Integration of SysML and Simulation Models

for Mechatronic Systems

Matthias Hrl Stefan Dierneder

Martin Hochwallner Rudolf Scheidl
Austrian Center of Competence in Mechatronics GmbH
TRUMPF Maschinen Austria GmbH
Linz Center of Mechatronics GmbH
J.K. University Linz, Institute of Machine Design and Hydraulic Drives
Outline

Introduction and Motivation 1

TRUMPF Group
Bending Process
Current Situation
Challenge

Definition of Simulations within a SysML Model

Example Test Case

Summary
TRUMPF Group

2
TRUMPF Group Business Divisions
Machine Tools/ Laser Technology/ Medical
Power Tools Electronics Technology

Machine Tools Power Tools Laser Electronics Medical

Technology Technology

Machine Tools for Power tools for Lasers for Power supplies for Operating tables,
flexible sheet metal sheet metal production induction heating, surgical lights,
processing processing technology plasma and CO2 laser ceiling pendants
excitation

Sales (billion ) 1.050 Sales (million ) 387.4 Sales (million ) 151

Employees 5.263 Employees 1.902 Employees 565
End of fiscal year: June 30, 2008; consolidated within the business division; figures rounded
Bending Process

Process Details 3

High Quality
Bending Angle
Precision
Material
Machine Deformation
Work Piece Tools
Bending Sequence
Material Properties
Yield- , ultimate Strength +/- 0.3Bending Angle
Ductility +/- 20 m relative Tool Position
Youngs Modulus

Geometric Properties
Tolerance in thickness
Current Situation

Mechatronic System TruBend Cell 7000 4

Tests during Product Development

dynamic analysis
static FEM analysis
real world testing
...
Current Situation

Current Situation 5
standardized processes of the product development
Current Situation

Current Situation 5
standardized processes of the product development
documented requirements for products and components
Current Situation

Current Situation 5
standardized processes of the product development
documented requirements for products and components
sophisticated documentation of solutions
- e.g. mechanical domain: 3D CAD, 2D drawings, ...
Current Situation

Current Situation 5
standardized processes of the product development
documented requirements for products and components
sophisticated documentation of solutions

coverage of test cases checked manually

responsible person for test case

transfer of data done partially manual

consistency of data, checked by test engineer
Challenge

Potential of Improvement 6
Testing during Product Development
- coverage of all relevant components
- coverage of all requirements
- relevant test cases are up to date at a certain gate
- test cases, comprehensible by none-specialist

Data Transfer
- automated data transfer
- consistent data at test execution
- automated update of test cases
Outline

Air Bending 7

Simulation within a SysML Model

define / specify simulations within the system

Example Test Case

Summary
Simulation within a SysML Model

Requirement 8
Simulation within a SysML Model

Test Case according to the Requirement 8

Simulation within a SysML Model

Structure for the Test Case 8

Simulation within a SysML Model

Representative Load Cases 8

Outline

Air Bending 9

Simulation within a SysML Model

Example Test Case

structure of a conventional press brake
test case precision
automation

Summary
Structure of a Conventional Press Brake

Components 10
Test Case Precision

Derive Requirements 11
Test Case Precision

TestSetUp and LoadCaseSet for the Test Case 11

zpos
zwidth
Test Case Precision

Internal View of Simulation Structure 12

zpos
zwidth
Test Case Precision

Manual Test Execution 13

build/update simulation model

extract and process relevant data
verify requirement
Automation

Automated Update
Integration of / Setup
Simulation 14
CAD

SysML Machine Model

FE Model

LoadSets

Model
Outline

Air Bending 15

Definition of Simulations within a SysML Model

Example TestCases

Summary
Key Benefits
Outlook
Summary

Key Benefits 16
Common view and understanding of the System
Requirements / TestCases are defined in a common place
Transparent View of Interdependencies between ...
- Requirements and Structure
Coverage
Summary

Key Benefits 17
Common view and understanding of the System
Requirements / TestCases are defined in a common place
Transparent View of Interdependencies between ...
- Requirements and Structure
Evaluation of Complexity Trade Off

Fulfilment of Requirements
- Requirement and Requirement
Trade-off
Interdisciplinary Optimization
Summary

Outlook 19
Setup/Update of a FEM Analysis by a SysML Model

automated update of Simulations (Testing) synchronized with the

Product Development Process
Finished

Thank you for your Attention