VisSim 5

Application Pack 4:
Real-time
simulation
with data
acquisition
cards

®
❝Due to its power, flexibility, ease-of-use, and low
cost, VisSim has been Carrier’s choice for system
modelling, simulation, data acquisition and rapid
prototyping for each of the past five years❞
▼
▼

Mr. Richard Kolk

the technical computing people Manager Simulation & Control Technology

VISSIM 5 APPLICATION PACK FROM ADEPT SCIENTIFIC

 Real-Time simulation
with data acquisition cards
APPLICATION PACK 4
Contents

VisSim/Real-TimePRO data sheet..........................................................1

“Instron’s Motion Platform Designed with VisSim” ................................2

“Honeywell Models GE Gas Turbine with VisSim” ..................................3

“DuPoint & EnTech Use VisSim/RealTime

for Dynamic Process Control Simulation” ..............................................4

“Biomedial Systems: Modelling and Simulation

of Lung Mechanics and Ventilator Controls Design” ..............................5

isSim/Real-TimePro extends the power of

V VisSim by integrating a simulation with a

physical process for real-time hardware-in-
the-loop simulation and validation. As well as
detailing the software, this pack shows how
engineers have interfaced their models with
hardware such as motors, pumps and electric
▼
▼

drives through VisSim/Real-TimePRO.

 APPLICATION PACK 4
VisSim
Real-time simulation with data acquisition cards

Instron’s Motion
Platform Designed
with VisSim
When Instron Corp., of Canton, Massachusetts,
teamed up with LightSpeed Simulation Systems,
Inc. to build a new, modern entertainment,
motion simulator — named the Argo II — they
used VisSim to develop and test the motion
platform.

The platform, an advanced servohydraulic motion

system with 3 degrees of freedom and over 2 Gs
of vertical acceleration, provides the heaves, rolls,
and pitches for the Argo II. ▼
Argo II. Courtesy of Lightspeed Simulation Systems, Inc.

“One of the most time-consuming aspects of the

design was modelling the nonlinear behaviour of
the platform,” said Albert Barrett, Principal
Engineer at Instron. “With the many linkages
among the hydraulics, position transducers, and
pistons of the motion platform, the response of
the capsule would not follow linearly from the
behaviour of the transducers and pistons.”
VisSim’s comprehensive selection of nonlinear
functions combined with its graphical interface
allowed Barrett to easily design the motion
platform from a classical control perspective.
To obtain data of the nonlinear behaviour,
Barrett connected the motion controller to a PC
with an I/O board. When the controller received
a signal, it calculated the PID error control loop
and sent a valve drive signal back to the
software. Barrett used this empirical data to
complete the model in VisSim.
“One of our key discoveries was that the
bandwidth of the proportional valves was too
low. When we replaced the valves with ones
having a wider bandwidth, we saw the
improvement in the system,” explained Barrett.
After thorough testing through
simulation, Barrett arrived at the optimal settings
for the motion controller. Final testing with
Lightspeed’s capsule and simulation software was
completed in time to unveil the Argo II at the
International Association of Amusement Parks
and Attractions (IAAPA) tradeshow in New
Orleans, where it received overwhelmingly
positive reviews from the attendees. “Part of the
appeal of the Argo II is that it is a fine-tuned,
well-tested system,” said Barrett. “Not a hurried
product that just made the deadline.”

During simulation, dynamic graphs displayed

motor current, position, and velocity behaviour.
As Barrett interactively “tweaked” system values,
the effects of the changes were immediately
reflected in the graphs.

• Tel: 01462 480055 • Fax: 01462 480213 • Email: vissim@adeptscience.co.uk • WWW: www.adeptscience.co.uk • WebStore: www.adeptstore.co.uk
 APPLICATION PACK 4
VisSim
Real-time simulation with data acquisition cards

Honeywell Models
GE Gas Turbine
with VisSim
By Mohan Thiagarajah, applications consultant,
Honeywell UK
When Honeywell UK won a contract to retrofit an
existing control system on a General Electric LM2500
gas turbine, they required a simulation package that ▼
had the power and flexibility to model the General Electric LM2500 gas generator
nonlinearities of a turbine, as well as evaluate the
relationship between the turbine and controller. Based In the end, both Honeywell and their customer were
on previous experience, Mohan Thiagarajah, extremely satisfied with Thiagarajah’s work.
applications consultant at Honeywell, chose VisSim to Honeywell found that VisSim was the most effective
handle all of their development and testing needs. and easiest PC-based solution for developing complex
simulation models. Honeywell’s customer ended up
with an operational system that met all their
After only a few weeks, Thiagarajah created a basic requirements.
model of the gas turbine, including the compressor,
combustor, gas generator turbine, and power turbine.
Several iterations later, the model would grow to over “We have a similar project coming
2,000 blocks and encompass all the auxiliary units,
including fans, pumps, values, and pipes. According to up soon - an offshore oil rig in
Thiagarajah, features like drag-and-drop block
placement and compound blocks streamlined model Norway that has ten compressors
construction and greatly improved the readability of
the diagram.
and four Rolls Royce gas turbines.
I fully expect to use VisSim to great
One of Thiagarajah’s prime concerns was integrating
existing GE information into the overall model. In effect again.”
particular, Thiagarajah wanted to model the starter
motor, ignition system, ventilation fan, and lubrication
oil pumps based on GE specifications. “The map block
provided an easy and reliable way to incorporate this
data directly into the simulation,” explained
Thiagarajah. “I could perform 1-, 2-, or 3-D table look-
ups, depending on how the data was organised.”

With a fully functioning model, Thiagarajah was able

to create and validate complicated control algorithms
for start-up sequencing and fuel controls, and simulate
both the transient and steady-state behaviour of the
system. He also had a safe environment in which to
test emergency trips and alarms that would be too
costly or dangerous to perform on the physical system.

• Tel: 01462 480055 • Fax: 01462 480213 • Email: vissim@adeptscience.co.uk • WWW: www.adeptscience.co.uk • WebStore: www.adeptstore.co.uk
 APPLICATION PACK 4
VisSim
Real-time simulation with data acquisition cards

DuPont & EnTech

Use VisSim/Real
Time for Dynamic
Process Control
Simulation
Authors: Extracted from a paper by Hank
Graeser (DuPont) and Andy Waite (EnTech)

In a joint effort, engineers from E. I. DuPont de

Nemours and EnTech Control Engineering used Visual
Solutions VisSim control system design software, and ▼
its real-time option VisSim/Real-Time, to develop a Aerial view of the DuPont non-woven sheet manufacturing facility in
high-fidelity dynamic simulation model of DuPont’s Richmond, Virginia.

non-woven sheet manufacturing facility in Richmond,

Virginia. The model consists of approximately 31,500
blocks and 250 differential equations and simulates
roughly a half dozen interrelated processes. It is used
by DuPont’s control and design engineers to verify
process dynamics during product transitions; develop
and tune control strategies; and explore possible
design changes to enhance control performance. In
addition, system operators train on the model to
maintain proficiency and learn new procedures
without impacting plant operations.
According to Hank Graeser, senior engineer at DuPont,
“VisSim is a highly intuitive environment for
developing large scale high-fidelity process models.
The DuPont Spruance model, developed in VisSim, has
saved the company an estimated one million dollars
to date.
The Ideal Simulation Software
As DuPont engineers drew up the specifications for
the model, EnTech engineers were tasked with finding
the best simulation software with which to build it.
The sheer scope of the model, which included the
entire DuPont facility — 15 tanks; 20 sets of pumps,
lines, and valves; refiners; headbox and drainage
table; vacuum devices, dryer cylinders, and scanning
sensors; and other minutiae—warranted a simulation
software package capable of modeling and simulating
large, multivariable dynamic processes with a high
degree of fidelity.

We developed the model in a third of the time it

would normally take using conventional methods.
VisSim’s block diagram interface made it easy to
document and maintain the model.

Every time we use the model for control design and

off-line tuning, DuPont saves significant dollars as
plant down time is reduced. We also train our
operators using the VisSim model.”

DuPont paper machine simulation in VisSim,

▼

showing Reel Scanner Trends. Reel scanner

position, reel ash, dry weight, and moisture
scan averages are displayed.

• Tel: 01462 480055 • Fax: 01462 480213 • Email: vissim@adeptscience.co.uk • WWW: www.adeptscience.co.uk • WebStore: www.adeptstore.co.uk
 Modelling The Future
The software had to be interactive and
graphically oriented so that dynamic
information could be presented in an
intuitive manner. In addition, the block set
had to include a complete selection of
continuous, discrete, transfer function,
Boolean, arithmetic, and I/O blocks.
Other key requirements included the
capability to run in simulated time, real
time, and continuous time; drive
real-time analog and digital I/O; stop and
continue simulations; initialise all state
variables; and extend the block set with
custom blocks written in C, for enhanced
speed and additional functionality.
Because system operators would also use
the simulation model for training purposes,
the ability to create realistic control panels
with controller faceplates, dynamic tank
levels, and built-in alarms was also
important.
Based on these requirements, the
simulation software that best met EnTech’s
needs was VisSim and the VisSim/Real-Time
companion software.
Model Design
According to DuPont and EnTech engineers,
the DuPont model simulates the outputs of
80 sensors and transmitters and accepts
input from 50 controller outputs. In
addition, the model provides high integrity
dynamics as “seen” through the eyes of the
actual sensors and transmitters, with a time
constant in the range of about 3 seconds.
This means that the truly fast dynamics,
such as that of incompressible fluid flow,
which typically have time constants of 20
milliseconds, do not have to be solved
rigorously. Instead, the equations associated
with the pump curves, fluid flow, and
control valve characteristic curves can be
approximated by solving only the nonlinear
algebraic equations.
These “algebraic loops” involve the on-line
iteration from the last known flow and are
solved using algebraic loop time constants
of typically 1 second, which provides an
adequate safety margin compared to the
high-fidelity specification of 3 seconds.
VisSim
In the resulting simulation, the time
constant spread ranges from a fast value of
1 second to that of the mixing time
constant for some tanks of 20 minutes.
This time constant spread, even though
quite large, means that the simulation
avoids some of the pitfalls of “stiff systems
of differential equations” which are very
difficult to solve numerically.
The final simulation model is organised in a
multi-layer format in which detailed
simulation subelements collapse into
“compound blocks.” There are 900
compound blocks, in about six layers,
organised in an easy-to-follow, process-
oriented layout.
Model Verification
In the testing phase, close to 200 real-time I/O
For further
channels were used to validate the model and information on
control hardware. The simulated process runs VisSim 5 please
ten times faster than the real process on a
Pentium 100 MHz personal computer, at a
contact your
simulation step size of 0.5 seconds. nearest Adept
Scientific Office
Predicting the Future
UK
The DuPont model is an excellent example Adept Scientific plc
of how a dynamic multivariable process Amor Way, Letchworth,
control model can be developed and Herts, SG6 1ZA, UK
utilised using VisSim and VisSim/Real-Time. Tel: 01462 480055
Graeser and other DuPont engineers have Fax: 01462 480213
Email: info@adeptscience.co.uk
observed a “close match” between model WWW: www.adeptscience.co.uk
and actual plant data. Based on these WebStore: www.adeptstore.co.uk
results, they are confident that the DuPont
model can be used as a “life-cycle” tool to Denmark
faithfully predict the effects of future Adept Scientific Aps
design decisions before modifications are Nordre Jernbanevej 13C,
DK-3400 Hillerød, Denmark
actually made to the plant. Tel: +45 48 25 17 77
Fax: +45 48 24 08 47
Email: infodk@adeptscientific.dk
WWW: www.adeptscientific.dk
WebStore: www.adeptstore.dk
“High Fidelity modelling of a large
scale project can be done with USA
Adept Scientific Inc.
VisSim. From a financial 7909 Charleston Court,
Bethesda, MD 20817, USA
standpoint, it’s extremely Tel: +1 (301) 365-0720
Fax: +1 (301) 767-1675
worthwhile to the process control Email: info@adeptscience.com
community. There are tremendous WWW: www.adeptscience.com
WebStore: www.adeptstore.com
cost savings in reduced downtime ®
due to offline tuning and control Copyright © 2002
Adept Scientific plc.
design as well as operator training.” All rights reserved.
All trademarks
recognised.
Andy Waite: Chief Designer DuPont
E&OE
Model EnTech Control Engineering
APPLICATION PACK 4
VisSim
Real-time simulation with data acquisition cards

VisSim/Real-TimePROTM 5 Highlights
• Supports Advantech, • Cold junction
DATA ACQUISITION, CONTROL Analogue Devices, Data
Translation, Measurement
compensation
• Thermocouple
AND HARDWARE-IN-THE LOOP Systems, MetraByte,
National Instruments,
linearisation
• Up to 10 kHz data
VALIDATION Precision Micro Dynamics,
and Technology 80 I/O
sampling rate
• PID tuning
cards • Counter-timer
VisSim/Real-TimePRO provides the capability to couple • Universal library support • Quadrature encoding
a VisSim system model directly with a "real" process or for all analogue, digital, • Connect up to 16 boards
controller. With VisSim/Real-TimePRO, hardware-in- and thermocouple simultaneously
NEW Measurement Systems • Simultaneous use of
the-loop (HIL) systems can be configured and executed boards, including all PCI boards from different
by interfacing VisSim plant or controller models with boards vendors
real-world hardware, such as manufacturing plants, • Real-time data acquisition • 48 direct input channels,
chemical processes, motors, pumps, and electric drives. and display 48 output channels, and
The interface to real-world hardware is through • Real-time hardware-in- 48 digital I/O channels per
the-loop execution board
computer I/O cards; high-speed motion control
• Real-time data logging • Multiplexer add-ons
interface cards; or serial port connections to with gating provide up to 112
Programmable Logic Controllers (PLCs) or Distributed • Closed-loop process channels per board
Control Systems (DCSs). And no code generation or control • Data switching of 120V AC
programming is involved to configure an HIL system • Pulse width modulation systems
with VisSim/Real-TimePRO.
Sample Applications
VisSim/Real-TimePRO has been used successfully in a • Biomedical engineering • Precision servo design
wide variety of industries to: • Furnace control • Pulp and paper
• HVAC • Real-time simulation
• Develop and validate control strategies • Model verification • System identification
• PLC commissioning
• Perform off-line tuning
Technical Specifications
• Verify the feasibility of product and process transitions • Up to 5000 Hz closed-loop • Up to 384 digital output
data rate channels
• Up to 1792 analogue • Up to 48 frequency input
• Train system operators (on the plant model, not
input channels channels
the actual plant) • Up to 256 analogue • Up to 48 frequency output
output channels channels
• Up to 384 digital input
channels

System Requirements
• Professional VisSim 5.0

• 8MB RAM

• 500K disk space

Real-time data input (middle) and

▼

▼ driver set-up (left) dialogue boxes

Real-time hardware-in-the-loop simplify the set-up process.
simulation of a fan-paddle
system.

• Tel: 01462 480055 • Fax: 01462 480213 • Email: vissim@adeptscience.co.uk • WWW: www.adeptscience.co.uk • WebStore: www.adeptstore.co.uk
 I/O Boards Supported by VisSim/Real-TimePRO
VisSim
Advantech Measurement Systems MetraByte
PCL-711 (continued) Analogue Input
PCL-711S Analogue Output DAS-08
PCL-718 CIO-DAC02 DAS-08/AO
PCL-812 CIO-DAC08 DAS-08/LT
PCL-812PG CIO-DAC08-I DAS-08/PGA
PCL-818 CIO-DAC16 DAS-16
PCL-818PG CIO-DAC16i DAS-1400
CIO-DDA06 DAS-1600
Interface Board
PCLD-789 Counter Timer Analogue Output
CIO-CTR05 DAC-02
Analogue Devices CIO-CTR05/H50 DAC-16
RTI 815 CIO-CTR102 DDA-06
CIO-CTR10/H503
Data Translations Digital Input & Output
DTI-2811PGH Digital Input & Output PDIS08
DTI-2811PGL CIO-DIO244 PIO-24
CIO-DIO24DD
For further
INTECO CIO-DIO24H National Instruments information on
RT-DAC4/PCI CIO-DIO485 Lab-PC+ VisSim 5 please
CIO-DIO48DD PC-AO-2DC
CIO-DIO48H5
contact your
Measurement Systems PC-DIO-24
CIO-DIO966 PC-DIO-969 nearest Adept
Analogue Input CIO-DIO1927
CIO-DAS08 All boards supported by NI- Scientific Office
CIO-PDIS08 DAQ universal driver software
CIO-DAS08/AO
CIO-DAS08/AOH UK
Interface Boards to Digital Input & Output Adept Scientific plc
CIO-DAS08/AOL
CIO-DAS08/Jr Digital I/O DAQCard-1200 Amor Way, Letchworth,
CIO-DUAL-AC5 DAQCard-DIO-24 Herts, SG6 1ZA, UK
CIO-DAS08PGA Tel: 01462 480055
CIO-DAS08PGH CIO-ERB08 DAQCard-AO-2DC Fax: 01462 480213
CIO-DAS08PGL CIO-ERB24 Email: info@adeptscience.co.uk
CIO-DAS16 CIO-ERB48 Precision Micro WWW: www.adeptscience.co.uk
CIO-DAS16/Jr SSR-RACK08 Dynamics WebStore: www.adeptstore.co.uk
CIO-DAS16/330 SSR-RACK24
MFIO-3A (3 axis Denmark
CIO-DAS16/330i SSR-RACK48
quadrature encoder Adept Scientific Aps
CIO-DAS481 with 3 16-bit analog Nordre Jernbanevej 13C,
CIO-DAS48PGA PCMCIA (laptop) outputs) DK-3400 Hillerød, Denmark
CIO-DAS1601/12 Analogue & Digital I/O Tel: +45 48 25 17 77
CIO-DAS1602/12 PCM-DAC028 Fax: +45 48 24 08 47
Technology 80 Email: infodk@adeptscientific.dk
CIO-DAS1602/16 PCM-DAC088 5650 a WWW: www.adeptscientific.dk
PCM-DAS168 5651 WebStore: www.adeptstore.dk
PCM-DAS16/128
PCM-DAS16S/128 USA
PCM-DAS1616/168 Adept Scientific Inc.
7909 Charleston Court,
Bethesda, MD 20817, USA
1. Equivalent to three CIO-DAS16 on a single board. Tel: +1 (301) 365-0720
2. Equivalent to two CIO-CTR05 on a single board. Fax: +1 (301) 767-1675
Email: info@adeptscience.com
3. Equivalent to two CIO-CTR05/H50 on a single board. WWW: www.adeptscience.com
4. Also supported in 24 input and 24 output modes. WebStore: www.adeptstore.com
®
5. Equivalent to two CIO-DIO24 on a single board.
Copyright © 2002
6. Equivalent to four CIO-DIO24 on a single board. Adept Scientific plc.
All rights reserved.
7. Equivalent to eight CIO-DIO24 on a single board. All trademarks
recognised.
8. Supported by VisSim/Real-TimePRO on Windows 95 only.
E&OE
9. Equivalent to four PC-DIO-24 on a single board.