Multi-physics with MotionSolve

Innovation Intelligence®

Multi-Physics with MotionSolveRajiv Rampalli & Keshav Sundaresh, Altair

Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.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

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Real Models Are Complex

H d li & Fl ibl & N liHydraulics & Control systems

Flexible & Non-linear components

Virtual tires & Virtual driverVirtual tires & digitized roads

Virtual driver models

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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Industrial Processes Are Complex

TIRE & ROAD

POSTGMBD POSTFATIGUEMBD

DRIVER

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FEDRIVER FE


The Conundrum

Systems Software

Multiple DomainsDiverse Phenomena

Single DomainSingle Formulation

Many Technologies One Integrator

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Introducing MotionSolve…

• A natural environment for multi-disciplinary studies• Open architecture for coupling domains• Many different choices available for coupling

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Model Connection Methodologies

Master

System Equations

S-1 S-2 S-2

Simulator-1 Simulator-2

Co-Simulation (Sharing signals)Sharing Equations

SharedData

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Sharing Linear Models


Sharing Linear Models: With Simulink

MatlabM ti S l MatlabSimulinkMotionSolve

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MotionSolve exchanges state matrices with Matlab/Simulink


Sharing Linear Models: With FE

MotionViewHyperMesh MotionViewMotionSolve

HyperMeshRadioss

9MotionSolve shares data with a variety of FE codes


Sharing Equations: via User Subroutines

ObjectCode

MotionSolveDLL

User Subroutine MotionSolvePython Script

U b ti ll t li k th i ti t MS

DLLSubroutine

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User subroutines allow users to link their own equations to MS


Sharing Equations: via Code Export

ObjectCode

MotionMotion

“C”MotionSolve

SolveDLL

RTW“C”Code

Co simulation

SimulinkController

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Co-simulation

Native RTW code import from Simulink


Sharing Signals: MotionSolve + Simulink

System Model

MotionSolveMotionSolvemodel

ControllerS-Function (MS ) Simulink Window

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MotionSolve is an S-Function in Simulink


Sharing Signals: MotionSolve + DSHplus

System ModelSystem Model

Hydraulic SystemUser Block (MS ) DSHplus Window

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MotionSolve is a user block in DSHplus


Sharing Signals: MotionSolve + Driver

System Modely

Speed Controller

Controls & Switching Signals

Gearbox ControllerFeedbackSignals

ControllerOutputs

Driver ModelVehicle Model(MS)

Steering Controller

14MotionSolve can include complex driver models via co-simulation

( )






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Co-simulation – Wind Turbine Emergency Stop

“Grid loss” – Sudden drop in generator torqueGrid loss Sudden drop in generator torqueReaction: 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 0.1s120.4s Maximum brake pressure & reversing pitch angle135.0s Pitching complete

16Mechanical system, Wind loads – lift and drag forces v/s pitch angle, Tower shadow - %ge drop of wind forces in front of the tower


Initial Results

• Grid loss and braking generate massive t t i tirotor torque variations

• Large blade vibrations during overshoot• Blades vibrate during initial braking, causing

high frequency variations of rotor torque.

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Control Requirements

• Implement a non-linear braking pressure to:

• Reduce blade deflection

• Eliminate overshoot

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Brake controller: Blade deflection v/s Brake magnifierBrake release: Rotational speed v/s release factorLow pass filter to the braking signal – to avoid rapid vibrations


Control Model in Simulink

Rotor Velocity C t l P t Flex SensorsRotor Velocity

Flex Sensors

Controller

Control ParameterPlant Outputs

MS Model Sensors

Plant OutputsFlex Sensors

Rotor Velocity

1z

Flex Sensors

1z

Rotor Velocity

Blade Deflection

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Co-Simulation Results

100% Rotor Speed

Simulink Rotor SpeedSimulink Rotor Speed

100% R t S d Si li k R t S d100% Rotor Speed Simulink Rotor Speed100% Rotor Speed

Simulink Rotor Speed

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Brake controller: Blade deflection v/s Brake magnifierBrake release: Rotational speed v/s release factor






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Faurecia – Glass guidance simulation

• Challenge: • Find the cable positions to meet requirements

l f f diff t bi ti fon normal forces for different combinations of friction.

• Solution: • Mechanism analysis with MotionSolve to find• 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.requirements.• A fast & automated design process leading to

fewer errors & better designs.

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“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 Systems


Summary

• Real systems are complex • A full understanding of these requires multi-disciplinary

simulation• MotionSolve has an architecture that facilitates coupling• MotionSolve has an architecture that facilitates coupling

of different solvers to enable multi-disciplinary simulation• Many different options for coupling are availabley g• The simulation requirements and coupling

difficulty dictate which choice should be used.

Thank You!

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Innovation Intelligence®

Rajiv RampalliKeshav Sundaresh([email protected])

Multi-physics with MotionSolve

Technology

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