Evaluation an Adaptation of Open-Source Development Tools for Mechatronic Systems Bachelor Thesis : Zack Stull Computer-Aided-Design Programs

1. 20.12.2016 | Fachbereich Maschinenbau | Institut SAM | Prof. Melz | 1
Zack Stull | Bachelor Thesis | 2016
Evaluation and Adaptation of Open-Source
Development Tools for Mechatronic Systems

2. 20.12.2016 | Fachbereich Maschinenbau | Institut SAM | Prof. Melz | 2
Overview
• Introduction
• Methods
• Research & Testing
• Scoring
• Results
• Computer-Aided Design
• Finite-Element Analysis
• Simulation Environments
• Analysis
• Conclusions

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INTRODUCTION

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OpenAdaptronik Project
• Maker Movement
• Adaptronic Systems
• Open-Source Toolkit
• Engineering Development Tools

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Computer-Aided Design Programs
• QCAD
• LibreCAD
• OpenSCAD
• Solvespace
• FreeCAD

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QCAD

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LibreCAD

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OpenSCAD

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Solvespace

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FreeCAD

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Finite-Element Analysis Programs
• Elmer
• Salome-Meca (Code_Aster)
• FreeCAD (Calculix)

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Elmer

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Salome-Meca (Code_Aster)

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FreeCAD (Calculix)

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Simulation Environments
• OpenModelica
• Hopsan
• Scilab

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OpenModelica

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Hopsan

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Scilab/Xcos

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METHODS

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Literature Research
• User Manuals
• Documentations
• Wiki Pages
• Forums
• Academic Studies

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Testing (CAD)
• 3-dimensional
• Nonlinear features
• Requires several extrusions
• Sketching on different faces

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Testing (FEA)
• Imported geometry
• Meshed geometry
• Assigned initial & boundary
conditions
• Analyzed results

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Testing (Simulation)
• One DOF System
• Mechanically modeled
• Two systems
• Passive
• Velocity feedback

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Scoring
• Created metrics
• Based on features
• Binary scoring
• 1 for feature
• 0 without feature
• Divided into subcategories
• Overall scores
• Sum of subcategories

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RESULTS

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CAD Programs
• Operating Systems
• Help & Support
• User Interface
• File Format Capability – Import
• File Format Capability – Export
• Design & Editing Functionality
• Overall Scores

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Overall Scores
Overall FreeCAD Solvespace QCAD LibreCAD OpenSCAD
Operating Systems 3 3 3 3 3
Help & Support 4 3 3 4 4
File Format – Import 9 3 4 3 3
File Format – Export 10 8 5 4 4
User Interface 7 5 6 6 3
Design & Editing 14 10 6 6 6
Total 47 32 27 26 23

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FEA Programs
• Operating Systems
• Help & Support
• User Interface
• Mesh File Import
• Geometry File Import
• Functionality
• Advanced Materials
• Overall Scores

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Overall Scores
Overall
Salome-
Meca
FreeCAD Elmer
Operating Systems 1 3 3
Help & Support 3 4 4
User Interface 7 8 5
Mesh Import 5 5 5
Geometry Import 6 6 6
Functionality 13 12 14
Advanced Materials 5 5 2
Total 40 43 39

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Simulation Environments
• Operating Systems
• Help & Support
• User Interface
• Simulation Capability
• Additional Capabilities
• Interoperability
• Overall Scores

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Overall Scores
Overall Scores Scilab OpenModelica Hopsan
Operating Systems 3 2 2
Help & Support 4 3 3
User Interface 6 6 5
Simulation Capability 5 5 5
Additional Capabilities 8 3 2
Interoperability 7 5 4
Total 33 24 21

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ANALYSIS

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CAD Programs (3-dimensional)
• FreeCAD
• Highest score
• Most similar to industry products
• Solvespace
• Scored well
• Portable
• Better-suited for smaller projects
• OpenSCAD
• Lowest scoring
• Integrated into FreeCAD

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CAD Programs (2-dimensional)
• QCAD & LibreCAD scored well in 2D metrics
• Outscore Solvespace
• Good 2D alternatives
• QCAD outscored LibreCAD
• Difference in file compatibility
• DWG & SVG

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FEA Programs
• FreeCAD (Calculix)
• Highest scored
• Small difference in scores
• Salome-Meca (Code_Aster)
• Operating system compatibility
• CAELinux
• Elmer
• Outscored in ‘Functionality’
• Underperformed in ‘Advanced Materials’

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Simulation Environments
• Scilab/Xcos
• Highest scored
• Integrated Matlab alternative
• Functional Mock-up Interface
• Potential to integrate OpenModelica or Hopsan
• GNU Octave
• Little research into products
• Future studies of capabilities recommended

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CONCLUSIONS

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Conclusions
• Computer-Aided Design
• FreeCAD
• Finite-Element Analysis
• FreeCAD & Salome-Meca
• CAELinux
• Simulation Environments
• Scilab/Xcos
• Trend towards integrated products

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Thanks for your attention!

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Questions?

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CAD Subcategories

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Operating Systems
Operating Systems FreeCAD Solvespace QCAD LibreCAD OpenSCAD
Windows 7+ 1 1 1 1 1
Mac OS X 1 1 1 1 1
Linux 1 1 1 1 1
Total 3 3 3 3 3

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Help & Support
Help & Support FreeCAD Solvespace QCAD LibreCAD OpenSCAD
Documentation 1 1 1 1 1
Forums 1 1 1 1 1
Tutorials 1 1 1 1 1
Wiki 1 0 0 1 1
Total 4 3 3 4 4

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User Interface
User Interface FreeCAD Solvespace QCAD LibreCAD OpenSCAD
Graphical User Interface 1 1 1 1 1
No Programming
Required
1 1 1 1 0
Command Line 1 0 1 1 0
Custom Tool Palette 1 1 1 1 0
Import Existing Designs 1 1 1 1 1
Macros 1 0 0 0 0
Installer 1 1 1 1 1
Total 7 5 6 6 3

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File Format Capability - Import
Import FreeCAD Solvespace QCAD LibreCAD OpenSCAD
DWG* 1 1 1 1 0
DXF* 1 1 1 1 1
IGS/IGES 1 0 0 0 0
GCODE 1 0 0 0 0
OBJ 1 0 0 0 0
STP/STEP 1 0 0 0 0
STL 1 0 0 0 1
SVG* 1 0 1 0 0
Image Files* 1 1 1 1 1
Total 9 3 4 3 3
*2-dimensional file formats

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File Format Capability - Export
Export FreeCAD Solvespace QCAD LibreCAD OpenSCAD
DWG* 1 0 1 0 0
DXF* 1 1 1 1 1
IGS/IGES 1 0 0 0 0
GCODE 1 1 0 0 0
OBJ 1 1 0 0 0
STP/STEP 1 1 0 0 0
STL 1 1 0 0 1
SVG* 1 1 1 1 1
PDF* 1 1 1 1 0
Image Files* 1 1 1 1 1
Total 10 8 5 4 4
*2-dimensional file formats

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Design & Editing Functionality
Design & Editing FreeCAD Solvespace QCAD LibreCAD OpenSCAD
2D Drawing Tools 1 1 1 1 1
3D Modeling Tools 1 1 0 0 1
Parametric Modeling 1 1 0 0 0
Layer Manager 1 1 1 1 0
Snap Tool 1 1 1 1 0
Text Editing 1 1 1 1 1
Color Editing 1 1 1 1 1
Textures 1 0 0 0 0
Hatching 1 0 1 1 0
Transparency Options 1 0 0 0 1
Lighting Effects 1 1 0 0 0
Photorealistic Rendering 1 0 0 0 0
Extrude 3D Models from
Imported 2D Designs
1 1 0 0 1
Create 2D Designs from
Imported 3D Models
1 1 0 0 0
Total 14 10 6 6 6

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FEA Subcategories

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Operating Systems
Operating Systems
Salome-
Meca
FreeCAD Elmer
Windows 7+ 0 1 1
Mac OS X 0 1 1
Linux 1 1 1
Total 1 3 3

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Help & Support
Help & Support
Salome-
Meca
FreeCAD Elmer
Documentation 1 1 1
Forums 1 1 1
Tutorials 1 1 1
Wiki 0 1 1
Total 3 4 4

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User Interface
User Interface
Salome-
Meca
FreeCAD Elmer
Graphical User
Interface
1 1 1
No Programming
Required
1 1 1
Command Line 1 1 0
Macros 1 1 0
Installer 0 1 1
Preprocessor 1 1 1
Postprocessor 1 1 1
Graphical Geometry
Modeler
1 1 0
Total 7 8 5

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Mesh File Import
Mesh Import
Salome-
Meca
FreeCAD Elmer
CGNS 1 0 0
DAT 1 1 1
INP 0 1 1
MED 1 1 0
MSH 0 0 1
STL 1 1 1
UNV 1 1 1
Total 5 5 5

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Geometry File Import
Geometry Import
Salome-
Meca
FreeCAD Elmer
BREP 1 1 1
GCODE 0 1 0
IGS/IGES 1 1 1
OBJ 0 1 0
STP/STEP 1 1 1
STL 1 1 1
VTK 1 0 0
XAO 1 0 0
Total 6 6 4

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Functionality
Functionality Salome-Meca FreeCAD Elmer
Linear Static 1 1 1
Nonlinear – Large
Displacements
1 1 1
Nonlinear – Contact 1 1 0
Transient Linear 1 1 1
Transient Nonlinear 1 0 1
Natural Frequency 1 1 1
Linear Buckling 1 1 1
Acoustic 1 0 1
Heat Transfer 1 1 1
Electric/Magnetic 0 1 1
Fluid Flow 0 1 1
Fluid Structure Interactivity 1 0 1
Solid Structures 1 1 1
Shell Structures 1 1 1
Beam/Rod/Tie 1 1 0
Total 13 12 14

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Advanced Materials
Advanced Materials
Salome-
Meca
FreeCAD Elmer
Anisotropic Materials 1 1 1
Composites 1 1 0
Hyperelastic/Rubber 1 1 0
Plasticity 1 1 0
Viscoplastic/Creep 1 1 0
Piezoelectric 0 0 1
Total 5 5 2

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Simulation Subcategories

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Operating Systems
Operating Systems Scilab OpenModelica Hopsan
Windows 7+ 1 1 1
Mac OS X 1 0 0
Linux 1 1 1
Total 3 2 2

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Help & Support
Help & Support Scilab OpenModelica Hopsan
Documentation 1 1 1
Forums 1 1 1
Tutorials 1 1 1
Wiki 1 0 0
Total 4 3 3

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User Interface
User Interface Scilab OpenModelica Hopsan
Graphical User Interface 1 1 1
Block Diagram 1 1 1
Command Line 1 1 1
Scripting 1 1 1
Debugger 1 1 0
Installer 1 1 1
Total 6 6 5

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Simulation Capability
Simulation Capability Scilab OpenModelica Hopsan
Controller Design 1 1 1
Real-Time Simulation 1 1 1
Optimization 1 1 1
Transmission Line
Modeling
1 1 1
Co-simulation 1 1 1
Total 5 5 5

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Additional Capabilities
Additional Capabilities Scilab OpenModelica Hopsan
2D Plotting 1 1 1
3D Plotting 1 1 0
Frequency Analysis 1 0 1
Signal Processing 1 0 0
Image Processing 1 0 0
GUI Development 1 0 0
Instruments Control 1 0 0
In Browser Simulation 1 1 0
Total 8 3 2

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Interoperability
Interoperability Scilab OpenModelica Hopsan
C/C++ 1 1 1
Fortran 1 0 0
Java 1 1 0
Matlab 1 0 0
Modelica 0 1 1
Python 1 1 1
Simulink 1 1 1
Tcl 1 0 0
Total 7 5 4