System Simulation enables faster development and better products

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Tom Boermans

LMS – Account manager

tom.boermans@lmsintl.com

INNOVATIONDAY 2011

System Simulation enables faster development and better products

Tom BoermansAccount Manager

1D System SimulationLMS Imagine.Lab AMESimAMESim references cases

Overview

IntroductionSystem Simulation basicsSystem simulation using LMS Imagine.Lab AMESimAMESim reference casesAMESim reference cases

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IntroductionIntroduction

Introduction to LMS30 years of engineering innovation

Servicing more than 100.000 R&D engineers … in 5.000 manufacturing companies

A unique ‘Solution Provider’ ofTest Systems, CAE Simulation tools and related

services

Top talent in 30+ offices Worldwide… almost 1.200 professionals

Visionary, industry-leading innovator … 25% of budget in R&D

Strong financial track record of profitable growth

Introduction to LMSGlobal Talent for Global Customers

R&D Centers

Brasov Breda

ChennaiCoralville Gottingen

Kaiserslautern Leuven

LyonPlymouthRoanne Torino

Sales Offices

BaltimoreBangaloreBejingCoventryDetroitLeonbergLeuvenLos AngelesLyonMoscowMunich

Representatives

Bangkok Bangalore Beckum

Bucharest Cairo

Kfar Saba Krakow

Kuala Lumpur Ljublijana

Madrid Moscow

Engineering Services

BejingBrasov Chennai

Coralville Detroit

Kaiserslautern Leuven

LyonTorino

YokohamaTorinoMunich

NovaraParisSao PauloSeoulShanghaiToulouseYokohama

Moscow Nilufer BURSA

Psáry São Paulo

Sarov St. Petersburg

Sydney Veliky Novgorod

Europe40%

Americas20%

Japan/Korea20%

RIC20%

33 15

Hybrid TEST/CAE Partner1.000 people

Horizon 20XX

LMS

201

1

UVIntroduction to LMSLMS, delivering Transformational Solutions

Transforming is …Addressing

the future problemsof our customers

Leading partner in Test and Mechatronic Simulation

Horizon 2020

LMS

201

0

19951980

TEST-NVH Partner200 people

1995 2010

Engineeringthe passion

LMS

201

0

LMS

the

Roo

ts

Design - CAD

Imagine.Lab Platform – Mechatronic System Simulation

Controls

Introduction to LMSA unique portfolio of engineering innovation platforms and best practices

Virtual.Lab Platform3D Performance Simulation

Modal – NVH – Acoustics – Durability Laboratory Mobile

Test.Lab Platform – Test Based Engineering

Multi-physics ModelingSystem Synthesis System Data Management

Test.XpressSCADAS Platform

People Highly skilled engineers

Know-How Engineering Expertise

- Process re-engineering & deployment- Technology transfer, Trouble shooting

Project Management % Problemssolved

100%

Proto & Refphase

Proto & Refphase

Engineeringphase

Engineeringphase

ConceptPhase

ConceptPhase

Proto & Refinementphase

Proto & Refinementphase

Engineeringphase

Engineeringphase

Conceptphase

Conceptphase

Improved initial design

Faster optimization

Shorter time to market

Feedback JML – change to lay-out MI – no references- DONEIntroduction to LMS

LMS Engineering Services, development partner of choice…

Process & Technology Frontloading Multi-attribute Engineering Technology Transfer

Highly skilled engineers Strong global teaming Flexibility

Tools Test facilities & tracks Use of “multi-physics ” models for

control development Software tools (own and 3 rd party)

Addressing key engineering challenges of AOEMModel Based System Engineering (MBSE)

Introduction to LMS“From troubleshooting to design first time right”

Controls Engineering(Mechanical/Electronic

Integration)

4

DESIGN / ENGINEERINGSPECIFICATION VALIDATION CERTIFICATION TROUBLESHOOTING

Concept & design PhaseSystem Modeling(Multi-Physics)

3

Design PhaseHybrid Test/3D CAE

(Correlation)

2

Validation PhasePrototype Testing

1

System Simulation basicsSystem Simulation basics

The new Paradigm Shift : Towards a Model Based Development Process

Traditional

Mechanical functionsDesign ManufacturingControl&

SoftwareFunctions

“Systems” -levelThermal FunctionsFuture

Model Based System Engineering

MechanicalFunctions

Control & SoftwareFunctions

3D Design Manufacturing

VehicleArchitecture

DetailedDesign

Subsystems

VehicleIntegration

& Calibration

“Systems” -levelEngineering Framework

Introduction to Systems

What is a System?

A group

of

multi-domain / multi-physics componentsmulti-domain / multi-physics components

interacting together

Systems have structure, defined by parts and their composition

Systems have behavior, which involves inputs, processing and outputs of material, energy or information

Systems have interconnectivity: the various parts have functional and structural relationships

What is a system? Example

Washing Machine

ControlControlElectricHydraulicMechanicThermal

What is System Simulation?

Usual design issues : Is the electric motor powerful enough? What is the time response of the system? Is there any risk of vibration? How to optimize the control design?

Key words : Multi-physics with power exchange Dynamic system (function of time) Physical system model = Plant model

Control Electric Hydraulic Mechanic

AMESim plant model

Abstraction Level – Equations – Representation

Equations are usually written as time dependent Computing state derivative of variables to assess transient evolution Equations are represented by readable objects (icons)

Mechanics02

/²/*22 =+⋅⋅⋅+

−−=

nn szs

KxdtRdxFdtdxM

ωω

Equations Physical Icon Representation

Electric

Hydraulics

And many other physical domains…

CIdtdU

IRU

//

*

==

PdisplT

displQ

∆= Ω=

*

*

System simulation is linked to the power flow and power conservation within a dynamic system Each power network can be modeled using different physics with gates for sub-system connections

Power Flow within dynamic system

Electric Hydraulic Mechanic

You are manipulating equations not drawing a circuit !

Electric power

network

Hydraulic power

network

Mechanic power

network

Power flow

Multi-domain simulation system benefits

DRIVE INNOVATION

Explore a wider range of ideas and solutions

Early validation of technical feasibility

Test and compare new ideas via simulation

STREAMLINE PROCESS

Reduce design cycle by virtual system integration

Increase reusability through knowledge capitalization

IMPROVE QUALITY

Improved product behavior predictability

Better collaboration between disciplines

Tighter integration of functions (components or systems) to build a final product

REDUCE COSTS

Reduce development costs with fewer physical prototypes

Minimize risk on test beds

Reduce products breaks and failures

System simulation to answer your challenges

Technology agendas

Green Comfort Safety Performance

From sequential to integrated product developmentIncreased virtual development: CAE tools and processes at the heart of the technology agenda

Are systems correctly sized?

How to integrate more and more electronics?

How to reduce energyconsumption?

How to ensure the dynamic behavior of the full system?

System simulation using System simulation using Imagine.Lab AMESim

Why AMESim for system simulation?

INTELLIGENT SYSTEMS

MULTI-DOMAIN MULTI-LEVEL BEHAVIOR

Model and simulate complex,

regulated and controlled systems

Optimize the complex

interactions between several physical domains

Use from detailed component

analysis to global system synthesis

Run both transient and static analysis

to assess performance and energy efficiencyphysical domains energy efficiency

Plant modelLink to controlsReal-time capabilities

ThermalHydraulic and PneumaticMechanicElectricElectromechanical

From high frequency to mean value modelsFrom early pre-design to specification and integration

Time and frequency domains analysisFunctional performance and energy consumption

LMS Imagine.Lab Libraries

> 30 libraries, > 4000 validated models

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LMS Imagine.Lab suite

Hydraulics Pneumatics Thermal-Hydraulics

Two-PhaseFlow

GasMixtures

Mobile HydraulicActuation

ApplicationSolutions

Data Management

SysDM

AMESimModelica Platform

Real-timeScripting facilities

Analysis ToolsSolver and NumericsSoftware Interfaces

Fluids Thermal Mechanical Electrical

PhysicalLibraries

AuthoringPlatform

MECHANICS HYDRAULICS

FEM

CONTROL

MBS

CFD

AMESim positioning in CAx world

3D simulation

CONTROL PNEUMATICS

THERMALPOWER ELECTRONICS

MAGNETIC

1D system simulation

LMS Imagine.Lab AMESim

LMS Imagine.Lab AMESim, an Open Platform with…

MBS

CFD

LMS Virtual.LabMotion

CFX

PIDO

ControlReal Time

EM

OPTIMUS

LMS Imagine.Lab platform

Create Simulate Capitalize Deploy

•Development of new

components

•Modeling

•Simulation

•Analysis

•Libraries management

•Model Packaging

•Run only

•Parametric studies

AMESim AMECustom AMERunAMESet

User expertise User number

Expertise Deployment

Starting Point

AMESim Pre/Post-processing tools

AMESim Tools enable to pre/post-process and analyze simulation data Pre and post-processing tools: table editor, plot manager, HTML report generator, 3D

animation,.. Analysis tools: FFT, linear analysis, model reduction, optimization,…

Frequency Domain Design Exploration

DOE Optimization Monte-Carlo

AMESim - Simulink InterfaceCoupling the plant model

within a control model in Simulink

AMESimComplete systems engineering

simulation platform

SimulinkThe de-facto standard for

control system design

Physical & Control modeling

Obtain the best features of both platforms

Analyze coupling between physical and thecontrol systems

Eliminate the need to re-write complexmodels on various platforms

No limitation in model size or complexity

3 types of interface: Co-simulation Export from AMESim to Simulink Export from Simulink to AMESim

Example 1: public water regulation valve

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Example 1: displacements of the two valves, downstr eam pressure and pressure in the upper chamber

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Example 1: displacements of the two valves, downstr eam pressure and pressure in the upper chamber

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Example 1: Pressure variations

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variations of the pressure in the pilot valve Downstream pressure for three different nozzle diameters

Example 2: Excavator with planar mechanics

AMESim reference casesAMESim reference cases

KYB reduced the design cycle of hydraulic system

KYB is a leading Japanese hydraulics company specia lized in hydraulic technology which is widely used in the au tomotive, aeronautical, construction machinery, rail and mari time industries.

Challenges Reduce design cycle delays of hydraulic system Demonstrate to customers products’ efficiency through

simulation.

Solution A flexible simulation tool that engineers could easily understand,

adapt to various customers’ requests and interface with other simulation software (multibody software, Simulink)

LMS Imagine.Lab Fluid Systems

“LMS Imagine.Lab AMESim helps us to reduce our desig n cycle by two months.”

Mr.Kazuhide Maehata – KYB – Hydraulic Components Opera tions General Manager

Home appliances manufacturerReinforcing the “Eco” home appliances brand values

Challenges Reduce costs and delays and develop

eco-friendly, innovating refrigerators Keep and grow competitive advantage

Solution LMS Imagine.Lab Two-Phase Flow

solution Stop and Start capabilities

AMESim helped to test virtually early in the design cycle theenergetic performance of their refrigerators according to variousconfigurations and to simulate complex standard working cy cles.

Benefits Seamlessly model fridges with complex test cycles standards to fit industry

requirements Test several refrigerating configurations rapidly and analyze the impact Replace hours of test sessions by minutes of simulation Have a more deep insight on control loops

Cold rolling mill productivity optimization

Company:Manufacturer of cold rolling mill for steel plate production line

Issue:Optimization of the hydraulic control of the roll gap to keep

constant thickness of the steel plate

Solution:Solution: Evaluation of new “intelligent” system to control chatter

effect of hydraulic roll mill The simulation model covers the plant control and

regulation functions Prediction of vibration problems

LMS Imagine.Lab AMESim with hydraulic libraries (HYD and HCD)

Study on Tetra Pak S.p.A machinery workflow to increase production rate with LMS Imagine.Lab AMESim

Challenges Development of more efficient hydraulic

actuation systems , that enable a higher productivity and an overall power saving

Solution Analysis of the dynamic behavior of an automatic

packaging machine hydraulic circuit of Jaw and Filling System, with LMS Imagine.Lab AMESim

Modified layout has been proposed, adopting a simpler circuit configuration.

“With the new layout configuration, requested produ ction rate can be assured supplying the circuit wit h a lower power which enables an increasing of the syst em efficiency”

C. Angeloni, S. Castagnetti, M. Ernetti, F. Franzoni, M. Milani from DISMI University of Modena and Reggio Emilia - “The Twelfth Scandinavian International Conference on Fluid Power, May 18-20, 2011, Tampere, Finland

simpler circuit configuration.

Benefits The circuit has been optimized, considering the

proper interaction between the different parts Productivity increased from 6000 to 10000

packages/h System efficiency increased

Multi-physics modelling and system analysis of elec trical distribution network devices at SCHNEIDER Electric

Challenges Integration Power and Control Increase of product functionalities (both hardware & software) Decrease energy consumption

> New Product architectures: global optimization of the products

Solutions Electromechanical Components solution Trainings and technical expertise

Benefits Benefits Technical capabilities of the tool to perform multi-physic

(electrical, mechanical and thermal) and electronic simulation Capabilities to capitalize and transfer the models along our

design process Accuracy of the simulation results versus the simulation delay Many different uses of models for our investigations

““““LMS Imagine.Lab offer a wide environment that allo ws designers to share their viewpoints, model and simulate devices on the whole, and find solutio ns quicker”

François CAZALS – Schneider Electric – System and Mec hatronic expert designer

Thank you !