From Months to Days

A collection of Maplesoft customer application stories

Discover how engineers and researchers are using Maplesoft solutions to
rapidly accelerate their design projects.

A C y b e rn e t Gro u p C ompa ny
 A Word From Maplesoft’s President

Welcome to “From Months to Days,” a collection of Maplesoft application

stories.

Engineers from around the world use Maplesoft technology to solve extremely difficult
problems in a diverse range of industries and technical disciplines: FLSmidth uses
Maplesoft technology to develop a new relocatable mining machine; researchers
at the University of Waterloo, in cooperation with the Canadian Space Agency, use
Maplesoft technology to model a robotic space rover; Engineered Arts uses Maplesoft
technology to help model Byrun - a walking, hopping and jumping robot. In this
collection of application stories, you’ll find these and many other exciting examples
of how Maplesoft technology is used in advanced engineering projects.

In engineering research and design, detail is vital. Design engineers and researchers
must not only develop models quickly, but they also require in-depth analytical
tools to help them understand on a fundamental level the intricacies of their models
and the system-level behavior. Fortunately, MapleSim and Maple are available to
TM TM

researchers to aid in their model development and analysis.

The application stories in this collection demonstrate how the use of technical
computing software, physical modeling and simulation technology, and real-time
simulation solutions have allowed engineers to reduce design and prototyping costs
significantly while fulfilling the demands of governments and markets. They illustrate
how engineers and researchers use Maplesoft solutions to rapidly accelerate their
design projects, reducing their model development time from months to days.

Please enjoy this collection of Maplesoft customer application stories, with our thanks.
To learn more, please visit www.maplesoft.com/demo.

Sincerely,

Jim Cooper
President and CEO
Maplesoft

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Contents

4 Revolutionary Mining Equipment

6 Planetary Rovers

8 NASA’s Jet Propulsion Laboratory

9 Solar Panel Foil Systems

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10 Unmanned Aerial Vehicles

11 Chain Drive System Resonance

12 Small Humanoid Robot

14 Hybrid and Electric Vehicle Batteries

15 High-speed Robots

18 Walking, Jumping, Hopping Robot

20 Robotic Manipulator Models

22 Engine Noise and Vibration

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23 Auto Parts Manufacturing Deployment

24 Unmanned Vehicle Robotics

26 Automation, Robotics, and Mechatronics

27 Efficient Washing Machines

28 Battery Modeling

30 Broadcast Networks
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31 Vehicle Driving Simulators

www.maplesoft.com 3
 Maplesoft Engineering Solutions Team Helps FLSmidth
Develop Revolutionary Mining Equipment
FLSmidth
In the mining industry, processing plants are generally
constructed on the site of extraction. Mined ore gets transported
by super-heavy duty trucks to the plant, where it gets crushed
into smaller sizes before being stockpiled, or transported offsite
for further processing. Besides the ore, the mine typically has
to move four times as much overburden as ore. Big mines
typically have to move 700,000 tonnes of material per day. As
the mine gets larger, the trucks have to travel longer distances
to deposit their load, resulting in significant increases in the
cost of fuel and vehicle maintenance.
To address this problem, FLSmidth engaged the services of the
Maplesoft Engineering Solutions team to develop design and
analysis tools that would help them design a Dual Truck Mobile
Sizer (DTMS) - an innovative machine that can be relocated
throughout a project, as the haul distances increase.
The DTMS increases in-pit crushing efficiency due to its dual-
skip configuration. A truck backs into one skip until it reaches
a restraining curb in the floor. After dumping its load on the
skip floor, it then slowly pulls ahead, lowers its bed, and pulls
away. Once the truck clears the end of the skip, the skip can
be raised. As the skip is elevated, it pours material from the
discharge of the skip and deposits the material into the apron
feeder hopper. As material is introduced onto the apron feeder,
it conveys the material to the sizer where it is crushed to the
appropriate size. After being crushed, the material is deposited
onto the discharge conveyor where it is taken to the bench
conveyor. This process is performed while another haul truck
is depositing material into the twin skip, thereby increasing the
number of truck cycles.
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The DTMS is a very large
and complex machine. The
ability to model all aspects of
its operation during the design
phase using MapleSim gave us
confidence that the product we
would ultimately build would
function correctly the first time.
We cannot even begin to put a
value on what this means to us.
- Willem Fourie, FLSmidth
To create tools that would help FLSmidth to design this innovative
piece of equipment, the Maplesoft team first had to develop
a deep understanding of the dynamics of the skip system.
They began by using MapleSim, the advanced modeling and
simulation platform, to develop a fully parameterized model
of the skip. Taking advantage of MapleSim’s multidomain
modeling capabilities, they were able to create a high-fidelity
model that incorporated all the key components of the skip -
from its geometric structure and mechanical operation, to the
hydraulic circuits and controllers. “The DTMS is a very large
and complex machine,” says Willem Fourie, Global Product
Line Manager - Mobile Sizer Stations, FLSmidth. “The ability
to model all aspects of its operation during the design phase
using MapleSim gave us confidence that the product we would
ultimately build would function correctly the first time. We cannot
even begin to put a value on what this means to us.”
MapleSim’s modeling approach not only addresses the basic
requirements of dynamic multidomain simulation, but through
seamless access to the underlying symbolic equations, enables
the user to rapidly create targeted design tools using Maple’s
high-performance symbolic computation engine.
The creation of the skip model was complemented with the
development of multiple design tools to aid in adjusting the
model to achieve the desired behavior. One such design tool
is the Geometric Design Evaluation tool, which provides the
ability to evaluate changes in the dimensions of the skip design
and their effect on the dynamics of the system. The tool uses
Maple, Maplesoft’s symbolic computation tool, to perform
a parameter sweep, by simultaneously running simulations
using the different parameter values provided. Maple then
presents the results overlaid on a single plot window for easy
comparison and evaluation. Other tools developed include tools
for sizing the hydraulics and components, designing the motion
profile, investigating the dynamic loading on the bearings, and
estimating the material flow load.
As part of developing and testing the skip model, Maplesoft’s
technical team also evaluated the design, to identify the sources
of vibrations and their effects. They developed an approach
to perform stability analysis, which was made possible by the
fact that the skip model provided easy access to key geometric
features and dynamic properties of the design. The stability
analysis approach was demonstrated using a case study in
which the location of the feedback sensor was varied. The
analysis identified a potential issue very early in the design
phase, enabling engineers at FLSmidth to develop a more
robust design.
3D skip model, and corresponding 2D model with hydraulics
Full DTMS model, including footings and soil
interactions
“The stability analysis performed by the Maplesoft team was very
insightful,” said Fourie. “Knowing about a potential issue early
on enabled us to design with it in mind, rather than having to go
back and rework our design at a later stage. This contributed to
keeping our project on track, and saved us millions of dollars
down the line.” The stability analysis design approach and all
the other analysis tools developed by Maplesoft were delivered
to FLSmidth, enabling them to apply them to future projects.
Once the modeling and testing of the skip system was completed,
during the following phases of the project, Maplesoft staff went
on to develop the chassis model, and finally the full DTMS.
Many more design tools were created, providing the ability to
evaluate joint flexibility, center of mass variations as the skip
was raised and lowered, and even soil modeling to investigate
the vertical displacement of the system on different types of soil.
“From start to finish, Maplesoft provided truly knowledgeable and
professional service,” concludes Fourie. “Their team worked
tirelessly to accommodate our schedule, and the power of
the Maplesoft toolset is second to none. The level of design
detail and the amount of insight we gained have enabled us to
revolutionize onsite crushing through the development of the
DTMS. We could not have achieved this without the services
of the Maplesoft Engineering Solutions team.”
www.maplesoft.com 5
 MapleSim Breaks New Ground in Hardware-in-the-Loop
Real-Time Simulation for Planetary Rovers

University of Waterloo • Canadian Space Agency The main advantage of this approach is that it significantly
reduces the overall development time in the project. It also
In the space industry, the design, building, and testing of rover allows for component testing under dangerous scenarios without
prototypes is extremely expensive. System testing typically does the risk of damaging a full rover prototype.
not occur until late in the design/testing process, when it is more
difficult and time consuming to make changes. In response to Rover Kinematics
this situation, Dr. Amir Khajepour, Canada Research Chair in In addition to simulating the rover dynamics, the MapleSim
Mechatronic Vehicle Systems and Professor of Engineering modeling environment was used to automatically generate the
in the Mechanical and Mechatronics Engineering department kinematic equations of the rover.
at the University of Waterloo (UW), and his team worked with
the Canadian Space Agency (CSA) and Maplesoft to develop
a hardware-in-the-loop (HIL) test platform for solar powered
planetary rovers. The intuitive nature of
MapleSim allowed my team to
Their approach allows component testing within a simulation
loop before a full rover prototype is available. It essentially
create high fidelity models in a
creates a virtual testing environment for the component short period of time.
under test, “tricking” it into thinking it is operating within a full
prototype. Using MapleSim, the modeling and simulation tool
- Dr. Amir Khajepour, University of Waterloo
from Maplesoft, high-fidelity and computationally efficient models
were created for this real-time application.
These equations then formed the basis for other tasks in the
project such as HIL simulations, path planning, and power
Using this test platform, scenarios that are hard to replicate in a
optimization. The modular system setup enables users to quickly
lab setup, such as the Martian environment or components that
change the rover configuration and explore different approaches
are not yet available, can be modeled in software. Hardware
in a short time.
components can then communicate with these software models
for real-time simulations. The goal is to progressively add
hardware components to the simulation loop as they become Hardware-in-the-Loop Framework
available. In this way, system testing takes place even without Figure 2 shows an overview of the test platform. Information
all the hardware components, bridging the gap between the regarding the rover’s position, orientation, tilt, speed, and
design and testing phases. power consumption (obtained from dynamic models of the

6

Figure 1 - Automatic generation of kinematic equations
rover) is used as input to the software models. A library of rover
components was developed within MapleSim and imported
within LabVIEW Real-Time where the HIL program and
TM
interface were developed. The program was then uploaded
to the embedded computer within National Instruments PXI
where communication between the hardware components
and the software models was established and the real-time
simulation was run.
“Due to the multidomain nature of the system (mechanical,
electrical, and thermal), it was desirable to model all the
components within one modeling environment such that
critical relationships can be easily discovered. In addition,
computational efficiency is crucial in real-time simulations,”
said Dr. Khajepour. “MapleSim was found to be the ideal
environment for this application due to its multidomain abilities,
use of symbolic simplification for higher computational efficiency,
and ease of connectivity to LabVIEW.”
In addition to making use of MapleSim’s built-in component
library, custom components were also easily developed. A
model to estimate the solar radiation that a tilted surface would
Figure 2 - Hardware-in-the-loop framework
receive on Mars was implemented using MapleSim’s Custom
Component Block. This model took into account the sun’s
position and the rover’s latitudinal and longitudinal position,
orientation, and tilt as it traveled from point A to point B. This
was used together with a solar array model to estimate the
power generation of a rover throughout the day.
“The intuitive nature of MapleSim allowed my team to create high
fidelity models in a short period of time,” said Dr. Khajepour.
“This played a key role in the success of this modular HIL test
platform, which allowed for component testing, power level
estimation, as well as the validation of power management and
path planning algorithms.”
The team also used MapleSim as a key tool in an earlier part of
the project to develop a full solution for the power management
system of autonomous rovers. They used MapleSim to
rapidly develop high fidelity, multidomain models of the rover
subsystems. The goal was to develop a path planning algorithm
that took rover power demands and generation into account.
Using the models, the path planner found the optimum path
between point A and point B such that the rover maintained the
highest level of internal energy storage while avoiding obstacles
and high risk sections of the terrain.
Dr. Khajepour and his team were able to create the mathematical
model of the 6-wheeled rover without writing down a single
equation. “MapleSim was able to generate an optimum set of
equations for the rover system automatically, which was essential
in the optimization phase,” he said. Dr. Khajepour was also
impressed with MapleSim’s graphical interface. “In MapleSim,
you can simply re-create the system diagram on your screen
using components that represent the physical model. The ability
to see the model, to see the moving parts, is very important to
a model developer,” he concluded.
Figure 3 - Solar array model
in MapleSim
www.maplesoft.com 7
 NASA’s Jet Propulsion Laboratory Begins
Widespread Adoption of Maplesoft Technology
NASA’s Jet Propulsion Laboratory
Maplesoft announced a major adoption of its products by
NASA’s Jet Propulsion Laboratory (JPL). JPL is implementing
Maple, MapleSim, and MapleNet in its various projects. Whether
creating America’s first satellite, Explorer 1, sending the first
robotic craft to the moon, or exploring the edges of the solar
system, JPL has been at the forefront of pushing the limits of
exploration.
Curiosity, JPL’s latest space rover, which launched in 2012,
aims to explore Mars to investigate whether the planet could
have ever supported microbial life. Other JPL projects include
spacecraft missions to comets, asteroids, and the edge of the
solar system, as well as satellites that monitor the land, oceans,
and atmosphere of our own planet.
Maplesoft products are expected to help JPL save time and
reduce cost by providing more efficient and smarter methods
for mathematical analysis, modeling, and simulation. Maplesoft
solutions are built within a natively symbolic framework,
avoiding some of the worst sources of error and computational
8
inefficiencies generated by traditional, numeric-based tools,
thus providing great tools for precision-rich projects such as
those of JPL.
In addition to using Maple for advanced mathematical analysis,
JPL will use MapleSim, Maplesoft’s high-performance physical
modeling and simulation platform, as a key tool in its engineering
workflow. MapleSim works in combination with Maple. It accesses
Maple’s symbolic computation technology to efficiently handle
all of the complex mathematics involved in the development of
engineering models, including multi-domain systems, multibody
systems, plant modeling, and control design.
“Maplesoft products will allow JPL to unify their approach to
mathematics, modeling, and simulation,” says Paul Goossens,
Vice President, Applications Engineering, Maplesoft. “MapleSim’s
intimate connection to the underlying physics of the system
models, combined with the knowledge capture and analysis
capabilities inherent in Maple, will make project design and
development faster and more accountable. JPL scientists will
arrive at optimal solutions much faster, and their models will
be much more reusable.”
Maple and MapleNet Streamline the
Development of Solar Panel Foil Systems

Eppstein Technologies • Dr. P. Waegli-Research

As a technology consultant, Dr. Peter Waegli works with a

wide range of companies to bring the latest and most efficient
technology to his clients. His firm, Dr. P. Waegli-Research,
provides technology-based strategies and solutions to clients.

Dr. Waegli recently advocated the use of Maple in a project

related to solar panels. Solar panels are composed of a
collection of connected photovoltaic cells, and the type of cell
interconnection technology affects the performance of the solar
panel. Eppstein Technologies, a subsidiary of EppsteinFOILS,
is a developer of innovative foil systems for interconnecting
and encapsulating photovoltaic cells. In a recent project with
Eppstein Technologies, Dr. Waegli used Maple and MapleNet
to help the company streamline the development process of Light engine seen under an angle from the measuring plane,
their foil systems. where the module is placed

Being a consultant, Dr. Waegli needs a software tool that

Using MapleNet, I feel more provides him the flexibility to share his work with different teams,
in control of the data I share. located in different places, without his clients having to invest
in new software. MapleNet provides him that facility because
- Dr. Peter Waegli, Dr. P. Waegli-Research of its internet-based delivery. “Using MapleNet, I feel more in
control of the data I share. Unlike other tools, MapleNet doesn’t
need a player, which makes it very easy and convenient to use.”
A simulation model for a module tester, which illuminates the
test modules to measure their power conversion performance,
was built in Maple. This model simulates the light distribution
and intensity for various arrangements and specifications of the
LED-sources. These results were then used to optimize LED
positions, properties of the LEDs, and the collimation optics
and distance of the LED assembly from the measuring plane.
Based on the results of this optimization during the modeling
phase, the tester light source was built and performed correctly
on the very first try. Maple was then used to create simulation
models of the modules. With virtual models of both the modules
and the test platform, the company was able to optimize their
designs early in the process, reducing the number of expensive
physical prototypes they need to create and test.
PV-Module Evaluator
The model and the results were fully described in interactive user interface
Maple documents and shared using MapleNet. As a result, every
design engineer on the project has access to the information
and can run simulations with their own parameters online.

Dr. Waegli feels that Maple has significant advantages over its
competition, “Maple is much easier to use compared to other,
similar products. Its intuitive user interface makes it simple to
manipulate parameters, and it has excellent compatibility with Typical light distribution in the
measuring plane over the area
other tools. In addition, its document interface is very useful as
of an individual photo-voltaic cell
it provides ample opportunities to document my work.”

www.maplesoft.com 9
 Using MapleSim in Unmanned Aerial Vehicle Models
Provides Insights Not Possible with Traditional Tools
Quanser Inc.
Unmanned aerial vehicles (UAV) are an increasingly important
tool in situations where it is dangerous or extremely difficult for
humans to enter. In addition to military applications, UAVs are
used in environmental surveys, agriculture, and disaster relief
I was very impressed with
how little time it took us to
configure a high-fidelity model
using MapleSim.
- Derry Crymble, Quanser Inc.
efforts, and are one of the most active areas of contemporary
engineering research. In order to help researchers develop
new algorithms for controlling UAVs under a variety of different
conditions, Quanser Inc. developed the QBall-X4, a UAV
experiment platform for research in UAV control and design.
MapleSim, Maplesoft’s modeling and simulation product, is a
key tool for Quanser design engineers in developing
the QBall. The QBall-X4 is a quadrotor helicopter
design with four motors and speed controllers
MapleSim was used to fully capture the dynamics of the gyroscopic
effects for a quadrotor helicopter.
10
fitted with 10-inch propellers. The entire mechanism is enclosed
within a protective carbon fiber cage. The first step in its
development was to create high-fidelity 3-D dynamics models
of the system and its flying characteristics. The results and
insights gained through using MapleSim were then transferred
to the remaining toolchain to complete the development.
MapleSim gave Quanser engineers two significant advantages
over traditional tools. The most important benefit to using
MapleSim was its ability to fully capture the dynamics of the
gyroscopic effects, the stabilizing effects of the spinning parts of
the QBall. With traditional tools, gyroscopic effects are extremely
difficult or impossible to treat, as developing sufficiently high
fidelity models by hand is simply too difficult and too time
consuming. Typically, design engineers resort to making
various model simplifications or compromises for the model;
ultimately, this reduces the accuracy and effectiveness of the
simulation process. Since MapleSim automatically derives the
system equations directly from the model diagram, the Quanser
engineers developed a very high fidelity model with gyroscopic
effects in very little time and with little effort.
Secondly, because it was so easy to make design changes in
the MapleSim physical modeling environment, Quanser was able
to test different designs for the rotors and choose the one that
worked the best for them. MapleSim let them efficiently
consider and dismiss alternate UAV configurations,
such as single rotor, or coaxial counter rotating
propeller configuration, before settling on
the quadricopter design.
Quanser was surprised by the speed
with which the models were developed.
Derry Crymble, lead engineer for the
QBall-X4 project commented, “I was
very impressed with how little time
it took us to configure a high-fidelity
model using MapleSim.”
Dr. Jacob Apkarian, Founder and CTO
of Quanser added, “MapleSim was an
eye-opener for us. It gave us insights that we
otherwise would not have had. We discovered
behaviors in the system we hadn’t taken into account
until we ran MapleSim simulations. We learned a lot
about the system using MapleSim.”
Today, the Qball-X4 is one of Quanser’s premier
products and is used by researchers in both academic
research and industry. MapleSim continues to be a
valuable tool in Quanser’s development initiatives.
Maple Helps Ford Motor Company with Analytical
Predictions of Chain Drive System Resonances

Ford Motor Company

Like other automotive manufacturers, Ford Motor Company

wrestled with a common concern – incessant noise and vibration
in chain drive systems. Chain drives have been widely used for
power transmission in automotive systems for decades. While
chain drives are effective, undesirable noise and vibrations have
always been a problem. This was particularly the case when
Ford detected a severe 1800 – 1900 Hz chain noise in a new
transmission prototype. Sound pressure levels were 10 -15 dB
over nominal values and the cause was unknown.

At Ford, Jack S.P. Liu, Das Ramnath, and Rajesh Adhikari set
out to understand the source of the noise and develop simple,
analytical models for quick computation of the chain drive
system resonances.

Earlier experimental research identified chain-sprocket meshing

noise as the most significant noise source, and suggested that
chain drive system dynamic parameters such as speed, tension,
mass and pitch of the chain, sprocket inertia, and the natural
frequencies of the chain sprocket system are closely related
to the meshing noise. The Ford team took on the challenge of By using Maple, Ford could validate mathematical model
analytically predicting chain drive system resonance based on predictions against both an ABAQUS CAE model and the
the assumption that existence of chain resonances can amplify experimental test results. Also, Ford created a predictive
the radiated chain meshing noise. design tool to develop analytical models and predict chain
drive dynamics using Maple’s embedded components, including
The team started with the analysis of the chain noise test data features such as variable slider inputs to modify design variables.
and compared this with the theoretical mathematical model. Their This design tool will enable other technical staff to perform
results indicated that three future predictions of chain-
types of chain resonance drive resonances in a quick
existed: the transverse We were amazed at the power and easy manner.
strand resonance, the
longitudinal chain sprocket
of Maple. Its analytical power and “We were amazed at the
coupled resonance, and modeling capabilities enabled us to power of Maple. Its analytical
the longitudinal chain stress power and modeling
wave type resonance.
get the accuracy we were aiming for. capabilities enabled us to
- Jack S.P. Liu, Ford Motor Company get the accuracy we were
To help deal with the aiming for,” said Jack S.P.
complex calculations and Liu, a CAE engineer at Ford
analysis involved in developing these advanced models, Motor Company. “I especially appreciate embedded components
Ford used the mathematical software Maple. Its extensive and their role in GUI design. Maple’s symbolic math capability
symbolic and numeric math solvers were used in modeling exceeds that of other CAE tools in areas where we used it.”
the physical system to gain an understanding of the vibrational
behavior. The partial differential equations used in the model The Ford team was able to accurately determine the exact
were solved quickly and easily using Maple’s world-leading locations of the 1800 Hz noise source and the problematic
differential equation features. When describing results, such noise peak. By combining transverse and longitudinal natural
as the eigenfunctions that represent the unique mode shapes frequencies, both the analytical and CAE models predicted the
of the natural resonant frequencies, Maple’s extensive plotting 1800-1900 Hz longitudinal chain resonance as observed in chain
capabilities were indispensable. In addition, the unique test data. The team concluded that a thorough understanding of
documentation capability of Maple enabled Ford to publish all types of chain resonances is critical for powertrain engineers
integrated worksheets and reports for easy and convenient to design a quiet and smooth chain drive system.
dissemination across the organization.

www.maplesoft.com 11
 Modeling the Nao Robot in MapleSim
Aldebaran Robotics
Nao is a small humanoid robot created by
Aldebaran Robotics. Standing 58 cm tall, Nao is
used to teach students around the world programming,
and to give engineers and software developers
a platform for experimentation and robotic
applications. Nao was even adopted
recently by a financial institution in
Japan to use as bank tellers!
Engineers at Maplesoft decided
to see if they could create a model
of Nao in MapleSim, the advanced
system-level modeling and simulation tool that applies
modern techniques to dramatically reduce model
development time, provide greater insight into system
behavior, and produce fast, high-fidelity simulations.
Building the Model
Nao is a highly complex multibody mechanism with 25 degrees
of freedom. Using MapleSim’s multibody library, Maplesoft
engineers created a model using Denavit-Hartenberg (DH)
convention to define the robot’s joints coordinate frames. CAD
models were then imported to define body mass, rotational
inertia and center of mass. Because MapleSim is a physical
modeling system, the model diagram corresponds closely to
the physical system itself, as can be seen in Figure 1.
Servo motors appear at each joint to drive the movement.
Signals from the controller trigger the motor to reposition each
joint. In combination, these individual servo motors determine
how Nao moves.
Multibody model of the Nao robot
12
The engineers were also able to model
the contact between Nao’s foot and
the floor. This was done by creating
custom components in MapleSim, and
supplying the mathematical equations
that govern friction and normal force.
These components were included in
the model at each point of contact
on the base of each foot.
The MapleSim model also includes
a Li-ion battery pack model from the
MapleSim Battery Library that powers
the motor, so that the behavior of the battery and
its interactions with the rest of the system can be
modeled as well.
Sensor readings of each joint were exported from Aldebaran
Robotics Choregraphe™ to MapleSim via a time lookup table.
These were then used as the command signal for each joint.The
model responded in the same way the physical robot did. For
instance, the MapleSim model can perform Tai Chi as adeptly
as its physical counterpart.
Teaching Nao New Tricks
Now that they had a model that simulates the movements of
the Nao robot, the Maplesoft engineers then wanted to see if
they could not just simulate its behaviour accurately, but also
teach it do to something new.
Using MapleSim’s ability to extract and analyze the mathematical
equations of motion of a model, as well as its multibody analysis
tools, they determined the symbolic solution to the inverse
kinematic problem for the motion of the robot’s arm. With this
solution, they could calculate the joint motions necessary to
place the arm in an arbitrary location in space. They used this
information to add a new custom component to the model that
takes the desired end position and calculates the movements
needed to achieve it. Then, they taught the virtual Nao to draw.
They created an application that allows a human to sketch a
shape, image, or word using a mouse. The sketch is analyzed to
determine the coordinates of the lines, and then the information
is fed into the simulation model. The result? Nao moves his arm
and draws the same thing!
Further leveraging MapleSim’s ability to solve inverse kinematics
problems, Maplesoft engineers have also taught Nao other
new tricks, including various dances, playing volleyball, and
tracking a quadrocopter.
Why This Is Interesting

If you are working on a robotics research or design project

where understanding multidomain interactions is important,
then using a multidomain modeling platform like MapleSim, as
this example demonstrates, will allow you to bring together all
aspects of your project into one place.

• 3D Multibody Modeling: Take advantage of 3D Multibody

modeling, simulation, and visualization capabilities

•
Parameterized Models: Conveniently access system
parameters to quickly apply design changes and consider
a family of designs or products

• Multidomain Support: Augment the dynamic mechanical Servo motors for each joint drive the movement of
system with accurate models of electric motors, controllers the robot’s arm
and batteries

• Virtual Testing and Analysis: Investigate system-level behavior

and interaction of multidomain subsystems, without the need
to build expensive and unpredictable physical prototypes

• Component Sizing: Easily run batch simulation and parallel

processing, and collect data that can be used to assist in
component sizing

• Full Access: Leverage direct access to equations and a full

programming language to expand the same simulation model
to be part of model design and trajectory optimization tasks

• Optimized Code Generation: Generate highly optimized c-code

from the model for an essential part of model-based control
design
Equation-based custom components were used to model the
contact points between the foot and the ground

Inverse kinematics were used to teach the Nao model to draw

www.maplesoft.com 13
 MapleSim Used to Create High-Fidelity Physical
Models of Hybrid and Electric Vehicle Batteries

Toyota

In recent years, the demand for hybrid-electric and fully electric

vehicles has increased enormously. The development of such
vehicles is a significantly more complex task than designing
conventional cars because they incorporate many different
engineering domains into a single system. At the same time,
competitive pressures are forcing auto manufacturers to come
up with new designs faster than ever before. The industry is
turning to math-based physical modeling techniques, which
allow engineers to accurately describe the behavior of the
components that comprise the system and the physical
constraints on the system. These model equations are then used
to develop, test, and refine designs very quickly, and without
the expense and time required to build physical prototypes.

One of the most important components of a hybrid-electric or fully

electric vehicle is the battery itself. Having a good virtual model
of the battery is essential so that both battery behavior and the
physical interaction of the battery with all the other components
are properly reflected in the model. Because the battery plays
such a vital role in the vehicle, capturing these interactions is
essential to designing an efficient, effective electric vehicle.

Dr. Thanh-Son Dao and Mr. Aden Seaman worked with Dr. John
McPhee, the NSERC/Toyota/Maplesoft Industrial Research
Chair for Mathematics-based Modeling and Design, to develop
high-fidelity models of hybrid-electric and electric vehicles,
including the batteries. The research was done at the University A high-fidelity battery model is essential to the development
of Waterloo. They chose MapleSim because they have found of electric and hybrid-electric vehicles.
the symbolic approach in MapleSim to be an effective way to
develop simulation models that have fast real-time speeds automatically generated optimized set of governing equations.
for hardware-in-the-loop (HIL) testing and very high fidelity The HEV model consists of a mean-value internal combustion
compared to models created in conventional modeling tools. engine (ICE), DC motors driven by a chemistry-based NiMH
battery pack, and a multibody vehicle model. Simulations were
Battery Electric Vehicle (BEV) Model then used to demonstrate the performance of the developed
HEV system. Simulation results showed that the model is viable
Using MapleSim, Dr. McPhee and Mr. Seaman designed
and, as a result of MapleSim’s lossless symbolic techniques for
a math-based model of a complete battery pack, and then
automatically producing an optimal set of equations, the number
developed simple power controller, motor/generator, terrain,
of governing equations was significantly reduced, resulting in
and drive-cycle models. The resulting differential equations
a computationally efficient system. This HEV model can be
were simplified symbolically and then simulated numerically. A
used for design, control, and prediction of vehicle handling
variety of driving conditions were simulated, such as hard and
performance under different driving scenarios. The model can
gentle acceleration and driving up and down hills. The results
also be used for sensitivity analysis, model reduction, and real-
were physically consistent and clearly demonstrated the tight
time applications such as hardware-in-the-loop (HIL) simulations.
coupling between the battery and the movement of the vehicle.
This model will form the basis for a more comprehensive vehicle
“With the use of MapleSim, the development time of these models
model, which will include a more sophisticated power controller
is significantly reduced, and the system representations are
and more complex motor, terrain, and drive-cycle models.
much closer to the physics of the actual systems,” said Dr. John
McPhee. “We firmly believe that a math-based approach is the
Hybrid-Electric Vehicle (HEV) Model best and quite possibly the only feasible approach for tackling
Dr. McPhee, Dr. Dao, and Mr. Seaman used MapleSim to the design problems associated with complex systems such
develop a multi-domain model of a series HEV, including an as electric and hybrid-electric vehicles.”

14
High-speed Robot, DeltaBot , Designed
using Maplesoft Technology
AEMK Systems
Following the completion of the DeltaBot, a robot based on an
innovative cable-actuated delta-style design, Dr. Amir Khajepour
received a surprising number of requests from industry for
its use. Based on this commercial demand, Dr. Khajepour
established AEMK Systems, a company specializing in the
design and distribution of high-speed, cable and vision-based
robotics systems for use in a variety of industrial applications.
The DeltaBot is capable of over 120 pick-and-place cycles per
minute and handling up to 20 kg.
These products make it
possible for us to be very
responsive to the needs of our
customers and the changing
demands of industry.
- Dr. Amir Khajepour, AEMK Systems
The AEMK DeltaBot robots use cables instead of rigid arms
to reduce moving inertia and mechanical equipment costs.
The simple design and scalability of the DeltaBot means that
it can easily integrate into existing automation environments.
The DeltaBot is capable of over 120 pick-and-place cycles per
minute. One of the distinctive features of the DeltaBot over other
delta robots is its high payload capacity. While other delta robots
are limited to payloads under 3 kg, the DeltaBot is capable of
handling up to 20 kg. Its high speed, low maintenance costs,
TM
Maplesoft products are used to design and test innovative, high-speed
robots capable of over 120 pick-and-place cycles per minute.
and high payload capacity make it a very attractive industry
alternative in many automation applications.
Early in the initial research phase, Dr. Khajepour chose
Maple, Maplesoft’s advanced technical computing software,
as a key tool in the robot research project. All subsequent
design improvements and enhancements to the Deltabot system
were developed using Maple and MapleSim, Maplesoft’s high-
performance physical modeling and simulation solution. Maple
and MapleSim are built on a foundation of advanced symbolic
computation technology, which lets users obtain highly accurate
results about the system behavior.
“Maplesoft technology was an integral part of the design process
of the DeltaBot system, and is now an integral part of the
robot’s ongoing development,” says Dr. Khajepour, President
and Founder of AEMK Systems, and University of Waterloo
Professor of Mechanical Engineering. “With the use of Maplesoft
technology, the initial development time for the robot was
significantly reduced, and we continue to benefit from shorter
development cycles as we make enhancements to our products.”
AEMK Systems is currently using MapleSim to model and
simulate the DeltaBot system for use in real-time hardware-
in-the-loop (HIL) testing, as part of its ongoing research and
development program. When converting the concise model
equations to real-time source code, the code generation tools in
MapleSim apply additional optimization steps, further improving
simulation speed so the results can be used in real-time systems.
“By using MapleSim and Maple, we will be able to design and
test enhancements to the DeltaBot much more quickly than
with other design tools,” says Dr. Khajepour. “These products
make it possible for us to be very responsive to the needs of
our customers and the changing demands of industry.”
www.maplesoft.com 15
 From Months to Days...
Do you want to develop complex system-level models quickly?

Power-Split Hybrid Electric Vehicle Wind Turbine

3 months to 15 days 1 month to 4 days
A complex, multi-domain model that covers all aspects of A full wind turbine model that simulates stabilized power
a hybrid electric vehicle, including a mean-value internal output using controlled wind blades.
combustion engine.

Unmanned Aerial Vehicle Vibration Analysis for Marine Driveline

Systems
1 month to 4 days
An aerial vehicle model that provides behavior insights
24 months to 20 days
not possible with traditional tools. A full model of the vibrational modes found in a marine
driveline system.

16
Planetary Rover Solar Array
3 months to 10 days 1 month to 3 days
A complex multidomain model that simulates A full solar array model that simulates power generation
planetary rover motion, wheel/soil interaction, energy of both stationary and tracking solar panels.
consumption, and more.

Electro-Hydraulic Clutch Actuator Biomechanical Walking Robot

1 month to 3 days 1 month to 5 days
A highly realistic clutch actuation system incorporating A dynamic model of a walking robot which incorporates
effects from seven different domains in one model. both kinematic behavior and ground contact
interactions.

Request a live technical demonstration of MapleSim:

www.maplesoft.com/demo
www.maplesoft.com 17
 Byrun, the Walking, Jumping, Hopping Robot, Built Using
MapleSim Models
Engineered Arts
MapleSim provides the advanced solvers that can tackle the
difficult equations used to develop Byrun’s motion algorithms.
In movies, robots can walk, talk, and even pretend to be human.
Their real-life counterparts are considerably more limited. But this
gap is closing, and Engineered Arts, a UK robotics company,
is seeking to bring reality closer to fiction.
Engineered Arts’ current flagship product is RoboThespian, the
robotic actor. A full-sized humanoid with a biologically inspired
design, RoboThespian is used by research and education
centres the world over, to inform, to entertain, and to investigate
new developments in robotics. Institutions in over 20 countries,
including NASA Kennedy Space Centre (USA), Gazientep
Planetarium (Turkey), Questacon Science Centre (Australia),
18
and numerous universities world-wide are using RoboThespian
every day. Maplesoft technology was used in the design and
modeling of balancing and talking RoboThespian robots.
MapleSim, the system-level modeling and simulation platform
from Maplesoft was used to design the biologically analogous
humanoid robot leg integrating a novel actuator, studying its
static and dynamic stability, and building the designed leg to
determine strategies for its control. However, RoboThespian,
for all his conversational appeal, is largely static. His legs are
powered, but he can merely squat and stand in place, never
moving from a fixed location.
The software saves us
significant time and cost, and
allows us to explore more
radical options.
- Guillaume Hirohide Sasagawa,
Engineered Arts
Enter Byrun, the latest Engineered Arts endeavour. Using
MapleSim, Byrun’s designers and engineers have developed
a biologically analogous leg design which will give Byrun the
ability to walk, run, jump and hop. Byrun will be a new kind of
full-scale dynamic humanoid that will take social robotics to
the next level. With a faster, stronger, more dexterous upper
body, a virtually infinite array of facial features (courtesy of his
projective head display), and the same speaking and singing
abilities as his predecessor, RoboThespian, Byrun has the
potential to revolutionize human-robot interaction.
According to Guillaume Hirohide Sasagawa, an engineer at
Engineered Arts, “In Byrun, we want to integrate more human-
like dynamics into the mechanical design. Using a human-
inspired approach at a hardware level makes walking, running
and jumping possible without rigid, robotic-looking motion.”
MapleSim assisted in Byrun’s design by allowing engineers to
simulate complex, nonlinear, compliant components such as
his pneumatic muscles and parallel springs. These are used
for safety compliance, shock absorption, energy efficiency, and
human-like smooth motion curves.
Engineered Arts specializes in unconventional actuation
solutions, chosen to best suit the application. Motors are fast
and precise, but inefficient and rigid. Pneumatic actuators, on
the other hand, are powerful and energy efficient, but difficult
to control. The conventional approach in robotics is to use a
single actuator for a single joint – Byrun will use a parallel electro-

pneumatic design, where multiple actuators control single joint
actions. This approach utilizes the best facets of both types of
actuation, while compensating for their drawbacks. Conversely,
some actuators will generate coupled motion across several
axes, to imitate (for example) the organic design of the human
shoulder. This makes for more natural looking motion, but can
be potentially difficult to control. Here, once more, Maplesoft
comes to the rescue, providing advanced solvers that can tackle
the difficult multi-variant control equations used to develop
Byrun’s motion algorithms.
By creating virtual prototypes of each design phase in
MapleSim, Byrun’s engineers can investigate the feasibility
of mechanical solutions without needing to create a laborious
series of prototypes. “The software helps us to create the
design parameters in a very fast virtual environment,” explained
Guillaume. “We are no longer required to rebuild the robot for
every design iteration, which saves us significant time and cost,
and allows us to explore more radical options. As well, complex
kinematics can be easily simplified with the use of Maple – this
is a powerful tool as the resources required for the project are
considerably reduced.” Byrun’s hardware requires modeling
mechanical, electrical, thermal and pneumatic elements with the
help of the simulation tool MapleSim, the component requirements
can be largely anticipated in advance.
The team at Engineered Arts has also found MapleSim useful
for its ability to simplify complex calculations. “MapleSim’s
ability to automatically generate complex mathematical models,
such as the leg dynamics, is outstanding. Different parameters
can be altered at different stages to reduce the complexity of
calculations,” Guillaume said. “In the case of Byrun, we were
able to dramatically simplify the leg dynamics, making the
computations much faster. This is extremely powerful and has
real impact on our project timelines and deliverables.”
In addition to designing Byrun’s electro-pneumatic hybrid
legs and upper body for fully mobile walking and running, the
engineers at Engineered Arts are also developing a robotic hand
with the same principles, creating a compact, highly efficient
compliant manipulator. They have designed an elbow joint with
unconventional kinematic characteristic in humanoid robotics
with electro-pneumatic parallel actuation, and are currently
making a full torso-shoulder-arm model in MapleSim. This model
will be used for solving forward kinematics, inverse kinematics,
end-effecter dynamics and compliance.
Robots like Byrun are setting a new standard for both
humanoid and more general robotic design. “To be worth
its cost, this robot must perform something never seen
before. If it can do just 10% of John Travolta’s walk, Margot
Fonteyn’s dance and Julia Roberts’ smile, we have a winner,”
William Jackson, Director of Engineered Arts, told the media.
“Achieving these goals is a daunting task. We are creating
not just an exciting piece of hardware, but one that will make
a great development platform for others to build on. When Byrun
takes his next step, so shall we.” Maplesoft
Engineering Solutions will continue
to be part of every step taken by
this revolutionary team of robotic
engineers.
www.maplesoft.com 19
 MapleSim Used to Speed Up Development of High-Fidelity
Robotic Manipulator Models
ABB Robotics
All across the world today, industrial robots perform tasks that
range from palletizing boxes in a warehouse, to transporting
hoppers of ingredients across a food preparation factory, to
precision welding on a vehicle assembly line. The successful
completion of these tasks relies on the accurate control of the
robotic manipulators to provide the required dexterity. With over
250,000 robots installed worldwide, engineers at ABB’s Robotics
business unit understand the challenges of designing and
controlling robotic manipulators. Their design process includes
rigorous testing with the aid of simulation models which they
had been deriving using non user-friendly tools. The tedious
nature of this process left them searching for a better solution.
Working with a research team from Linköping University in
Sweden, via the industry excellence center LINK-SIC, engineers
at ABB’s Robotics business unit in Västerås, Sweden, set out to
evaluate the use of MapleSim, the high-performance modeling
and simulation platform from Maplesoft, to develop high-fidelity
manipulator models that included flexible joints, gears, and
dynamic friction, and to determine the ease with which the
20
models can be exported and integrated with other software
tools for simulation or controller development.
Their goal was to create high-fidelity models that were realistic
enough to replicate the operation of a real manipulator, while still
being able to run simulations on a regular desktop computer.
While their previous process of deriving models using methods
such as the Euler-Lagrange formulation worked well, MapleSim’s
graphical interface eliminated the need to derive and manipulate
equations, drastically reducing the time needed to model a
manipulator.
MapleSim’s extensive library of built-in components enables
users to simply drag and drop, then seamlessly connect
components from different domains to create complex system-
level models. This ease of creating models radically changed
the way in which design engineers at ABB worked. They now
had a more user-friendly and flexible modeling tool. Using a
combination of multibody mechanics, 1-D mechanical, electrical
and custom components, they were able to create multiple
models of their robotic manipulator with MapleSim, in the same
amount of time it was previously taking them to create just one
model.
 MapleSim helped us to
work faster and smarter. We
were able to quickly create
multiple models of our robotic
manipulator design, and easily
compare them, to determine
the best fit.
- Mikael Norrlöf, ABB Robotics
They used the time saved to apply different modeling
approaches, and created models with different parameter
values and levels of complexity, to determine how best to meet
their design goals. Describing the flexibility that MapleSim
offered them, Mikael Norrlöf, Motion Control Architect at ABB’s
Robotics business unit said, “MapleSim helped us to work faster
and smarter. We were able to quickly create multiple models
of our robotic manipulator design, and easily compare them,
to determine the best fit.”
Having built a series of models representing the manipulator,
the next step was to integrate them with the rest of the system
for testing. ABB performs system-level testing using a complex
test environment built with Simulink®. Therefore, it is vital that the
tool used to generate the manipulator models is able to export
to, and integrate with Simulink®. This capability is provided
by the MapleSim Connector, which enables users to export
any MapleSim model to Simulink®, including models with
custom components. The MapleSim Connector automatically
creates S-function blocks from the symbolically simplified
The complete manipulator model, and a close up of a parallel linkage block
system equations, thus creating code that is compact and
highly efficient.
“Being able to export to Simulink® is very important for us,” said
Mikael Norrlöf. “We were able to seamlessly integrate the models
created with MapleSim into our test environment, without having
to modify our established workflow. This was a key factor in our
decision to adopt MapleSim for model creation.”
The simulation results using the MapleSim models were
comparable with measurements obtained from a real manipulator
– demonstrating conclusively how MapleSim can be used to
generate and export high-fidelity multidomain models that
replicate their manipulator’s behavior. As a result of the research
carried out by the team from Linköping University, ABB has
adopted MapleSim for model creation. As their engineers
continue to develop new ways to increase the fidelity of the
models they use to test their products, MapleSim will be an
integral part of that process moving forward.
www.maplesoft.com 21
 Leading Car Manufacturer Renault Solves
Unwanted Engine Noise and Vibration Using Maple

Renault
When an engine stops, several engine components take part
in the process. Components can produce unwanted noise and
vibrations when the engine slows down, which can lead to their
deterioration. Jean-Louis Ligier, a Research and Development
manager at Renault, and his team were tasked with determining
the sources of these noises and vibrations in a 2.2 liter 4-cylinder
Laguna line of cars. The model of the engine was a system of five
differential equations and focused primarily on the crankshaft,
the dual mass flywheel (DMF), as well as the whole power train.
From these equations, Ligier could estimate the level of vibration
created during the deceleration of the engine. After plotting the
results of the simulation, it became apparent that the vibrations
were primarily occurring from shocks inside the DMF. To rectify
the problem, a rather simple solution was implemented, which
involved modifying the air intake while decelerating.

Discovering the exact cause of the problem led to a substantial

In comparison with others, cost-saving benefit to Renault because it meant that the problem
was fixed with a simple solution—only a slight modification of
Maple can do in a couple of the engine was required.
hours what other software can
By analyzing the simulation results, Ligier reduced the noise by
take days to compute. as much as 30%. Modeling the engine in Maple allowed him to
- Jean-Louis Ligier, Renault analyze the symbolic equations, which enabled a more in-depth
understanding of the system. The numeric results were plotted
and the location of the unwanted vibrations was discovered. By
using Maple, he was able to create and run his model in one
turbo diesel engine. They found Maple to be the most efficient tool
day, which was a substantial time saver in comparison to other
to model the engine and determine the source of the unwanted
software, which took over a week for the same task. “I have
noise. More importantly, they also used Maple to determine a
always liked how easy Maple is to use, and how powerful it is.
solution to the problem.
The ability to perform both symbolic and numeric computations
Ligier, who has a Ph.D. in Mechanical Engineering, has been is a huge time saver for me, allowing me to get results in a day,
using Maple for over 20 years. He has used the software in instead of weeks with other software,” concluded Ligier.
several applied research projects, such as time-varying thermal
analysis in gearbox components, engine friction optimization,
and vibration analysis. He has been with Renault for many years,
managing thermal behaviors and mechanic fatigue on engine
components, as well as determining new simulation methodology.
His primary goal in using Maple was to write equations that
control the engine components very easily.

When creating mathematical models of various components,

different software can be implemented. Ligier has found through
his experiences that Maple is the easiest and fastest software
for his tasks. “In comparison with others, Maple can do in a
couple of hours what other software can take days to compute,”
he said. “The natural math notation allows me to enter the
equations as if I were writing them by hand. The fact that I can
do symbolic calculations allows me to do optimizations that
are virtually impossible with other software. What’s more, the
results are extremely accurate.”

When speed decreases in an engine, several mechanical

resonances are generated. If there is too much movement within
the engine, not only do the components create noises disturbing
to the driver, but they also begin to wear out prematurely. The
goal of the study was to model and understand the cause for the
vibrations. The modeled engine was a 4-cylinder from Renault’s

22
Maple Used for Analyses and Deployment at Renowned
Automotive Parts Manufacturing Company
A global supplier of vehicle technology has chosen Maple, the
technical computing software from Maplesoft, to automate their
engineering analyses functions, and as a deployment solution
throughout their organization. Maple, the technical computing
software from Maplesoft, provides a complete environment for
rapid solution development within any technical organization,
from original concept to solutions deployed in the field.
A team of electrical engineering managers at this leading
automotive parts company chose Maple because of its
engineering notebook interface, math functionality and the
ability to freely deploy interactive applications to a broader
audience. One aspect of the technology that was of particular
importance was Maple’s ability to translate SPICE netlists into
transfer functions. This automatically removes errors from what
is traditionally a manual task.
The team is responsible for developing applications for the rest
of the organization as well as external customers to use. The
team identified three classes of Maple users at their company
- application authors, end users, and engineers.
Application authors use Maple to develop sophisticated analyses
for electrical engineering. They use a wide range of Maple
features to develop their applications, including non-linear
fitting, symbolic transfer function manipulation, plotting, and
programming. This functionality offers greater power and
flexibility than the tools in their previous math package.
For example, their previous math tool had the following key
limitations that Maple does not have:
• It would not let them create a program with a variable
number of arguments - this meant they had to create
multiple versions of the same program to handle
different scenarios. Maple does not have this limitation,
allowing the team to simplify their code.
• It did not have built-in tools for generating Bode plots.
Maple, on the other hand, offers a complete set of
tools for analyzing and visualizing transfer functions.
The second class of users, considered the end users, both
internal and external, utilizes the applications developed by
the application authors. The applications are deployed with the
Maple Player, a free solution that lets users view and interact
with Maple documents to solve problems, visualize solutions,
and explore concepts, even if they don’t have Maple.
Engineers, the third class of users, explore the solution space
for electrical design problems with Maple. They use Maple to
investigate problems using natural math notation, plots, and
numeric and symbolic math functionality. These analyses are
documented with text and diagrams in Maple’s smart document
environment to ensure auditability. Before Maple, engineers at
the company employed other tools that did not offer the same
level of analysis and documentation capabilities provided by
Maple.
The team feels that using Maple makes them better able to
complete advanced engineering analyses, deploy solutions to
the end users and engineers, and preserve corporate knowledge.
www.maplesoft.com 23
 Simulating Clearpath Robots in MapleSim
Clearpath Robotics
Key challenges in robotic systems are that robots are expensive
and they usually depend on batteries. What if you want to run
an experiment with 100 robots, running for 10 hours? Clearpath
Robotics, a global leader in unmanned vehicle robotics for
research and development knows these questions all too well.
To address such concerns, Clearpath’s Robot Operating System
has built-in support for robot simulation. While this works quite
well, it is currently unable to simulate physical properties like
batteries, temperature, or surface roughness. “If your robotics
research depends on accurate models, you may want to
consider looking at MapleSim - a high performance physical
modeling and simulation tool developed by Maplesoft,” noted
Ilia Baranov, Senior Electrical Designer of Clearpath Robotics.
“Using MapleSim, we created a video of the Grizzly Robotic
Utility Vehicle taking an open loop control path around a surface.
Elements like current and voltage provided by the batteries,
surface slipperiness, and weight distribution play a role in where
the Grizzly actually ends up. The graphical representation in
MapleSim is easy to understand and quick to modify.”
24
The MapleSim model features a 200 Ah lead-acid battery pack
with a nominal voltage of 48 V, similar to the Type B battery pack
used in the robot, to provide electrical power to move the vehicle
on an uneven terrain. The lead acid battery used in the model
is part of MapleSim Battery Library. The physical behaviors of
the battery are described by mathematical expressions, which
are curve-fitted based on experiment measurements, to provide
the accurate battery voltage and state of charge during the
operations of the robot.
The interaction forces and moments at the tire-terrain contact
points are generated based on a 3D tire model in MapleSim.
A 3D mathematical expression is used to describe the terrain
surface to allow the tire-terrain contact points to be calculated
based on the position of the vehicle. This 3D function is also
used to generate the STL graphics of the terrain for animation.
The model also outputs electric motor torques, speeds, and
battery state of charge as shown in the following images.
 If your robotics research depends on accurate models, you may
want to consider looking at MapleSim - a high performance physical
modeling and simulation tool developed by Maplesoft.
- Ilia Baranov, Clearpath Robotics
MapleSim and Maple provide a testing and analyses environment,
based on the virtual prototypes of the model, to perform several
analyses:
Virtual testing and analysis: an engineer can easily test the
operations of the robot for any design in a virtual environment
through simulations in MapleSim. Using Maple, different terrain
surface conditions and tire force models to fit different test
scenarios can be generated. As an example, the plot to the left
shows different battery energy consumption (state of charge)
rates under different terrain conditions.
Battery optimization: the developed MapleSim model can
be coupled with Maple’s powerful optimization toolboxes
to determine the optimal battery size, and to optimize the
Battery Management System (BMS) in order to minimize energy
consumption, reduce battery temperature, and increase battery
service life.
Motor sizing: the robot is equipped with four electric motors
which are independently controlled to provide wheel torques
and steering maneuvers. The seamless integration with Maple
will allow the motor sizing optimization to be performed based
on MapleSim simulations.
Chassis design and payload distribution: the virtual prototype
of the system will allow engineers to easily vary payload locations
and distributions as well as analyze their effects, e.g., roll-over,
stability, controllability, etc., on certain tasks.
Path planning: using Maple, different terrain surface conditions
and tire force models to fit different test scenarios can be
generated for path planning.
Model-based controller design: the MapleSim model will allow
the control strategies to be designed and tested for accuracy
before being deployed on a real vehicle.
Localization and mapping: the high-fidelity dynamic model
of the robot will allow state estimation algorithms, such as
Kalman filter and other Bayesian-based filtering algorithms, to
be performed at a high accuracy.
Optimized code generation: optimized C code can be generated
from the MapleSim model for the purpose of implementations
of control, localization, and path planning strategies.
For more information on simulating the Grizzly in MapleSim,
view the Grizzly RUV Model in the MapleSim Model Gallery:
www.maplesoft.com/ModelGallery
www.maplesoft.com 25
 MapleSim and Maple Used in Advanced Research
Projects at the ARM Lab at SUNY Buffalo
SUNY Buffalo
The Automation, Robotics and Mechatronics (ARM) Lab
is a research laboratory in the Department of Mechanical
& Aerospace Engineering at the School of Engineering &
Applied Sciences in The State University of New York (SUNY)
at Buffalo. The lab combines an in-depth understanding of
mathematical theory with experimental validation to develop a
new generation of smart mechanical and mechatronic systems.
Their work includes projects in haptic devices for surgical
simulations, musculoskeletal simulation to refine human-machine
interactions, cooperative payload transport by robot collectives,
and omnidirectional wheeled robots. Several of their research
projects have directly resulted in the creation of commercially
available devices that are then used by labs around the world
for education and further research.
Since most of their projects start with an in-depth analysis of the
underlying mathematics of the system, the ARM Lab requires
tools for developing and analyzing mathematical equations. They
have chosen Maple and MapleSim as key tools to complete
these tasks. Dr. Venkat Krovi, director of the ARM Lab, finds
using a symbolic approach invaluable to their work. “Performing
these calculations symbolically allows for the development of
exact, closed form expressions. We don’t need to worry about
accumulating errors from numerical calculations. Perhaps even
more importantly, with the exact mathematical equations, we can
identify singularities, perform parametric design refinements,
and improve the real-time model-based control strategies.”
One of the ARM Lab’s research projects involved the study
of kinematic and dynamic simulations of 6 degree of freedom
26
6-Prismatic-Universal-Spherical (6-P-U-S) type manipulators.
This type of manipulator combines a platform that moves and a
fixed base, interconnected by several legs. In his research, Dr.
Krovi and his research team analyzed a general 6 DOF 6-P-U-S
manipulator. They used Maple and MapleSim to automatically
generate the governing equations, and conducted a kinematic
analysis of those equations with Maple. Starting with these
general equations, specialized equations were extracted from
the general system that correspond to a specific architecture
with desirable properties – superior structural design with
minimal interior singularities within its workspace. They were
then able to analyze the workspace of such parallel-architecture
manipulators, with the primary goal of optimizing the link
geometries and parameters to enhance overall workspace
and other selected geometric workspace-based performance-
measures.
Dr. Krovi and his team then worked with Quanser Consulting
Inc., a world leader in the design and manufacture of advanced
systems for real-time control design and implementation, to
create a physical prototype of the parallel arm manipulator
corresponding to the design developed from the specialized
kinematic and dynamic equations. Quanser also used
MapleSim’s modeling and simulation capabilities during the final
design and development process. The 6 DOF motion platform,
termed the Hexapod, is now part of Quanser’s mechatronic
controls collection and can be used in various applications,
including vibration studies, earthquake simulations, and flight
simulations. Dr. Krovi continues to use the Hexapod in his
research and teaching and MapleSim and Maple in ongoing
research projects at the ARM Lab.
3-D Hall Sensor Algorithm Developed in Maple
Produces a More Efficient Washing Machine Design
Marquardt GmbH
Dr. Frank Allmendinger leads a research and development
project team at Marquardt GmbH, a German company that
develops and manufactures switches and switching systems.
His team designed an innovative three-dimensional load and
imbalance sensor, which is used in a new washing machine
model from a well-known company in the “white goods” sector.
I found Maple’s user
interface very easy and smooth
to work with.
- Dr. Frank Allmendinger, Marquardt GmbH
In industry, the trend is to move from washing machines with a
drum capacity for 5 kg of laundry to larger ones with a capacity
of 7 or 8 kg. However, these large drums are still being placed
in the standard washing machine housing with a width of 60
cm, which means there is a much smaller space left
between the drum and the housing. This means
collisions are more probable. It is therefore
necessary to measure the position of the
drum relative to the housing, use this signal
to identify impacts of the drum against the
housing in advance, and react accordingly.
Marquardt’s sensor was developed to detect
the relative position, in three dimensions, of
the washing machine drum to the housing.
Having the ability to measure the drum
position gives several other advantages; for
instance, it is possible to sense imbalances
and detect resonant frequencies of the
mechanical system during the machine’s
spin cycle. These imbalances can be
reduced by slowing the rotation speed
and distributing the weight more evenly. It
even becomes possible to measure a load
of clothing as it is placed into the machine
and give a recommendation of how much
detergent to use!
The Marquardt team, in close collaboration with the Fraunhofer
Institute for Integrated Circuits, developed a new 3-D Hall sensor
application-specific integrated circuit (ASIC) that measures
the three vector components of a dipole magnetic field. The
complete measurement system consists of a magnet affixed to
the drum in the washing machine and the 3-D Hall sensor ASIC
attached to the unit housing. The Hall sensor measures both
the direction and strength of the magnetic field, determining
the relative movement of the magnet simultaneously in all three
dimensions. This information is then communicated to the
onboard microcontroller, which uses a proprietary algorithm to
determine how to control the movement of the drum.
To develop the algorithm, the Marquardt group used Maple.
Dr. Allmendinger found Maple to be an invaluable tool, allowing
him to work on complex problems such as modeling the
magnetic fields, estimating the allowed tolerances for the
magnet, and determining whether the tilt of the 3-D Hall sensor
module was within a very small tolerance of approximately two
degrees. The resulting algorithm was translated to C code to
run on the controller.
Dr. Allmendinger first worked with Maple while studying
at university. He was impressed by Maple’s ability to work
with symbolic mathematics, its powerful graphing tools, its
technical document interface, and its export capabilities to other
languages (such as C, MATLAB®, and Java). Dr. Allmendinger
said, “It was very simple to work in Maple, even with the
complex mathematics involved.
We found it quite easy to
enter and modify equations,
determine whether they had
a solution, then go back and
make necessary changes.
I found Maple’s user interface
very easy and smooth to work
with, especially the export
capabilities; interoperability
with other technical programs
have become much better,
and it is now invaluable in
rapid solution development.”
The new 3-D positioning
algorithm in the Hall sensor
yields several advantages.
First, assembly is simple
because there is no mechanical
connection between the magnet and the
sensor. As the measured values of the three
magnetic field components can be recorded simultaneously,
the sensor system also offers the option of calculating speed.
Overall, the design enables natural resources to be handled
more responsibly. The use of mathematic field modeling makes
it possible to discard traditional 3-D mapping techniques and
use a smaller, more cost-effective microcontroller. Also, fewer
resources are used by creating the considerably smaller magnet.
www.maplesoft.com 27
 Maplesoft’s Battery Modeling Solution Helps Increase Safety
and Reduce Costs, Set-Up Time in HIL testing

The use of rechargeable batteries in consumer products, life or, in extreme cases, destruction or even explosion due to
business applications and industrial systems continues to thermal runaway, a common problem in many battery-powered
grow substantially. The global market for all batteries will reach systems.
almost $74 billion this year, and rechargeable batteries will
account for nearly 82% of that, or $60 billion, according to
market researcher Frost & Sullivan. Growth like this means
several things. First, large companies have moved or are moving
into the market, designing and offering products ranging from
hand-held devices to large power back-up systems. Second,
as the systems get larger, battery technologies have to match
the technical challenges of increasing cell capacity, thermal
stability, life extension and disposal.

Meeting the Technical Challenges

Monitoring and controlling larger cell arrays through Battery
Management Systems (BMS) helps to minimize charge times
and maximize efficiency and battery life. Design and testing
of a sophisticated BMS can pose challenges, however, as
was discovered by one of the largest producers of electronic
products in the world. That’s why they recently relied upon
Maplesoft and ControlWorks Inc., a real-time testing systems
integrator with deep experience developing BMS test stands, to
develop a Hardware-in-the-Loop (HIL) test system for the BMS
in one of their large Energy Storage System (ESS) products.
An attractive solution to these testing challenges is to use
virtual batteries - mathematical models of battery cells that
are capable of displaying the same dynamic behavior as real
ones - for early-stage testing of the BMS. Not only have these
models proven to be highly accurate, they are computationally
efficient and are able to achieve the execution required to deliver
real-time performance for batteries containing hundreds of cells
on real-time platforms.
The battery modeling technique employed by Maplesoft uses
a partial differential equation (PDE) discretization technique to
streamline the model to a set of ordinary differential equations
(ODE) that can be readily solved by system-level tools like
MapleSim. The advanced model optimization features of
MapleSim also allow the resulting code to be very fast and
capable of running in real-time.
The resulting battery models can also be employed in the
prediction of charge/discharge rates, state of charge (SoC),
heat generation and state of health (SoH) through a wide range
of loading cycles within complex, multi-domain system models.
This approach provides the performance needed for system-
level studies with minimal loss in model fidelity. The user can also
allow for energy loss through heat, making these models useful
for performing thermal studies to determine component sizes in
cooling systems to manage battery temperature. Not carefully
controlling the temperature can lead to reduced operational
Simulation of thermal runaway using the Li-Ion model from the
MapleSim Battery Library
Model Structure for this Application
For the purpose of this ESS test system development project,
the key requirements for the battery model were:
1. Up to 144 Li-Ion polymer cells for testing the BMS
of the client’s ESS products
2. Ease of configuration for different requirements
(parallel/series networks)
3. Several sensors per cell (current, voltage, SoC, SoH)
4. Variation of chemistry make-up due to manufacturing
tolerances
5. Fault-insertion on each cell (open-circuit, shorting)
6. Capacity to run in real-time (target execution-time
budget of 1 ms)
In the case of energy storage systems, like this example, each
ESS battery is made of several “stacks” that, in turn, contain
several cells. The MapleSim model follows this structure with
each cell being a shared, fully parameterized subsystem.
Each cell can also be switched to open circuit using logical
parameters.
The stack model is made of 18 cell subsystems connected
either in parallel or series, depending on the requirement.
Input signals are provided for charge balancing from the BMS.
Output signals are provided back to the BMS to monitor the
condition of the stack (supply voltage, SoC and SoH). Finally,
the full ESS is made of several stacks with IO signals fed to
and from the BMS.
Model Calibration and Validation
Much of the accuracy of this model is dependent on
experimentally derived parameters, determined from charge/
discharge test results. Project engineers determined that any

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 deviation in performance due to manufacturing variations needed
to be included in order to test the charge-balancing capability
of the BMS. Instead of testing every cell, engineers relied on
random variants generated from the statistical distribution
determined by the charge/discharge test results on 48 cells.
This was applied to all 144 cells and then compared with the
real test results. The maximum variance of the voltage from the
experimental data was 14mV, while from the simulation it was
13mV, acceptable for the purpose of this project.
Maplesoft and ControlWorks Inc. engineers also determined
the average cell response using the parameter-estimation
tool supplied with the MapleSim Battery Library. This uses
optimization techniques to determine the values of cell-response
parameters that provide the closest “fit” to the experimental
results. This response was then validated against response data
from other cells to ensure close estimation of the resulting model.
SoH behavior was implemented as a look-up table based on
experimental results. The model determines the capacity and
internal resistance based on the number of charge/discharge
cycles and depth of discharge (DOD) from the lookup.
Finally, the model was converted to ANSI-C through the
MapleSim Connector, producing an S-Function of the battery
model that can be tested for performance and accuracy with a
fixed-step solver on a desktop computer in MATLAB/Simulink®
before moving it to a real-time platform. The simplest solver was
used and the performance bench showed that the average
execution time was approximately 20 times faster than real-time,
occupying 5.5% of the real-time system time budget. This shows
that the battery model can be easily scaled up, if required.
The end result was a battery model capable of being configured
to represent a stack of up to 144 cells that can be connected in
any combination of parallel and series networks. Fault modes
were also built-in, such as individual cells shorting or opening,
as well as incorporating variations in charge capacity from cell
to cell, and degradation of capacity over the life of the cells.
The Cell Stack, ESS Battery models, and SoH simulation showing effect on battery voltage
The final BMS test station provides the client’s engineers with
the ability to configure the battery model (number of cells,
series/parallel, etc.) and apply a range of tests to it. The
engineer can go back to the MapleSim model at any time to
make any necessary changes to the model configuration, and
then generate the model for use on the real-time platform. In
this system, the real-time software is National Instruments’
VeriStand™, driving a PXI real-time system. The MapleSim
Connector for NI VeriStand™ automates the model integration
process, allowing the engineer to produce the real-time model
quickly and reliably.
The ControlWorks Inc. system also integrates real-time
platform, signal processing, fault-insertion tools and standard
communications protocols (CANbus for automotive, Modbus
for industrial applications), allowing the engineer to run the
BMS through a range of tests on the battery model, including
Constant Current (CC) and Constant Voltage (CC/CV) charge/
discharge cycles, as well as Constant Power (CP) and Constant
Resistance (CR) discharge cycles.
“We were pleased to be able to partner with Maplesoft on this
project,” said Kenny Lee, PhD, Director of Research Center of
Automotive Electronics, ControlWorks Inc. “The use of battery
models in this case proved to be an effective alternative to the
use of real batteries,” he added.
Summary
Test automation and simulation is critical in system-level testing,
allowing time and cost of failure analysis, constant development
pressure, expense of repeated tests, and lengthy set-up times
all to be addressed.
“The use of high-fidelity, ready-made battery models allows the
engineer to avoid the risks of damage to batteries, along with
subsequent costs, while testing and optimizing the BMS design
in a close-to-reality loading environment,” said Paul Goossens,
Maplesoft VP of Engineering Solutions.
The use of virtual battery technology in the design of test systems
can facilitate the development of better products, reduce project
risks, and get products to market faster.
www.maplesoft.com 29
 Broadcasting Benefits of Math and Analysis Software
Arqiva
Maple mathematics software is helping broadcast network
operator Arqiva to model antennas and analyze systems,
ensuring that broadcast signals are received over the specified
range.
Responsible for much of the UK’s broadcast and mobile
communications infrastructure, Arqiva delivers wireless, satellite,
and terrestrial broadcast services to a growing number of
countries around the world. All land-based transmissions for UK
television stations, including the new digital networks as well as
wireless provision for cellular, wireless broadband, voice, and
data services for both commercial and government markets,
are handled by the company. Ensuring that its stations conform
and deliver the power and coverage needed is paramount.
Arqiva engineers are constantly upgrading the capabilities of
their products and the software tools they use. “In order to fully
understand how our products work and the nature of the maths
behind it, we need something to quickly and simply check what
is happening,” says Arqiva Senior Technologist Karina Beeke.
“Maple offers just that, with 3-D graphics and an easy interface.”
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Maple allows analysis in engineering and science projects
to be streamlined and the quality enhanced. With fly-through
animations and 3-D plot annotations, the package includes
advanced mathematical functions and point-and-click tools for
control systems design. With features such as context-sensitive
menus and powerful problem-solving tools, the software is
intuitive and can be used with little training.
Having a wealth of features useful to Arqiva, Maple includes
space curve, aptitude, curve fitting, and the ability to rotate and
zoom in to elements. A major benefit, according to Karina, is its
flexibility and range, “With Maple we can start simply and then
develop as we go without having to completely understand the
full capability.” Arqiva also uses the Maple Global Optimization
Toolbox to help with matching antenna features for best fit.
Karina is also positive about the ‘very good support’ and the
extensive online resources available from Maplesoft. A user
forum complements an online library of algorithms and a
troubleshooting guide.
MapleSim Used in the Creation of Breakthrough
Vehicle Driving Simulator Technology
Ansible Motion
As automotive manufacturers compete on features of efficiency
and safety, they are also battling to provide the best driving
experience for their customers. As a result, vehicle engineering is
becoming more complex, involving multiple disciplines. There is a
growing desire to provide test drivers and evaluators with simulated
driving experiences, so that their feedback can be incorporated
early in the design process. Based on this, automakers are
introducing a new element in the complex assessment process
between virtual prototyping and vehicle on-road testing.
With support from Maplesoft, VI-grade, an engineering simulation
software provider, has produced the award-winning, breakthrough
driving simulator technology, VI-DriveSim Dynamic. This high-
end driving simulator allows automotive OEMs and racing teams
to test full vehicle configurations, from the engine through the
transmission to the suspension and tires, using a human driver
and a virtual vehicle.
Very often, test drivers and track engineers cannot sufficiently
influence the vehicle design, because their feedback comes far
too late in the prototyping process. VI-DriveSim Dynamic enables
the implementation of a new validation stage in the design cycle
by letting real drivers drive the virtual car. Driver feedback can
then be taken into account and improvements made before any
expensive physical prototypes are built. The simulator needs to
be so accurate that the most sensitive professional driver can
feel the smallest change in vehicle performance.
MapleSim was a big part
of our ability to develop this
technology.
- Kia Cammaerts, Ansible Motion
The VI-DriveSim Dynamic simulator works by running a virtual
mathematical model of the vehicle and track, and linking it to
a 6 degree of freedom motion platform designed expressly for
automotive requirements by Ansible Motion. The inputs to the
virtual model are supplied by actions of the human driver in the
simulator as he shifts, steers, brakes, and accelerates. In turn,
the platform controller provides real-time input to the platform
actuators, according to what happens to the vehicle model as
it responds to the inputs. The physical simulator platform thus
provides inertial feedback to the driver, allowing him/her to interact
in a natural way with the virtual vehicle model.
An inverse kinematics/dynamics model of the motion platform
is required so the software knows what changes to the platform
will produce the correct forces on the driver to simulate the
vehicle in motion. The challenge here is to acquire these inverse
relationships, which will provide the most accurate response of
the system. To accomplish this, Ansible Motion used Maplesoft’s
system-level modeling and simulation tool, MapleSim, to build
the platform model, and to analytically solve for the inverse
kinematic equations. Having access to these equations is crucial,
and could not have been achieved without a symbolic/analytical
computational engine such as Maple, the mathematical engine
behind MapleSim. In effect, MapleSim gives the controller an
exact analytical solution for the inverse kinematics, giving the
best possible simulation.
“Driving simulator technology is emerging as an integral part
of the vehicle development process for motorsports teams and
production vehicle manufacturers,” said Kia Cammaerts, Technical
Director, Ansible Motion. “MapleSim was a big part of our ability
to develop this technology. Our team would not have been able
to efficiently develop our systems for VI-grade or our other clients
without a tool such as MapleSim, which we used to develop the
inverse kinematic solutions for the actuators, saving us months
of painstaking, error-prone effort.”
VI-grade’s flagship solution, VI-CarRealTime, powers the system
with a real-time validated vehicle model. The partnership between
Maplesoft and VI-grade makes real-time modeling applications
more cost and time-effective by integrating MapleSim models
with the VI-CarRealTime framework.
“The combination of MapleSim and VI-CarRealTime allows for
the fast, accurate modeling of automotive subsystems, such
as powertrains, suspensions, and steering mechanisms,” said
Paul Goossens, Vice President of Applications Engineering at
Maplesoft. “Automotive engineers can easily do innovative work,
exploring their designs in new and deeper ways, detecting
problems earlier in the design cycle, and developing high-quality,
practical solutions to their design challenges.”
VI-DriveSim Dynamic, has been awarded “Development Tool
of the Year 2012” by Vehicle Dynamics International Magazine.
www.maplesoft.com 31
 About Maplesoft
Maplesoft provides engineers with the tools and expertise they need to enable a model-driven innovation process that helps manage
design complexity. Offering experts in a variety of engineering fields, extensive experience in model-based design, and the superior
system-level modeling and analysis tools MapleSim and Maple, Maplesoft helps companies reduce development risk and bring
high-quality products to market faster. Through Maple, Maplesoft also provides a complete concept-to-deployment environment for
advanced analysis and rapid development of technical applications and engineering calculation tools. Maplesoft products and services
are used in machine design, robotics, aerospace, automotive, and many other fields where engineers face complex challenges.
Customers include Boeing, FLSmidth, Ford, Google, Intel, NASA, and Samsung.

Maplesoft is a subsidiary of Cybernet Systems Group. For further details, please visit www.maplesoft.com

A C y b e rn e t Gro u p C o m p a n y

www.maplesoft.com

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All other trademarks are the property of their respective owners.

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