and tire modeling. It is important to note that, unlike traditional tools like Simulink, connections between components represent physical connections and not just signals flowing in one direction. This greatly simplifies the modeling task and dramatically reduces the complexity of the resulting block diagram.
- Maple is our interactive environment for mathematical analysis and design exploration. Maple allows you to go beyond simulation and get deep insight into your designs. Over 5000 mathematical functions are ready to tackle problems like parameter tuning, optimization, Monte Carlo, sensitivity analysis, vibration analysis and linearization. In addition, because at the core of Maple and MapleSim is a powerful engine for symbolic computing, you are able to extract system equations, compute symbolic Jacobians and get analytic solutions for inverse kinematics and dynamics. The Maple document interface allows you to easily capture every step you take and the resulting interactive documents are easy to share, review, validate and re-use. These documents can even be shared on a server and are fully interactive within a web browser. A full programming language allows you to script and automate analysis tasks but also allows you to define custom modeling components from first principles. In all, Maple provides you with a very powerful environment for design exploration. .. - Tool-path planning
- In close collaboration with FLSmidith’s designers and engineers, Maplesoft’s Application Engineering team contributed to the follow area: Preliminary Hydraulic System for Skip Lifting System Vibration Analysis of the controlled hydraulic Skip Mechanical Design – Dynamic loading Parameter study tool Motion profile design tool Automatic reporting on loading (hinges, footings) Hydraulic system requirements (max flow rate, max pressure,…) Overall system response (vibrations, load distribution, footing sinkage) Parametric models to cover three size classes of the product Continuous Update and Maintenance of the models in accordance with the design updates Uneven Loading on Skips Truck/Choke Impact Simulation
- Production Notes: Use pic_001.png Speaker Notes: Starting with the skip model, its geometry is fully parameterized in MapleSim which give the designers a straightforward way to check the design modifications from a dynamic standpoint.
- The location of the eigenvalues on this plot is crucial as it indicates whether the system is stable or not. Eigenvalues on the right of the y axis indicate system instability and eigenvalues on the left of the y axis indicate stablility (*IMAGE*).
- It was shown that the current design of the DTMS can exhibit unstable behaviours under certain circumstances. An approach to perform stability analysis was developed. Concept was demonstrated through a case study by varying feedback sensor location Approach can be used for stability analysis in future projects
- Based on an initial DEM simulation, the model in MapleSim captured the same load/motion profile. Further development resulted in a tool to adjust the loading to account for changes in the motion profile and the type of load (sticky/non-sticky load)
- Maple and MapleSim are very powerful tools and enable a model-driven innovation process. In addition, Maplesoft has a lot of expertise in system-level modeling, design validation and HIL. We have worked with dozens of engineering organizations around the world to help them take advantage of modern techniques and tools to allow them to deal with growing complexity and to produce better designs, faster. Our mission is to help make your engineering projects succeed
- Maple and MapleSim are very powerful tools and enable a model-driven innovation process. In addition, Maplesoft has a lot of expertise in system-level modeling, design validation and HIL. We have worked with dozens of engineering organizations around the world to help them take advantage of modern techniques and tools to allow them to deal with growing complexity and to produce better designs, faster. Our mission is to help make your engineering projects succeed