Multi-physics with MotionSolve
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The document discusses the necessity and application of multi-physics simulations in complex systems, specifically focusing on the control of wind turbines and the integration of various simulation technologies. It highlights how Motionsolve facilitates coupling between different domains to optimize system performance and reduce errors in design. A case study on optimizing cable positions for Faurecia illustrates the practical benefits and automated processes achievable through co-simulation with Motionsolve and MATLAB/Simulink.
Multi-physics with MotionSolve
- 1. Multi-Physics with MotionSolve Rajiv Rampalli & Keshav Sundaresh, Altair Innovation Intelligence®
- 2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation Outline • Need for Multi-Physics simulations • Case Study: Control of a Wind Turbine • How other customers are doing Multi-Physics simulations 2
- 3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Real Models Are Complex Hydraulics & H d li Flexible N Fl ibl & Non-linear li Control systems components Virtual tires & Virtual driver digitized roads models 3
- 4. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Industrial Processes Are Complex TIRE & ROAD MBD FATIGUE G POST DRIVER FE DRIVER FE 4
- 5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. The Conundrum Systems Software Multiple Domains Single Domain Diverse Phenomena Single Formulation Many Technologies One Integrator 5
- 6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Introducing MotionSolve… • A natural environment for multi-disciplinary studies • Open architecture for coupling domains • Many different choices available for coupling 6
- 7. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Model Connection Methodologies Master System Equations S-1 S-2 S-2 Sharing Equations Co-Simulation (Sharing signals) Simulator-1 Simulator-2 Shared Data Sharing Linear Models 7
- 8. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Linear Models: With Simulink Matlab MotionSolve M ti S l Simulink MotionSolve exchanges state matrices with Matlab/Simulink 8
- 9. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Linear Models: With FE HyperMesh MotionView Radioss MotionSolve MotionSolve shares data with a variety of FE codes 9
- 10. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Equations: via User Subroutines Object Code User MotionSolve Subroutine Python Script DLL MotionSolve User subroutines allow users to link their own equations to MS U b ti ll t li k th i ti t 10
- 11. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Equations: via Code Export Object Code Motion Motion “C” Solve RTW Solve Code DLL Simulink Controller Co-simulation Co simulation Native RTW code import from Simulink 11
- 12. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Signals: MotionSolve + Simulink System Model MotionSolve model S-Function (MS ) Controller Simulink Window MotionSolve is an S-Function in Simulink 12
- 13. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Signals: MotionSolve + DSHplus System Model User Block (MS ) Hydraulic System DSHplus Window MotionSolve is a user block in DSHplus 13
- 14. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Sharing Signals: MotionSolve + Driver System Model y Controls & Switching Signals Speed Controller Gearbox Controller Feedback Controller Signals Outputs Steering Controller Vehicle Model Driver Model ( (MS)) MotionSolve can include complex driver models via co-simulation 14
- 15. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation Outline • Need for Multi-Physics simulations • Case Study: Control of a Wind Turbine • How other customers are doing Multi-Physics simulations 15
- 16. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Co-simulation – Wind Turbine Emergency Stop “Grid loss” – Sudden drop in generator torque Grid loss Reaction: Immediate blade pitching and activation of the brake disk. E-stop event • 0-60s Ramp up to full effect, 1MW. 120.0s “Grid loss” 100-0% in 0.1s 120.4s Maximum brake pressure & reversing pitch angle 135.0s Pitching complete Mechanical system, Wind loads – lift and drag forces v/s pitch angle, Tower shadow - %ge drop of wind forces in front of the tower 16
- 17. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Initial Results • Grid loss and braking generate massive rotor torque variations t t i ti • Large blade vibrations during overshoot • Blades vibrate during initial braking, causing high frequency variations of rotor torque. 17
- 18. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Control Requirements • Implement a non-linear braking pressure to: • Reduce blade deflection • Eliminate overshoot Brake controller: Blade deflection v/s Brake magnifier Brake release: Rotational speed v/s release factor Low pass filter to the braking signal – to avoid rapid vibrations 18
- 19. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Control Model in Simulink Rotor Velocity Flex Sensors Control Parameter C t lP t Plant Outputs Plant Outputs Flex Sensors Rotor Velocity Controller MS Model Sensors Flex Sensors 1 z Rotor Velocity 1 z Blade Deflection 19
- 20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Co-Simulation Results 100% Rotor Speed Simulink Rotor Speed 100% R t S Rotor Speed d Simulink Rotor Speed Si li k R t S d 100% Rotor Speed Simulink Rotor Speed Brake controller: Blade deflection v/s Brake magnifier Brake release: Rotational speed v/s release factor 20
- 21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation Outline • Need for Multi-Physics simulations • Case Study: Control of a Wind Turbine • How other customers are doing Multi-Physics simulations 21
- 22. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Faurecia – Glass guidance simulation • Challenge: • Find the cable positions to meet requirements on normal f l forces f different combinations of for diff t bi ti f friction. • Solution: • Mechanism analysis with MotionSolve to find the normal forces • Design optimization with HyperStudy to find the optimal cable positions. • Benefits: • An optimal design that meets all conflicting requirements. • A fast & automated design process leading to fewer errors & better designs. “Co-simulation of window regulator with MotionSolve and Matlab/Simulink gives a full mechatronics model of the system, allowing simultaneous design of both mechanism and actuator” – Dany Desrus, Leader Product Line EE & Mechatronics, Faurecia Interior Systems22
- 23. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Summary • Real systems are complex • A full understanding of these requires multi-disciplinary simulation • MotionSolve has an architecture that facilitates coupling of different solvers to enable multi-disciplinary simulation • Many different options for coupling are available y g • The simulation requirements and coupling difficulty dictate which choice should be used. Thank You! 23
- 24. Rajiv Rampalli Keshav Sundaresh(keshavs@altair.com) Innovation Intelligence®