Multi-physics with MotionSolve
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Multi-physics with MotionSolve

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The real world is inherently multi-disciplinary. In order to accurately understand the behavior of such systems, there is a need to simultaneously combine hitherto separate physical disciplines in a ...

The real world is inherently multi-disciplinary. In order to accurately understand the behavior of such systems, there is a need to simultaneously combine hitherto separate physical disciplines in a logical manner to generate higher-level mathematical models that can accurately represent natural behavior.
Simulation tools have traditionally focused on a single discipline such as controls, fluid dynamics, structures or motion. There is a pressing need to efficiently combine these various representations, solve the resulting model and predict reality.

Due to its system level focus, multi-body simulation is a natural environment for integrating the different technologies together. MotionSolve is an Industry proven multi-body simulation tool that provides a logical environment to integrate different technologies and solve the combined problem.

This presentation discusses three topics:

(a) The need for multi-disciplinary simulations and strategies for combining models
(b) Simulating real world phenomena using MotionSolve
(c) Case studies illustrating how customers have successfully used MotionSolve to solve multi-physics problems.

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Multi-physics with MotionSolve Multi-physics with MotionSolve Presentation Transcript

  • Multi-Physics with MotionSolve Rajiv Rampalli & Keshav Sundaresh, AltairInnovation Intelligence®
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Presentation Outline• Need for Multi-Physics simulations• Case Study: Control of a Wind Turbine• How other customers are doing Multi-Physics simulations 2
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Real Models Are Complex Hydraulics & H d li Flexible N Fl ibl & Non-linear li Control systems components Virtual tires & Virtual driver digitized roads models 3
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Industrial Processes Are ComplexTIRE & ROAD MBD FATIGUE G POST DRIVER FE DRIVER FE 4
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.The Conundrum Systems Software Multiple Domains Single Domain Diverse Phenomena Single Formulation Many Technologies One Integrator 5
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Introducing MotionSolve…• A natural environment for multi-disciplinary studies• Open architecture for coupling domains• Many different choices available for coupling 6
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Model Connection Methodologies Master System Equations S-1 S-2 S-2 Sharing Equations Co-Simulation (Sharing signals) Simulator-1 Simulator-2 Shared Data Sharing Linear Models 7
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Linear Models: With Simulink Matlab MotionSolve M ti S l Simulink MotionSolve exchanges state matrices with Matlab/Simulink 8
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Linear Models: With FE HyperMesh MotionView Radioss MotionSolve MotionSolve shares data with a variety of FE codes 9
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Equations: via User Subroutines Object Code User  MotionSolve Subroutine Python Script DLL MotionSolve User subroutines allow users to link their own equations to MS U b ti ll t li k th i ti t 10
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Equations: via Code Export Object Code Motion Motion “C” Solve RTW Solve Code DLL Simulink Controller Co-simulation Co simulation Native RTW code import from Simulink 11
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Signals: MotionSolve + Simulink System Model MotionSolve model S-Function (MS ) Controller Simulink Window MotionSolve is an S-Function in Simulink 12
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Signals: MotionSolve + DSHplus System Model User Block (MS ) Hydraulic System DSHplus Window MotionSolve is a user block in DSHplus 13
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Sharing Signals: MotionSolve + Driver System Model y Controls & Switching Signals Speed Controller Gearbox Controller Feedback Controller Signals Outputs Steering Controller Vehicle Model Driver Model ( (MS))MotionSolve can include complex driver models via co-simulation 14
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Presentation Outline• Need for Multi-Physics simulations• Case Study: Control of a Wind Turbine• How other customers are doing Multi-Physics simulations 15
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Co-simulation – Wind Turbine Emergency Stop “Grid loss” – Sudden drop in generator torque Grid loss Reaction: Immediate blade pitching and activation of the brake disk. E-stop event• 0-60s Ramp up to full effect, 1MW. 120.0s “Grid loss” 100-0% in 0.1s 120.4s Maximum brake pressure & reversing pitch angle 135.0s Pitching completeMechanical system, Wind loads – lift and drag forces v/s pitch angle, Tower shadow - %ge drop of wind forces in front of the tower 16
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Initial Results• Grid loss and braking generate massive rotor torque variations t t i ti• Large blade vibrations during overshoot• Blades vibrate during initial braking, causing high frequency variations of rotor torque. 17
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Control Requirements • Implement a non-linear braking pressure to: • Reduce blade deflection • Eliminate overshootBrake controller: Blade deflection v/s Brake magnifierBrake release: Rotational speed v/s release factorLow pass filter to the braking signal – to avoid rapid vibrations 18
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Control Model in Simulink Rotor Velocity Flex Sensors Control Parameter C t lP t Plant Outputs Plant Outputs Flex Sensors Rotor Velocity Controller MS Model Sensors Flex Sensors 1 z Rotor Velocity 1 z Blade Deflection 19
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Co-Simulation Results 100% Rotor Speed Simulink Rotor Speed 100% R t S Rotor Speed d Simulink Rotor Speed Si li k R t S d 100% Rotor Speed Simulink Rotor Speed Brake controller: Blade deflection v/s Brake magnifier Brake release: Rotational speed v/s release factor 20
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Presentation Outline• Need for Multi-Physics simulations• Case Study: Control of a Wind Turbine• How other customers are doing Multi-Physics simulations 21
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Faurecia – Glass guidance simulation • Challenge: • Find the cable positions to meet requirements on normal f l forces f different combinations of for diff t bi ti f friction. • Solution: • Mechanism analysis with MotionSolve to find the normal forces • Design optimization with HyperStudy to find the optimal cable positions. • Benefits: • An optimal design that meets all conflicting requirements. • A fast & automated design process leading to fewer errors & better designs. “Co-simulation of window regulator with MotionSolve and Matlab/Simulink gives a full mechatronics model of the system, allowing simultaneous design of both mechanism andactuator” – Dany Desrus, Leader Product Line EE & Mechatronics, Faurecia Interior Systems22
  • Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Summary• Real systems are complex• A full understanding of these requires multi-disciplinary simulation• MotionSolve has an architecture that facilitates coupling of different solvers to enable multi-disciplinary simulation• Many different options for coupling are available y g• The simulation requirements and coupling difficulty dictate which choice should be used. Thank You! 23
  • Rajiv Rampalli Keshav Sundaresh(keshavs@altair.com)Innovation Intelligence®