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NWC19-571 005
NWC19-571 005
Abstract
1. Introduction
During the last decade, the technologies involved on machines have greatly
evolved. This transformation has occurred in parallel with the development of
analysis platforms by simulation and numerical data treatment that are more
and more embedded in all stages of machine development process. However
the acceptability of these technologies, sometimes quite ambitious in their
scope, remains difficult to achieve and takes longer than expected to pierce
certain markets, which are aimed to replace older, less sophisticated, less
efficient technologies.
System simulation can certainly help to better target key characteristics early in
the development process of a product, particularly in the technologies aimed
for mass deployment or medium to long range of applications. This simulation
must then align certain factors that will ease its utilization.
In this paper, you will find reflections made over a decade allowing to stablish
characteristics that have and will always contribute to successful utilization of
system simulation to better implement key technologies. First, simplicity is
probably one of the most important factors allowing the implementation of
multi technology platforms. It is possible to add flexibility and reusability as
well, as essential characteristics to consider when simulating entire systems on
an integrated work environment.
Even if the scope of this paper is located on simulation software level for multi
technology/multi physics approach, specifically for electrohydraulic or
electropneumatic technologies, it could be easily extended to multiple domains
of expertise equally important such as finite element analysis, computational
fluid dynamics and others. We will also introduce some notions on a subject
that has gained ample relevance, the co-simulation between different platforms.
presented to show how the developed systems are an integral part of the Digital
Twin concept, which is another key topic in the industry. Finally, we will
conclude with the benefits of this approach that will ultimately allow closer and
stronger collaboration between engineering teams.
2. Definition
As already introduced in [1], we can split the concept of system simulation into
two abstraction levels that can be considered, with a wide spectrum of
intermediate specificity abstraction levels in between. The first level which
falls at the acutely specific end of the spectrum is the lumping of all the
phenomena involved in the system within a single all-encompassing transfer-
function type of representation that takes a set of input stimuli and converts
them into predetermined outputs. This approach is specific to the system being
studied and is practically unadaptable when a system is slightly modified. At
the most generic end of the spectrum, high-level representations of system
dynamics can follow a generic language like the one introduced by B. Zeigler
B. in “Theory of Modelling and Simulation“ [10]. This representation is indeed
general and can be adapted to practically any type of simulated systems.
However, because of this, it is often falls short to the practical needs of the user
and is thus challenging to implement this approach without translating it into a
more relatable format.
The dynamic part of the model is considered mathematically smooth and can
be represented by differential equations that account for steady-state or
transient analysis of physical phenomena.
2.2.2. Mapping
The integration of sub-models using inner and outer data exchange paths is also
shown in Figure 1, and explained [1]. The vertical arrows represent the
inputting of parameters and the probing of internal states by the user. The bold
horizontal arrows represent the main power variables that are exchanged with
adjacent blocks. Some translation processes may be necessary to precondition
some parameter inputs or to calculate user understandable outputs from the
internal states or parameters.
It is this inner organization, combined with the ability to nest blocks within
each other that give the approach its significance, as detailed in following
section. Whenever information about the system is lacking, simplified models
can be used within a block. When more precision is required, the same block
can be remodeled with more advanced dynamics without having to readapt
other blocks.
Hybrid simulation models were defined on the previous chapter. These type of
models allow to create subsystems with varying degrees of precision,
according to their intended use. This is at the heart of the Machine Knowledge
concept. In this chapter, we will stablish the foundations that will enable this
Machine Knowledge Software: Key Factors and Best Practices for Market
Adoption and Integration of Systems Simulation
When creating a simulation model, the user may follow one of two approaches:
Upstream or Downstream, as explain in [1].
3.3. Selectable/Adjustable
From Figure 2, this simply means having libraries or catalogs of parts and
functions (1) from different technologies that are compatible with each other.
The modeling effort would then be already done for one component, function
or system, and would be easily readapted and integrated (1’) in different
systems (2) and ultimately complete machines (3) using data mapping, with
minimum effort from different users.
Components from manufacturers’ catalogues can have more than one type of
simulation models. For example, it includes different models of pumps. There
are detailed models which can be used to animate, simulate and individually
control the inner components with high precision calculations. This model is
dedicated either to train people on the component or function or to analyse the
internal dynamic performances of the pump. However, if the project requires
simulating a complete system, it may be more appropriate to use a model
where the sub-component details are not considered without neglecting the
overall behaviour a complex pump. For real-time simulation, the time step
resolution for the calculation can be optimized to ensure accuracy of the
results.. Similarly, the valves also have different models. One type is kinematic
for a machine scope simulation, and another one is fully dynamics, to be used
for frequency analysis or other more refined simulation analysis.
Each entity in the chain of the simulation dataflow can be viewed as a box
where the inner workings as well as the inputs and outputs are embedded. The
system integration is done by simply chaining those elements. The link
Machine Knowledge Software: Key Factors and Best Practices for Market
Adoption and Integration of Systems Simulation
between an element and the adjacent ones represent a certain type of power
transfer as illustrated in Figure 6.
The choice of the embedded model will depend on the level of detail required
and on the information available. When enough simplification is allowed, some
internal elements may be modeled as simple data maps while others are
modeled with their dynamics.
Figure 6 shows this concept of “Gray Box” where a simulation model is a mix
of known dynamic and static models and of unknown functions represented as
high-level data input-output maps. These inner entities exchange information
among each-other and with the outside environment.
Source Output
The presented score 3 3 types: the machine, the function or the component, as
illustrated in Figure 7.
Function - Recently, the market demand for simulating functions has grown
considerably. This scope level has the benefit of offering quick and affordable
solutions for OEMs, system integrators, and component manufacturers. As
manufacturers are portraying themselves more and more as solution providers,
they are offering more and more functional solutions: power steering, braking,
power units, hydrostatic drive, etc.
Machine – Combined with a wider simulation spectrum, we approach the
objectives shared by all OEMs to integrate more simulation in their working
process by creating virtual models of their complete multitechnolgy systems.
This scope aims mobile equipment such as excavators as well as industrial and
offshore systems (for example: drilling infrastructure with its blowout
preventer (BOP) security system). As shown further in this section, according
to its scope, the simulation of a machine can be reused for various corporate
activities like training, engineering and maintenance. It can also be beneficial
to reuse it for the analysis of global performances criteria based on different
scenario and duty cycles.
PROJECT NEEDS – Establishing the project needs and the use of the
simulation. At this stage, simulation needs can be for some activities prior to
product development and prototyping such as the analysis of a component or
function dynamics or to validate its functional and logical behaviour only.
Also, it can be in the post development phases, to train new employees or
prepare diagnostic and failures materials. Finally, the simulation project can
also provide marketing and promotional interactive documents.
SOFTWARE OPTIONS – Select the right tools that increase the machine
knowledge access and speed up the decision making process, the learning
curves and moreover, the communication. The last step of the working process
depends greatly on the analysing and the measuring tool that the software
offers. The software features are listed in the Figure 8. The selection of those
features and corresponding tools for the project will be dictated by the needs
established at the step 2.
Machine Knowledge Software: Key Factors and Best Practices for Market
Adoption and Integration of Systems Simulation
The proposed methodology allows the decision maker to select the appropriate
simulation setting in order to meet the needs of multiple simulation scopes for
every step in the project’s lifecycle. This approach used to be called Machine
Knowledge Management Software. Some example developed over years will
be described briefly in following section.
This first example details a system that is co-simulated and controlled using
CAN bus communication. The whole model is developed using the Hydraulic
workshop and the Mechanism Manager workshop of Automation Studio™.
The purpose of this section is not to summarize or recreate simulation
formalisms and theories but rather to simply bring together existing approaches
to make the simulation world relatable and adapt it to real-world practical
needs, such as illustrated in [8] and [9].
The studied system is a front loader typically attached to a tractor, used in the
agricultural and construction industries. The mechanism consists of a boom
and a bucket, each actuated by two hydraulic cylinders. The loader’s self-
levelling function, meaning that the bucket angle in reference to the tractor
remains constant even when the boom is moving, is analysed more in details.
Figure 9 : Communication between Automation Studio™ and CAN bus components
This case study represents the new hydraulic specialist generation. By using an
integrated approach, it successfully combined advanced simulation and an
engineer field expertise, as well as the SUN Hydraulic test data. The project
was executed to develop and test the validity of a concept for a hydraulic
actuator’s inlet and outlet control through simulation – a function found in
Atlas Copco’s concrete spraying robots. More specifically, the aim of this
development was to improve the robot’s hydraulic cylinder control precision to
ensure a smooth displacement by using also independent-metering valves
concept. The approach is demonstrated in four steps.
As a first step, the existing inlet and outlet control solution for the hydraulic
actuator was recreated in a simulation environment to get the state of the art
circuit. As shown on Figure 11, this circuit is divided in three parts to
distinguish the hydraulic power supply, the closed loop control circuit and the
disturbance.
Figure 11 : Hydraulic Test Bench Circuit at State of Art
The logical question arises, whether this digital model can be reused once the
machine or the industrial system is put on the market or in production. With the
advent of the industry 4.0 and even 5.0, it would be indeed counterproductive
not to incorporate the final adjusted needed to achieve a virtual replica of the
real product. In short, create the Digital Twin of real product.
Considering that the digital twin is a high-fidelity replica of the real system, the
addition of feedback data (sensors) would increase the training of operators and
maintenance technicians.
Machine Knowledge Software: Key Factors and Best Practices for Market
Adoption and Integration of Systems Simulation
The use of a digital twin synchronized with the real system will allow, without
been exhaustive, to compare in real time the performance of the system and its
twin to detect and analyze deviations.
Figure 14 : BOP and Maritime Crane Digital Twins to Service and FMEA
Machine Knowledge Software: Key Factors and Best Practices for Market
Adoption and Integration of Systems Simulation
This full integration approach can help validate conceptual evolutions on the
existing systems in relation requests for improvements during production or the
replacement of components and their consequences in terms of energy and
financial costs as well their impacts on human and environmental ressources.
6. Conclusion
The main goal of this paper was to analyze the key parameters related to
system simulation to extract the relevant factors for system simulation
integration, to allow better acceptability of the innovative technologies.
Therefore, it has been shown that an Optimized Approach brings the expectant
flexibility that can leverage usage of simulation and :
7. References
Gagné R., & al., How to take advantage of a Machine Knowledge Management
Software to enlarge the simulation tool spectrum from the dynamics
performances of individual components up to a complete mechatronic systems
analysis & monitoring, KSFC Conference, 2014. [2]
Berto L., & al., Mechatronic Challenges to Develop and Implement New
Hydraulic Technologies: Independent-Metering Electrohydraulic Valve
Examples, KSFC, 2016 [3]
Machine Knowledge Software: Key Factors and Best Practices for Market
Adoption and Integration of Systems Simulation
Rémillard V., Sfeir J. et al. New Software Generation for Greener Energy
Efficient Mechatronic System Design & Analysis, KSFC Conference, 2013. [5]
Gagné R., & al., Efficiency Analysis of Mobile Applications Using Machine-
Based Simulation, 9. Kolloquium Mobilhydraulik, 2016. [6]
Diaz J. and al., Improving Training and Technical Publication Material Using
Data-Based Machine Simulation, 13er Congreso International de
Mantenimiento Minero, MAPLA-MANTAMIN, 2016. [10]