Simulation Model

Requirements and
Modeling and simulation Control Electrical
Specifications

of multi-domain
physical systems Embedded Mechanic
Software al

PLC HIL

Shripad Chandrachood
Sr. Application Engineer
MathWorks – Natick, MA

© 2013 The MathWorks, Inc.1

Motivation

 Many real-world physical systems are multi-domain:

Combination of Electrical, Mechanical, Hydraulic etc.

 Successful controller development requires thorough

and accurate understanding of the physical system
2
Motivation

 Many real-world physical systems are multi-domain:

Combination of Electrical, Mechanical, Hydraulic etc.

 Successful controller development requires thorough

and accurate understanding of the physical system
3
Motivation

 Many real-world physical systems are multi-domain:

Combination of Electrical, Mechanical, Hydraulic etc.

Blades
Nacelle
Geartrain
Hub
Generator
Rotor
Speed

Tower Grid

 Successful controller development requires thorough

and accurate understanding of the physical system
4
Case Study: Wind Turbine Modeling

Pitch
Wind Lift, Drag
Blades

Nacelle
Hub Geartrain Generator

Rotor
Speed
Generator
Speed
Yaw

Tower Grid
5
Agenda

 System-level simulation of a wind turbine

 Benefits of the Model-Based Design process
 Modeling multi-domain physical systems using Simscape
 Overview of MathWorks physical modeling tools
 Testing system integration

6
Key Points Simulation Model
Requirements and
Specifications
Control Electrical

 Efficient design of wind turbines Embedded

Mechanical
requires a smooth, continuous Software

development process
PLC HIL

 The ability to easily adjust

Actuator System
the level of model fidelity Inputs
(Ideal) (Include)
enables earlier detection of Actuator System
integration issues (Realistic) (Ignore)

 Automatically documenting
tests can speed up design
iterations and provide necessary
proof of system performance
7
Traditional Development Process

Requirements and Specifications

Requirements are
unclear, incomplete,
and not integrated in
design process
Design and Implementation
Separate simulation
models are difficult
Embedded
Control Software Mechanical Electrical to integrate

Errors are found too

Integration and Test late in the process
using expensive
prototypes

8
Model-Based Design Process

Simulation Model
Requirements Save time by
and developing in a single
Specifications simulation environment
Control Electrical
Produce better designs
by continuously
Embedded comparing design and
Software Mechanical specification

PLC HIL Lower costs by using

HIL tests and fewer
hardware prototypes

9
Demo: Wind Turbine System-Level Simulation

10
 Linking Specification and Design

Situation:

Simulation Model

Wind Turbine Req.

1. Control System

2. Electrical System Control Electrical

3. Mechanical System

Embedded
Software Mechanical

Problem: Matching design to

specification is difficult
Solution: Use Simulink
Verification and Validation
to link the design and specification
11
Detect System Integration Issues In Simulation

Model:

Mechanical Controls
Park
Hydraulic Supervisory
Logic Spin

Drag
Electrical Aero- Lift
dynamics
Wind

Problem: Test for system

integration issues before
building hardware prototypes
Actuator System
Inputs
Solution: Use the Simulink (Ideal) (Include)
environment to integrate the Actuator System
separate systems in simulation (Realistic) (Ignore)
12
Optimize System-Level Performance

Actuators

Sensors
u + s1 s2
System
y
s3

Controller Plant

 Simulating plant and controller in one environment

allows you to optimize system-level performance.
– Automate tuning process using optimization algorithms
– Accelerate process using parallel computing

13
 Detect Integration Issues Earlier

Plant Plant
Specification Model

Actuators

Sensors
u + s1 s2
System
y
s3

Controller Plant

 Controls engineers and domain specialists can work

together to detect integration issues in simulation
– Convert plant models to C code for hardware-in-the-loop tests
– Distribute models to other internal users without extra licenses
– Distribute models to external users while protecting IP

14
 Build Accurate Models Quickly

Plant
Multidomain
Fortran, C++ Plant
Specification Domain Knowledge Programming Effort Model
Mechanical
MATLAB, Simulink
Domain Knowledge Programming Effort
Hydraulic

Electronic Physical Modeling

Domain Programming
Power Systems Knowledge Effort

 Requires less domain knowledge and

programming effort than traditional methods
– Spend more time developing, less time modeling

15
 MathWorks Physical Modeling Products

Simscape
Mechanical Hydraulic Electrical
SimPowerSystems

Thermal Pneumatic Magnetic

SimHydraulics
N S

Custom Domains via

Simscape Language

Multidomain physical systems

Electrical power systems Fluid power and control

SimElectronics
SimMechanics

SimDriveline

Multibody mechanics (3-D) Mechanical systems (1-D) Electromechanical and

electronic systems 16
MathWorks Physical Modeling Products

SimPowerSystems
SimElectronics
SimMechanics

SimHydraulics
SimDriveline

Simscape
Mechanical Hydraulic Electrical Thermal Pneumatic Magnetic

17
Case Study: Wind Turbine Modeling

Pitch
Wind Lift, Drag
Blades

Nacelle
Hub Geartrain Generator

Rotor
Speed
Generator
Speed
Yaw

Tower Grid
18
The Technology of Modern Wind Turbines

Wind turbines have mechanical and electrical components

and are enabled by power electronics
19
 Model the Generator and Electrical Grid

Model:

Geartrain Grid

Transformer
Load

Problem: Model the generator and

electrical grid for the wind turbine
Solution: Use SimPowerSystems
built in components for induction,
synchronous generators, or wind
turbine modules 20
Model the Utility Grid

 Model localized power distribution grids that include synchronous and

asynchronous machines, transformers, transmission line dynamics and a
variety of specialized FACTS devices
 Use SimPowerSystems Discrete Simulation Type for detailed transient
analysis or switch to Phasor Simulation Type for steady state analysis

21
 Model the Geartrain in SimDriveline

Model:
Hub Generator
Shaft Shaft

Helical
Helical
Gear
Gear
Planetary
Gear

Problem: Model the geartrain

of the wind turbine within the
Simulink environment to determine
the torque loads.
Solution: Use SimDriveline
to model the geartrain.
22
Model DC to DC Power Converters

 Construct, test and re-use multiple power electronic

converter topologies quickly and efficiently

Buck (step-down) Converter

Boost (step-up) Converter

Buck-Boost Converter

23
Model DC to DC Power Converters

 Balance model fidelity and simulation speed according

to your needs

SimPowerSystems
Piecewise linear systems solution
Multiphase bridges and pulse generators
Transient and harmonic analysis
Faster simulation

SimElectronics
Nonlinear simultaneous equations solution
Include temperature effects
SPICE level switching device models
Detailed simulation

24
Model DC to AC Power Inverters

 Build complex, multi-phase, multi-level inverter circuits using the Universal

Bridge from the SimPowerSystems library

 Use the built-in tools in SimPowerSystems to perform harmonic analysis

directly on your simulation model
 Use average voltage models or ideal switching algorithms for control
design and faster simulation

25
Mechanical Design: Import the Entire Design
Directly from a CAD Tool

SimMechanics Model
SolidWorks Model

The translator automatically generates the SimMechanics model using CAD information

26
Mechanical Design: Using SimMechanics Link
to Import from a CAD Tool
 Automatically create SimMechanics
models from a CAD assembly
– Converts mass and inertia
to rigid bodies
– Converts mate definitions to joints
– Creates STL files for use
with SimMechanics visualization
 Directly connects SolidWorks,
ProEngineer and Inventor
 Public API for other CAD tools
 Free download from
www.mathworks.com
– Requires MATLAB
27
Mechanical Design: Using SimMechanics Link
to Import from a CAD Tool
 SimMechanics Link can
import XML file to:
– Create a new model
– Add to existing model
– Update an existing model
– Replace a portion of an
existing model

 Engineering teams can

collaborate on the same
system without doing
redundant work

28
 Model Blade Pitch
Linkage

Model:

Problem: Model the blade pitch

actuation linkage in the
Simulink environment
Solution: Use SimMechanics
to model the mechanical linkage
29
Flexible Bodies in SimMechanics

 Lumped parameter approach

– Chain of rigid elements connected by spring/dampers

Rigid Rigid Rigid Rigid Rigid

Body Body Body Body Body
FE
Software
 Finite Element Approach
– Export eigenmodes 1 2
Massless Reaction Reaction Massless
from FE program and Force
State-Space Force
Body Body
Model
import into Simulink
– Superimpose deflection Deflection
Deflection Deflection
due to flexibility Joint
Motion
Joint
onto rigid body motion
3 4
Rigid Body

30
 Flexible Blades in SimMechanics

Model:

Problem: Model the blades as

flexible cantilevers in the
Simulink environment.
Massless
Solution: Use SimMechanics to State-Space Body

model the flexible body with two Model

Deflection
Joint
approaches (lumped parameter,
imported FEA modes). Rigid Body 31
 Wind Turbine Control Systems

 Blade pitch control system

Pitch – Adjust pitch angle to regulate
rotational speed
Wind Lift, Drag
Blades  Supervisory control system
– Analyze operating conditions to
Nacelle determine state of turbine
Hub Geartrain Generator to enable/disable operation

Rotor
Speed
Generator
Speed
Yaw

Tower Grid
32
 Controlling Rotor Speed Using the Pitch Angle

Model:

Pitch

Lift

Rotor
Speed

Problem: Control the pitch

angle so that the generator Desired Desired Angle Pitch Angle
shaft spins at nominal speed Rotor Speed Control
of Attack
+
Command

Solution: Use Simulink to -

Actual Inflow
determine the pitch angle by Rotor Speed Angle
controlling the angle of attack 33
Integrating Simscape with Simulink

Actuators

Sensors
s1 s2

u + s3
Physical
System
y
Controller Plant
(SL/SF) (Simscape)

34
34
Automatically Document Tests And Results

Situation:
Test

Design
Change Document

Evaluate
Results

Problem: Evaluate test results

quickly to make design changes
 Fail
PDF,
and document the results HTML,
Solution: Use Simulink Report
Pass
Doc,
Generator to automatically …
document tests and results 35
 Automatically Generating C Code

Model:

P1 P2 Px
10 10 …
100 10 …
… … …

Problem: Minimize the simulation

time on a parameter sweep to Standalone
Executable
determine controller parameters.
Parameters 1
Solution: Use Simulink Coder to Parameters 2
create standalone executable. Parameters 3

Parameters 4 36
 Test Controller Hardware and Performance of
Generated Control Code

Model: Wind Turbine

Wind Pitch
Speed Pitch Command
Test Pitch
Control
Vector Actuator
Algorithm
Pitch Angle
Rotor Speed

Pitch
Anemometer Command
Signal

Pitch
Angle

Problem: Test control algorithm Solution: Generate C code for

on actual controller hardware controller and plant to run
without using prototypes hardware-in-the-loop tests
37
 HIL Test Setup
HIL System
Pitch command is
Anemometer communicated via CAN
measures wind speed to pitch actuators.
and provides input signal Pitch angle is sensed
to HIL system and sent back to
main controller via CAN.

Simulink Model

Bachmann electronic
M1 hardware controller
runs turbine model
in real time Model is configured for HIL tests,
converted to C code,
and downloaded to controller
38
 Model-Based Design

Plant Modeling Control Design Testing

SimMechanics Simulink Control Design xPC Target

Simscape Control System Toolbox MATLAB Coder
SimElectronics Simulink Design Optimization Simulink Coder
SimPowerSystems Optimization Toolbox DSP System Toolbox
Simulink Design Optimization
Optimization Toolbox

39
Summary

 Optimize system performance

– Develop in a single environment
– No cosimulation

 Find problems before building

hardware using HIL

 Discover integration problems

using simulation
– No cosimulation

 Create accurate, reusable

plant models quickly and easily
40
More on Physical System Modeling…

41
 Modeling Physical Systems
With MathWorks Products

Modeling Approaches

First Principles Modeling Data-Driven Modeling

Physical Networks Statistical Methods

Programming (Model Based System
(MATLAB, C) (Simscape and other
Physical Modeling Calibration Toolbox) Identification
(System Identification
Block Diagram products) Toolbox)
(Simulink)

Modeling Language Neural Networks

(Simscape language) (Neural Network
Toolbox)
Symbolic Methods Parameter Tuning
(Symbolic Math (Simulink Design Optimization)
Toolbox)

42
 Modeling Approaches

First Principles Data-Driven

Programming

Block Diagram

Modeling Language

Symbolic Methods

 Purpose: Explore design or physical parameters

 Requirements:
– Physics of system are well-known
– System-level equations can be derived and implemented

43
 Modeling Approaches

First Principles Data-Driven

Physical Networks
Programming

Block Diagram

Modeling Language

Symbolic Methods

 Purpose: Explore design or physical parameters

 Requirements:
– Physics of system are well-known
– Component-level models exist or can be created

44
 Modeling Approaches

First Principles Data-Driven

Physical Networks Statistical Methods
Programming System
Identification
Measured
Block Diagram
Model
Modeling Language Neural Networks

Symbolic Methods

 Purpose: Model an existing design (real or virtual)

 Requirements:
– Relevant set of measured data is available
– Design and physical parameters will not be changed

45
 Modeling Approaches

First Principles Data-Driven

k = ?
b = ?
Parameter Tuning

 Purpose: Ensuring parameter values are accurate

 Requirements:
– Relevant set of measured data is available
– Physically meaningful parameters can be automatically tuned

46
 Modeling Approaches

First Principles Data-Driven

Physical Networks Statistical Methods
Programming (Model Based System
(MATLAB, C) (Simscape and other
Physical Modeling Calibration Toolbox) Identification
(System Identification
Block Diagram products) Toolbox)
(Simulink)

Modeling Language Neural Networks

(Simscape language) (Neural Network
Toolbox)
Symbolic Methods Parameter Tuning
(Symbolic Math Toolbox) (Simulink Design Optimization)

 Use the approach appropriate for your situation

 Each of these approaches can be leveraged
using MathWorks products

47
 Simscape and Physical Modeling Products

Simscape
Mechanical Hydraulic Electrical
SimPowerSystems

Thermal Pneumatic Magnetic

SimHydraulics
N S

Custom Domains via

Simscape Language

Multidomain physical systems

Electrical power systems Fluid power and control

SimElectronics
SimMechanics

SimDriveline

Multibody mechanics (3-D) Mechanical systems (1-D) Electromechanical and

electronic systems 48
Quickly Build Intuitive Models Physical Modeling

Motor
Servoamplifier Hall Effect
Models that reflect system Sensor
DC Motor
Structure are easier to
understand,
modify, and reuse
Speed Controller

A B

T P T

Vehicle
Dynamics

Hydraulic Valve
Gears Diff
Engine

49
Quickly Build Intuitive Models Physical Modeling

Motor
Servoamplifier Hall Effect
Models that reflect system Sensor
DC Motor Best Practice
Structure are easier to
understand,
modify, and reuse
Speed Controller

A B

Aileron Mechanics
T P T

Hydraulic Valve

50
Electrical Systems in Equations

R DC Motor
dim
v  K e   imR wind  L wind
dt
L d
θ T  K t im  D  J
dt

Kt,Ke

J,b
i

51
Electrical Systems in Simscape

R DC Motor
dim
v  K e   imR wind  L wind
dt
L d
θ T  K t im  D  J
dt

Kt,Ke

J,b
i

 Simscape model advantages

– Easier to read than equations
– Quicker to create
– More intuitive – easier to explain to other engineers
52
Physical network approach (Simscape) vs.
Signal Flow approach (Simulink)

 Simulink Blocks are causal

– Transfer functions
– Input and output ports (signal flow)
– Graphically model system equations

τ,ω
 PhysMod “Blocks” are acausal
– Bi-directional energy flow
– Domain-specific physical ports
(electrical, hydraulic…)
– Graphically model system topology

53
 Demo: Signal Flow vs. Network Approach
Electrical example: RC circuit

Simscape (Network) Model

Simulation Results:
i  v/r
Input Stimulus: dv
ic
dt

input output

1
p 
RC
Simulink (Block diagram) Model
54
Signal Flow vs. Network Approach
with hardware interactions

Simscape Network Model

Simulation Results:

Simulink Block Diagram Model

input output

Cascading two filters gives different results … Why?

55
 Signal Flow vs. Network Approach
Modeling interactions

Simscape model System interactions

+ + vin  vout
 iin
iin iout R
vin vout

- - vout 
1
 iin  iout dt
C
Original Simulink model:

No interactions
No conservation

New Simulink model … … with interactions

56
Signal Flow vs. Network Approach
Summary

 Signal Flow (Simulink)

– No interaction between blocks unless explicitly specified
– The user must be aware the interactions exist and model the
effect
– System changes require model reformulation
 Network Approach (Simscape)
– System of equations automatically created and solved by
simulator
– Enforces conservation (KCL, Newton’s Law, etc…) at every
junction
– Topology changes easy to make, interactions occur
automatically

57
 Simscape Pre-defined Domains

 Simscape generalizes conservation laws across physical domains

– i = 0 at every junction (where i is the through variable)
 Simscape pre-defined domains:

Port Type Across Variable Through Variable

Electrical Voltage Current
Hydraulic Pressure Flow rate
Mechanical Angular velocity Torque
(rotational)
Mechanical Translational velocity Force
(translational)
Pneumatic Pressure and temperature Mass flow rate and
heat flow
Thermal Temperature Heat flow
Magnetic MMF Flux

58
Simscape Language Example: DC Motor

 DC motor with inertia load

p1
Motor Equations:
dim
v  K e  im Rwind  Lwind
dt
d
shaft Tq   K t im  D  J
p2 dt

v = Terminal voltage Rwind = Winding resistance

Kt = Torque constant Lwind = Winding inductance
Ke = Back emf constant Tq = Output torque
 = Shaft speed D = Damping coefficient
im = Motor current J = Moment of inertia

59
 Simscape Language Example: DC Motor

component dc_pm
nodes
p = foundation.electrical.electrical; % p:left
n = foundation.electrical.electrical; % n:left Physical
r = foundation.mechanical.rotational.rotational; % r:right
c = foundation.mechanical.rotational.rotational; % c:right Connections
end
parameters
Kt = {10 'N*m/A'}; % Torque constant
Ke = {10 'V/(rad/s)'}; % Back EMF Constant
Rwind = {1 'Ohm'}; % Winding Resistance Motor
Lwind = {1e-3 'H'};
J = {1 'kg*m^2'};
% Winding Inductance
% Motor Inertia
Parameters
B = {1 'N*m/(rad/s)'}; % Motor Damping
end
variables
theta = { 0, 'rad' }; % Angular Displacement
tq = { 0, 'N*m' };
w = { 0, 'rad/s' };
% Torque through variable
% Ang Vel across variable
Internal
i = { 0, 'A' }; % Current through variable Variables
v = { 0, 'V' }; % Voltage across variable
end
equation
w == theta.der;
v == Ke*w + i*Rwind + Lwind*i.der; % Motor Motor
end
tq == -Kt*i + B*w + J*w.der; % equations
Equations
end
60
Simscape Language Overview

 Provides first principles modeling at component level

 Enables control over model fidelity
– Add non-linear effects
– Include domain interactions (i.e. thermal effects)
– Supports conditional statements
 Leverage the foundation library source code as starting
point

61
61
Benefits of Network Modeling Approach

 Network analysis techniques used to solve system

 Burden on simulator not the user to formulate system
equations
 Fidelity of system model is determined by component
equations
 Network representation easy for non-experts to follow
and understand

62
62
Multi-Domain System in Simscape

6
7

4
1. Voltage is applied to motor
2. Motor generates torque to spin pump
3. Pump supplies pressure to the
8 hydraulic valve
3 4. Actuator is used to open/close the
2
valve and direct fluid flow
1 5. Hydraulic cylinder moves left or right
depending on valve position
6. Mechanical load provides opposing
force to cylinder
7. Motion sensor feeds position back to
controller
8. Control unit provides set point
9. Position control is achieved
10. No system equations derived!
63
63
Multi-Domain System in Simscape

6
7
9

4
1. Voltage is applied to motor
2. Motor generates torque to spin pump
3. Pump supplies pressure to the
8 hydraulic valve
3 4. Actuator is used to open/close the
2
valve and direct fluid flow
1 5. Hydraulic cylinder moves left or right
depending on valve position
6. Mechanical load provides opposing
force to cylinder
7. Motion sensor feeds position back to
controller
8. Control unit provides set point
9. Position control is achieved
10. No system equations derived!
64
64
Summary

 Optimize system performance

– Develop in a single environment
– No cosimulation

 Find problems before building

hardware using HIL

 Discover integration problems

using simulation
– No cosimulation

 Create accurate, reusable

plant models quickly and easily
65
Q&A

66