OpenModelica in Mechatronic Applications at Bosch Rexroth

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1 OpenModelica Annual Workshop February 02, 2009 Linköping University (LiU) OpenModelica in Mechatronic Applications at Bosch Rexroth Oliver Lenord Bosch Rexroth AG Virtual Engineering Development Simulation Software BR/ENA22

2 Overview Introduction Bosch Rexroth: The Drive & Control Company Virtual Bosch Rexroth Model-based System Engineering Engineering Process Simulation of a Mechatronic Application Requirements on a Model-based System Engineering Environment OpenModelica from a Business Perspective Conclusion & Outlook

3 The Drive & Control Company A5

4 The Markets - Branch Solutions Components, modules and systems for wind turbines Rexroth Company Presentation 06/2008 F23

5 The Markets Reference Projects Bolshoi Theater, Moscow F12

6 The Markets Reference Projects Great Beijing Wheel, China F10

7 The Markets Successful in all Industries Industrial and factory automation as well as mobile applications F2

8 The Company Data Figures for 2007 Total revenue 5,356 million Total employees 32,981 Research and development Investments Germany: 1,507 million Germany: 17,905 total: 250 million total: 377 million Europe minus Germany: 2,136 million Americas: 849 million Europe minus Germany: 8,032 Americas: 3,308 Cost share of revenue: 4.7 % Cost share of revenue: 7.0 % Asia/RoW: 864 million Asia/RoW: 3,736 A10

9 Virtual Bosch Rexroth

10 Virtual Engineering Component Development

11 Virtual Engineering Systems Engineering

12 Virtual Engineering Animation

13 Product Development of Tooling Machines Innovative Product High Performance Short Time-to-Market Distributed Development Virtual Engineering Processes Tools Infrastructure

14 Optimized processes through simultaneous engineering Waterfall model SOP Idea Concept Construction Software Engineering Commissioning Production / Operation Renewal Construction : T8 WZW G1 X100 G2 X200 G1 Y250 G1 X150 : Generation Selection Mechanics Automation Mechanik Elektrik Software Engineering PLC-Program Program Testing NC-Progr. Process optimization Retrofit Product overhauling Simultaneous Engineering Mechanics Electrics PLC-Program Program Commissioning Production / Operation : T8 WZW G1 X100 G2 X200 G1 Y250 G1 X150 : Renewal Testing NC-Progr. Process optimization Retrofit Product overhauling Saving potential Time

15 Macro cycle in the engineering process according to VDI 2206 Requirements Product System Design Iterative Verification Process System Integration Domain Specific Design Simultaneous Mechanics Engineering Electrical Engineering Engineering Computer Sciencs Virtual Modeling Engineering and Analysis

16 Application of the V-model Virtual Engineering Reduction in Time To Market Versatile machine concepts Optimized machine performance Simplified engineering Reduced startup time Higher quality and safety Increased availability Extended Warranty Retooling Concept Virtual Prototype Commissioning Generation Idea Selection Mechanics Automation Construction Testing Iterative Process PLC- Progr. Software Engineering Production / Operation : T8 WZW G1 X100 G2 X200 G1 Y250 G1 X150 : NC-Progr. Process optimization Renewal Retrofit Product overhauling Mechanics Electrics mcad ecad PLC-Program Program

17 Virtual engineering as interdisciplinary iterative process Software Engineering PLC Prog. I/O-behavior simulation mcad ecad PLC Prog. approved Commissioning PLC-Program Program Testing Function System simulation Transfer behavior Req. Spec. ecad Concept Dynamics (Load case) Structure simulation phys. Properties, Parameters Construction mcad Mechanics Automation Mechanics Electrics

18 Example: Cooperative Product Development Idea: Crossbarfeeder Concept: Animated Visualization for marketing purposes

19 Goals Design: Sizing of the electric drives Control Engineering: Parameter fitting for closed-loop controllers Verification: Cycle time of 12 strokes per minute Commissioning: Effort reduction through parameter application from the simulation model to the target system

20 Model of the Mechanical Part FEM Analysis of the elastic deformation of the mechanical structure MBS with flexible bodies Consideration of the elasticity of the power train (transmission and belt)

21 Model of the Mechanical Part Crossbar Feeder (CBF) CAD Model of the CBF MBS model in ADAMS

22 Model of the Electrical Part Model of the electric drive and control loops in Matlab/Simulink Electric drive Position controller Speed controller Current controller Sensorsystem

23 Co-Simulation of the entire System Simulation of the Overall System with 5 Axes Co-Simulation: ADAMS Matlab/Simulink F 1..n x 1..n; xp 2..n MSC-ADAMS MATLAB/Simulink

24 Simulation Results

25 Result A result is what finally works in the customers hands.

26 Application of the V-model Model-based Virtual Engineering Reduction in Time To Market Versatile machine concepts Optimized machine performance Simplified engineering Reduced startup time Higher quality and safety Increased availability Extended Warranty Retooling Concept Virtual Prototype Commissioning Generation Idea Selection Mechanics Automation Construction Testing Iterative Process Model PLC- Progr. Software Engineering Production / Operation : T8 WZW G1 X100 G2 X200 G1 Y250 G1 X150 : NC-Progr. Process optimization Renewal Retrofit Product overhauling Mechanics Electrics mcad ecad PLC-Program Program

27 Summery: Model-based Engineering Proposition of Bosch Rexroth Leading in Drive & Control solutions Component, Module and System Supplier Services (, System Engineering, ) Gain of Model-based Engineering Better products (component optimization) Better market fit (virtual prototyping of new concepts) More effective engineering services More successful customers - strong cooperation - effective communication - cutting edge solutions The Model is the vehicle to bring the BR-technology into our customers application.

28 Functional Requirements on a Model-based System Engineering Environment System Modeling Requirements Engineering System Topology Test cases Multi-physics modeling Drives (Hydraulics, Pneumatics, Electrics, Power train) Multi-body Dynamics (rigid, flexible, contacts) Controls, Sensors HiL/SiL Simulation Synchronized bus-communication Real-time Parameter Application µcontroller Code Generation

29 Non-Functional Requirements on a Model-based System Engineering Environment Modeling/Simulation functionality shall be: transparent performant extensible customizable Integration Data/Model exchange - non-proprietary - standardized - well supported Open interfaces reusable, redistributable, freely available

30 Conclusions SysML and Modelica: Have the potential to fulfill the requirements on a standardized common modeling language in the field of System Engineering Enable an effective communication of Bosch Rexroth and his customers OpenModelica: strengthens the Modelica language makes the model-based engineering affordable (even for small businesses) serves as a default interpreter of the Modelica language decreases the dependency on commercial simulators provides a good starting point for powerful in-house simulation tools

31 Outlook OpenModelica: Level 2 Member of the OSMC Contributes to the OpenModelica Compiler (i.e. Solver Interface) Cooperation with the OSMC members Integration of the OpenModelica Compiler into the Bosch Rexroth in-house simulation platform D&C Engine OPENPROD ITEA2 project Partner and national coordinator of the project proposal Work packages related to demonstrators and model reduction MODELISAR project Partially involved into the design of the Functional mock-up interface

32 Thank you for your attention Oliver Lenord BR/ENA (0)

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