Modelling and Simulation of coupled hydraulic and multibody subsystems (with extension to realtime application)

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1 1 / 20 Modelling and Simulation of coupled hydraulic and multibody subsystems (with extension to realtime application) Prof. S. Liebig, S. Dronka Technische Universität Dresden Prof. S. Helduser, M. Stüwing Technische Universität Dresden The presented results are generated by a project with the title Development tools for railway carriages with hydraulic components. The project was funded by the German Federation of Industrial Cooperative Research Associations Otto von Guericke (AiF-Nr B/1), on behalf of The Federal Ministry of Economics and Technology (BMWi), in the Section Fluid Power of the German Engineering Federation (VDMA). 11 October 2001

2 Motivation 2 / 20 Adding active elements into structures (mechatronic systems) Application of simulation tools in development process + = Need for multi-domain simulation tools Example: Tilting train Hydraulic components for Active tilting system Active secondary suspension Active axle steering system Hydropneumatic suspension Actuator for tilting system

3 Situation with the manufacturers 3 / 20 Manufacturer of actuators Model data valve cylinder supply transmission units hydraulic simulation F x, v, a Simple models representing mechanical part (vehicle) reduced masses one / two dof systems m F Hydr x, v, a Model data mass / Inertia tensor spring / damper Joints Track data Manufacturer of vehicle vehicle simulation F Simple models representing hydraulic part (actuators) s nonlinear functions (2D/3D/...)

4 Main topics of the project 4 / 20 Multi-body model Calculation of the coupled systems Hydraulic model F Simulation of coupled x, v, a multi-body and hydraulic systems under realtime conditions Behaviour of the actuator Measurem ent unit Behaviour of the vehicle Control of load simulation cylinder Hardware-in-the-Looptest rack Realtime simulation Load simulation by cylinder Construction of the test rack

5 Formulation of demands for the solution 5 / 20 Modelling of the subsystems Application of specialized tools Application of commercially available standard tools Tools must offer the possibility of model export Use of standard interfaces Coupling of the subsystems Crossover to the realtime hardware Software support for this step with a minimum programming effort

6 Software concept 6 / 20 MBS simulation tool SIMPACK Hydraulic simulation tool F x, v, a DSHplus Crossover to real-time hardware Export of model (FORTRAN) f2c (C) Multi-body model S-Function MATLAB/SIMULINK: Coupled simulation Simulation control Real-Time- Workshop S-Function Export of model (C++) Hydraulic model RT-LAB Routines Real-time simulation RT-LAB environment P 1 P 2 Real-time P 3

7 Potential of the solution I 7 / 20 Application of general software tools for modelling SIMPACK: - any* mechanical 3Dstructure can be modelled DSHplus: - any* hydraulic or pneumatic system can be modelled *) corresponding to the possibilities of the modelling tool Application of RTW for the crossover to real-time hardware Integrated tool chain from (offline-)simulation up to the level of real-time simulation There are several real-time systems available for using with RTW

8 Potential of the solution II 8 / 20 Use of standard interface (s-function) for integration of models into simulink Substitution of modelling tools 1) Addition of subsystems of other engineering disciplines 2) 1) tool with the possibility of model export (MKS: NEWEUL instead of SIMPACK, Hydraulic: AMESim instead of DSHplus) 2) models with continuous states, which can be described by ODE or DAE Multi-body model hydraulic model... additional model Model import Simulation of whole system S-Function S-Function... communication & simulation control S-Function Simulink as simulation back-plane

9 Survey of the HIL test bed 9 / 20 hydraulic subsystem multibody subsystem Real-time simulation motion actuator force Load simulation actuator position set value Tilting system actuator tilting cylinder acceleration sensor position sensor load simulation cylinder force sensor guided connection

10 Survey of the real-time system RT-LAB 10 / 20 Intranet HIL test bed diagram with RT-LAB real-time system Matlab/Simulink Real-Time- Workshop Matlab/Simulink Real-Time- Workshop Windows-NT Development computer Hub Windows-NT Development computer Local Network (Ethernet 100 Mbit/s Measurem ent unit Actuators behaviour Vehicles behaviour Load simulation controller I/O-Interfaces PCI/ISA I/O Karten QNX-real-time hardware for distributed simulation FireWire (400 Mbit/s) for real-time communication QNX-development computer (Compiler a. o. Software) Real-time simulation

11 Application of the tools 11 / 20 Modelling of the mechanical structure Modelling of the hydraulic system Generation of the Symbolic Code (model adaptation, source code generation, transformation to C) Creation of the coupled Simulink model Import of the multi-body model Import of the hydraulic model Non-real-time simulation Prepare model for real-time simulation Transfer to real-time hardware (Model separation, source code generation,transfer, Compiling and Linking, Distribution) Real-time simulation

12 Modelling of the mechanical structure (SIMPACK) 12 / 20

13 Reduction of the mbs model 13 / 20 Original model 74 states 5 constraints 42 force elements Reduced model 30 states no constraints 15 force elements Closing of the kinematic loop with spring No wheel-rail elements

14 Modelling of the hydraulic system (DSHplus) 14 / 20 Cylinder 2 Cylinder 1 Valve Controlled Actuator p A p B Safety valve Pilot valve Pilot valve Cylinder Pressure source p SYS Tank p 0

15 Design of the coupled model (Simulink) 15 / 20 F_Hyd F_Hyd F_Hyd v_cylinder Track_sensor Hydraulic MBS p_cylinder Signal valve Measured value Set value Controller

16 Design of the coupled model (Simulink) 16 / 20 F_Hyd F_Hyd F_Hyd v_cylinder Track_sensor Hydraulic MBS p_cylinder Signal valve Measured value Set value Controller

17 Investigation with tilting train at curve ride 17 / 20 Passing an S-curve curve radius: 450 m Design speed: 90 km/h Driving speed: 120 km/h Transverse acceleration on railway track tier: at 90 km/h: 0,44 m/s² at 120 km/h: 1,52 m/s² 2 controller variants - Control of the actuators position - V1: PI-Controller + feed forward - V2: PI-Controller

18 Selected results 18 / 20 Deviation Controller 1 Controller 2 Acceleration Coach body: Controller 1 Coach body: Controller 2 Railway track tier Control error [mm] Acceleration [m/s²] Animation Variant 1 time [s] time [s] Set signal for controller Controller 1 Controller 2 Hydraulic force Controller 1 Controller 2 Animation Variant 2 Position [m] Force [kn] time [s] time [s]

19 Summary and outlook 19 / 20 Realization of a tool framework for the coupled simulation of multi-body and hydraulic subsystems Features of the SIMPACK s-function - Track functionality (Repetition) - Write results of simulation in SIMPACK and MATLAB format - Read and write states from/to file Features of the DSHplus s-function - Read and write states from/to file Application for real-time simulation Off-line-simulation of the coupled models Real-time simulation of multi-body model Real-time simulation of hydraulic model Real-time simulation of coupled models Further job / extension possibility Realization of a real co-simulation (solution of multi-body models with constraints) Enlargement of the functionality (f.e. Read parameters of the multi-body model from file) Tuning of multi-body and hydraulic models

20 References 20 / 20 Links concerning the used hard- and software Homepage of SIMPACK: Homepage of DSHplus: Homepage of MATLAB / Simulink: Homepage of RT-LAB: References Liebig, S., Quarz, V., Dronka, S.: Schienenfahrzeuge mit aktiven Elementen, Proceedings of the conference 17. Verkehrswissenschaftliche Tage, Tagungssektion 3: Entwicklungstendenzen in der, 04./05. June 1998, Dresden, Germany Liebig, S., Quarz, V., Dronka, S.: Simulation von Schienenfahrzeugen mit MKS-Software, Proceedings of the conference SIM 2000: Simulation im Maschinenbau, P , February 24/25, 2000, Dresden, Germany Liebig, S., Helduser, S., Stüwing, M., Dronka, S. : Die Modellierung und Simulation gekoppelter mechanischer und hydraulischer Systeme, Proceedings of the conference 18th Dresden Conference on Traffic and Transportation Sciences, Session 2: Vehicle Mechatronics, September 17/18, 2001, Dresden, Germany

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