Lecture 9 – Modeling, Simulation, and

Systems Engineering

• Development steps
• Model-based control engineering
• Modeling and simulation
• Systems platform: hardware, systems software.

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 Control Engineering Technology
• Science
– abstraction
– concepts
– simplified models
• Engineering
– building new things
– constrained resources: time, money,
• Technology
– repeatable processes

• Control platform technology

• Control engineering technology
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 Controls development cycle
• Analysis and modeling
– Control algorithm design using a simplified model
– System trade study - defines overall system design
• Simulation
– Detailed model: physics, or empirical, or data driven
– Design validation using detailed performance model
• System development
– Control application software
– Real-time software platform
– Hardware platform
• Validation and verification
– Performance against initial specs
– Software verification
– Certification/commissioning
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 Algorithms/Analysis
Much more than real-time control feedback computations
• modeling
• identification
• tuning
• optimization
• feedforward
• feedback
• estimation and navigation
• user interface
• diagnostics and system self-test
• system level logic, mode change
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 Model-based Control Development
Conceptual Control design model: Conceptual control
Controls analysis

Analysis algorithm:
x(t+1) = x(t) + u(t) u = -k(x-xd)

Application Detailed simulation Detailed control application:

code: Simulink model saturation, initialization, BIT,
fault recovery, bumpless transfer

Systems platform:
System and software

Validation and Hardware-in-the- Run-time code, OS

Prototype
verification loop sim Hardware platform
controller

Physical plant Deployed

Deployment controller

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 Controls Analysis
Conceptual Data model Identification & tuning
Analysis Accomodation
x(t+1)Fault
= x(tmodel
) + u(t)
algorithm:
Control design model: u = -k(x-xdcontrol
Conceptual )
algorithm:
x(t+1) = x(t) + u(t) u = -k(x-xd)

Application Detailed Detailed control application:

code: simulation saturation, initialization, BIT,
model fault recovery, manual/auto
Simulink mode, bumpless transfer,
startup/shutdown

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 The rest of the lecture
• Modeling and Simulation
• Deployment Platform
• Controls Software Development

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 Modeling in Control Engineering
Physical system
• Control in a Measurement Control Control
system computing handles
system Sensors Actuators
perspective

• Control analysis
Physical
perspective system
Control
computing

Measurement System model Control

model handle
model
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 Models
• Why spend much time talking about models?
– Modeling and simulation could take 80% of control analysis effort.
• Model is a mathematical representations of a system
– Models allow simulating and analyzing the system
– Models are never exact
• Modeling depends on your goal
– A single system may have many models
– Large ‘libraries’ of standard model templates exist
– A conceptually new model is a big deal (economics, biology)
• Main goals of modeling in control engineering
– conceptual analysis
– detailed simulation

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 Modeling approaches
• Controls analysis uses deterministic models. Randomness and
uncertainty are usually not dominant.
• White box models: physics described by ODE and/or PDE
• Dynamics, Newton mechanics
x& = f ( x, t )
• Space flight: add control inputs u and measured outputs y
x& = f ( x, u, t )
y = g ( x , u, t )

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 Orbital mechanics example
• Newton’s mechanics
– fundamental laws
– dynamics
r
v& = −γm ⋅ 3
+ Fpert (t )
r
v r
r& = v
1643-1736

⎡ r1 ⎤
• Laplace ⎢r ⎥
⎢ 2⎥
– computational dynamics ⎢ r3 ⎥
(pencil & paper computations) x& = f ( x, t ) x=⎢ ⎥
– deterministic model-based ⎢ v1 ⎥
prediction ⎢ v2 ⎥
9-11 ⎢ ⎥
1749-1827

⎣ v3 ⎦
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 Sampled and continuous time
• Sampled and continuous time together
• Continuous time physical system + digital controller
– ZOH = Zero Order Hold

A/D, Sample Control D/A, ZOH

computing

Sensors Physical Actuators

system

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 Servo-system modeling
• Mid-term problem
• First principle model: electro-mechanical + computer sampling
• Parameters follow from the specs

c
F
u g m M
β b

m&y& + βy& + b( y& − x& ) + c( y − x ) = F

M&x& + b( x& − y& ) + c( x − y ) = 0
F = fI , T I& + I = gu
I

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 Finite state
machines
• TCP/IP State Machine

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 Hybrid systems
• Combination of continuous-time dynamics and a state machine
• Thermostat example
• Analytical tools are not fully established yet
• Simulation analysis tools are available
– Stateflow by Mathworks

off x = 70 on
x = 72 x& = − Kx x& = K ( h − x ) x
x ≥ 70 x ≤ 75
x = 75

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 PDE models
• Include functions of spatial Example: sideways heat equation
variables x
– electromagnetic fields
– mass and heat transfer Tinside=u Toutside=0
– fluid dynamics
– structural deformations
• For ‘controls’ simulation, model y
heat flux
reduction step is necessary
– Usually done with FEM/CFD data ∂T ∂ 2T
=k 2
– Example: fit step response ∂t ∂x
T ( 0) = u; T (1) = 0
∂T
y=
∂x x =1

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 Simulation
• ODE solution
– dynamical model: x& = f ( x, t )
– Euler integration method: x (t + d ) = x (t ) + d ⋅ f ( x (t ), t )
– Runge-Kutta method: ode45 in Matlab
• Can do simple problems by integrating ODEs
• Issues with modeling of engineered systems:
– stiff systems, algebraic loops
– mixture of continuous and sampled time
– state machines and hybrid logic (conditions)
– systems build of many subsystems
– large projects, many people contribute different subsystems

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 Simulation environment
• Simulink by Mathworks
• Matlab functions and analysis
• Stateflow state machines

• Ptolemeus -
UC Berkeley
• Block libraries
• Subsystem blocks
developed independently
• Engineered for developing
large simulation models
• Controller can be designed
in the same environment
• Supports generation of
run-rime
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Model development and validation
• Model development is a skill

• White box models: first principles

• Black box models: data driven
• Gray box models: with some unknown parameters
• Identification of model parameters – necessary step
– Assume known model structure
– Collect plant data: special experiment or normal operation
– Tweak model parameters to achieve a good fit

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First Principle Models - Aerospace
Airbus 380: $13B development
• Aircraft models
• Component and
subsystem modeling and
testing
• CFD analysis
• Wind tunnel tests – to
adjust models (fugde
factors)
• Flight tests – update
aerodynamic tables and
flight dynamics models NASA Langley – 1998
HARV – F/A-18

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 Step Response Model - Process
• Dynamical control inputs
matrix
control
(DMC) measured outputs
• Industrial
processes

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 Approximate Maps
• Analytical expressions are rarely sufficient in practice
• Models are computable off line
– pre-compute simple approximation
– on-line approximation
• Models contain data identified in the experiments
– nonlinear maps
– interpolation or look-up tables
– AI approximation methods
• Neural networks
• Fuzzy logic
• Direct data driven models

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 Empirical Models - Maps
• Aerospace and automotive – have most developed
modeling approaches
Example
• Aerodynamic tables
• Engine maps
– turbines – jet engines
– automotive - ICE

TEF=Trailing Edge Flap

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 Empirical Models - Maps
• Process control mostly uses empirical models

• Process maps in
semiconductor
manufacturing
• Epitaxial growth
(semiconductor
process)
– process map for
run-to-run control

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 Multivariable B-splines
• Regular grid in multiple variables
• Tensor product of B-splines
• Used as a basis of finite-element models

y (u, v ) = ∑ w j ,k B j (u ) Bk ( v )
j ,k

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 Neural Networks
• Any nonlinear approximator might be called a Neural Network
– RBF Neural Network
– Polynomial Neural Network Linear in parameters
– B-spline Neural Network
– Wavelet Neural Network
• MPL - Multilayered Perceptron
– Nonlinear in parameters
– Works for many inputs
⎛ 1⎞ ⎛ ⎞
y ( x ) = w1,0 + f ⎜⎜ ∑ w1, j y j ⎟⎟, y1j = w2,0 + f ⎜⎜ ∑ w2, j x j ⎟⎟
⎝ j ⎠ ⎝ j ⎠
1 − e− x y y=f(x)
f ( x) =
1 + e− x x
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 Multi-Layered Perceptrons
• Network parameter computation
– training data set [
Y = y (1 ) K y ( N ) ]
– parameter identification x (1) K x ( N )
y ( x ) = F ( x ;θ )
• Noninear LS problem
V =∑ y
2
( j)
− F ( x ;θ ) → min
( j)

• Iterative NLS optimization

– Levenberg-Marquardt
• Backpropagation
– variation of a gradient descent
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 Neural Net application
• Internal Combustion Engine
maps
• Experimental map:
– data collected in a steady state
regime for various combinations
spark
of parameters advance RPM
– 2-D table
• NN map
– approximation of the
experimental map
– MLP was used in this example
– works better for a smooth
surface
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 Fuzzy Logic
• Function defined at nodes. Interpolation scheme
• Fuzzyfication/de-fuzzyfication = interpolation
• Linear interpolation in 1-D

∑ y µ ( x) j j

y( x) = j
∑ µ ( x) = 1
∑ µ ( x)
j
j j
j

• Marketing (communication) and social value

• Computer science: emphasis on interaction with a user
– EE - emphasis on mathematical analysis
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 Local Modeling Based on Data
Heat Loads
• Data mining in the loop
• Honeywell Prague product
Multidimensional
Data Cube

Relational
Database

Heat
demand
Forecasted
Time variable
Outdoor of day
Query point
( What if ? ) temperature
Explanatory
variables

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System platform for control computing

• Workstations
– advanced process control
– enterprise optimizers
– computing servers
(QoS/admission control)
• Specialized controllers:
– PLC, DCS, motion controllers,
hybrid controllers

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System platform for control computing
MPC555
• Embedded: µP + software
• DSP

• FPGA

• ASIC / SoC

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Embedded
processor
range

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 System platform, cont’d
• Analog/mixed electric circuits
– power controllers
– RF circuits
• Analog/mixed other
– Gbs optical networks

EM =
Electr-opt
Modulator
AGC = Auto Gain Control

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 Control Software
• Algorithms
• Validation and Verification

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 System development cycle

Ford Motor Company

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 Control
application
software
development
cycle
• Matlab+toolboxes
• Simulink
• Stateflow
• Real-time Workshop

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 Real-time Embedded Software
• Mission critical
• RT-OS with
hard real-time
guarantees
• C-code for each
thread generated
from Simulink
• Primus Epic,
B787, A380

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 Hardware-in-the-loop simulation
• Aerospace
• Process control
• Automotive

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 System development cycle

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Cadence