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Domain specific fluid power simulation – a powerful extension for an integrated virtual engineering process Ronald Kett FLUIDON GmbH, Aachen Kett 1 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Overview of automobile applications Fluid rail Steering system K K K K Piezo injector Steering pump ee er st w Po Power steering s Clutc he 2 sys tem s ars Ge - the simulation tool for a wide range of automobile applications n Cardan joint Bra k ts en Crank lever Injection g in 1 rings Main break cylinder ms ste sy Chassis controls Mot or c o m po Hydraulic lash adjustor Break cylinder Hydro bearing Break valve Damping valve Air suspension Svivel drive Kett 2 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Overview of Interfaces -HIL Box SIMATIC WinAC MOBILE Generic C++-Source - flexibility and versatility for the development of hydraulic and pneumatic systems Generic C-Source RT-Linux Kett 3 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Project Phases of an Integrated Virtual Engineering Process (1) 1. Simulation Steer-by-Wire System Vehicle Co-Simulation Control Control Unit 2. Code Generation Steer-by-Wire System Real Time Operating System Vehicle Code Export Controller + I/O Blocks -RT Controller + I/O Blocks Kett 4 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Project Phases of an Integrated Virtual Engineering Process (2) 3. Controller HIL Test Control Unit I/O Steer-by-Wire System Vehicle Co-Simulation Controller Settings non real-time non real-time Kett 5 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Project Phases of an Integrated Virtual Engineering Process (3) 4. Operation Vehicle Control Unit I/O Steer-by-Wire System Vehicle Controller Settings real-time real-time Monitoring Settings Kett 6 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Steer-by-Wire system with hydraulic fail-safe Motor Pump Unit p v M V2L VS x SV µC Steering Actuator M Control Unit δ Steering Unit V2R V1L VB V1R Fail-Safe-Manifold Kett 7 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Control of the Steer-by-Wire System Position PositionControl Control Fail FailSafe SafeValves Valves Steering Angle Steering Angle Cylinder Stroke Cylinder Stroke Supply Pressure Supply Pressure Vehicle Speed Vehicle Speed Battery Voltage Battery Voltage Ignition Ignition Switches Switches Torque TorqueControl Control Force Observer Force Observer Pressure PressureControl Control Amplifier,Driver, Driver,PWM PWM Amplifier, Sensors, Sensors,Signals Signals SignalConditioning Conditioning Signal Variable Steering Ratio Variable Steering Ratio System SystemDiagnosis Diagnosis Motor-Pump-Unit Motor-Pump-Unit Motor Motor Safety Valve Safety Valve Servo ServoValve Valve Steering SteeringUnit Unit Motor Motor Bypass Valve Bypass Valve Kett 8 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON 1. Step: Simulation Steer-by-Wire System Vehicle Co-Simulation Ux dpSign Control U2Stroke Position Control xAct U2StgAngle Control ValveOffKomp deltaSet Nenner ValveLimit Udp PosContr pSensorL ValveLimit ValveOffKomp 2 xSet Sum3xdiff 3 USV1 vVeh ActRatio 2 1 UpL USV3 UpR 3 Sum5 USV2 Prod7 USV2 USV3 SignalEingang2 Ux 2 SpeedSensor pSensor Position Control xAct U2StgAngle 1 Zaehler StgAngle1 PosContr V2p Chassis Div1 Up deltaSet Nenner 2 xSet 3 ValveOffKomp Sum3xdiff USV1 pAct Pressure Control pAct MPU TorqueMot PressContr2 K UBY K Diff1 Diffp 3 UMPU PWMUnit nMax Prod8 V1 Prod5 SwAgility K Track VZero 1 KZero nPS1 nPS2 * 2 OffsetGains Prod5 1 nPS1 2 * Agility Offset nPS2 Max DT11 KZero Steering Unit YTrack OffsetGains DT11 deltaSensor SwitchPosition Plus11 xActN K SwSpeed SpeedSensor fPos2 fPos3 RatioVsSpeed 3 4 frequ vAct fSpeed1 fSpeed2 Sw3 Ratio Control K Udp pSensorL Plus11 Position Control xAct U2StgAngle Chassis Div1 PosContr ValveOffKomp ValveLimit V2dp 1 Zaehl er StgAngle1 deltaSet Nenner 3 Sum3 xdiff USV1 USV2 USV3 SignalEingang2 ActRatio pSensor Q 2 fPos2 5 v Hydro2Signal2 1 pS 3 pSet Diff1 Diffp UMPU * VS UpCont S1 1 1 * MPUChar 2 K xOffset2 Agility Offset SwAgility PWMUnit nMax K DT12 VZero SWReset Q_p Reset Min Min nPS0 2 3 PRV Pipe Prod5 2 * nPS2 PumpS Steering Unit nPWM DT11 Sum4 USV SV StgAngle StgRate xOffset1 RatoVsPos USU Plus11 fPos1 fPos2 vRectangle 123 SwitchSpeed RatioVsSpeed 3 SRAng TFric TPump 2 2 Sum1 S4 3 4 frequ vAct fSpeed1 fSpeed2 Sw3 5 1 3 K VOne KOne La 4 RangePos TorqueOffset 1 SFS1 *AimSearch * AimX * AimY * K 5 3 Zaehl er Nenner AngX1 RangeLoad AngX2 1 Sum7 SteerDelay ConstRatio S2 1 V3 frequ SteerDelay RatioVsSpeed vAct Sum8 StgAng2 Diff3 SteerDelay SteerAmpl Sum8 StgAng2 StgAng1 StgWheel Fail Safe AND1 VB V4 fPos2 V1R S3 StgAng4 fPos3 & S6 SteerAmpl Plus12 fSpeed1 SignalAusgang6 Prod2 p p_r Q Sw2 1 Sw3 * 2 * p_l 3 *Hydro2Signal3 4NOT2 * 5 NOT3 fSpeed3 1 fSpeed2 StgAng1 V1L K VOne K V3 Hydro2Signal1 SignalAusgang7 p S2 1 Fail Safe Manifold II ConstRatio Ratio StgAng3 SteerAmpl TorqueVsLoad StgWheel StgAng1 dpAct TorqueLimit Prod3 TSet1 2 Fail Safe Manifold II Ratio Psi AngX3 3 StgAng3 Manifold II AngX3 VB TorqueOffset S6 * TSet2 H TSet3 NOT3 SetSign StgAng4 & V4 1 StgWheel Sum7 AND1 lateral SRLoad 3 Q 123 StgAng3 NOT2 1 Diff2 DeltaX 2 2 Psi Diff3 V2dp 1 S2 Plus11 Sum2 KOne 3 AngX3 3 PT11 AngX2 lateral Psi Sum7 ULV 2 tan(x) SignalAusgang2 3 fPos1 THandwheel 2 tan(x) 1 2 Sum8 StgAng2 Diff3 arctan SignalAusgang2 K Decis * 3 SignalEingang6 Diff2 DeltaX 1 2 Div2 DeltaY Diagnosis 3 R V1L V3 1 2 AngX1 1 3 3 Nenner NOT2 2 1 2 RatoVsPos 3 Sum1 S4 Ratio Control xPos Driver Model lateral SFS2 2 AimDist Sum2 UFS * * * * V1L Ratio Control S Freq2Value1 PlusMin 1 1 AngX2 TFric TPump VTU TU 3 Zaehler 1 AimDist PumpSU 2 tan(x) THandwheel AngX1 Tdeltadot Nenner DeltaY 2 AimY K 3 Lock Detection vDiff FSFlipFlop THandwheel 1 fSpeed3 Plus12 2 StgRateSign vContr Torque NOT4 YTrack SRPos Prod2 Sw2 2 PT11 2 3 Tdeltadot TU fPos3 Freq2Value1 Prod4 1 SignalEingang6 arctan Div2 La arctan 2 Friction Sum2 Sum1 S4 1 sign() SignalEingang5 yPos 1 1 1 Norm SwSpeed TorqueMot Track Prod6 SRErr PumpSU VTU SWPos xActN K xRange Signum1 Sum6 SRPress ConstRatio VTdeltadot UDeltaStgAng K SwitchPosition PlusOnly xActN 3 Range SignalEingang4 2 3 2 3 Zaehler 1 UFS vVeh vVehSet1 Diff2 DeltaX Norm longitudinal Manifold I K RangeAngle Friction vSet ValveOffset RangeErr Ratio StgSpeed Sw1 deltaSensor K 5 3 AimY AimDist SignalEingang7 4 Fail Safe RangePress PT2 UOffset VOne KOne SignalEingang1 2 VR1 2 DeltaY ConstRatio USU K TSet3 * Torque Control SwSpeed * * vRectangle K * SignalAusgang3 Sw3 V5 K 1 nPS1 Max KZero OffsetGains K fSpeed3 V2L VL1 1 V1 MPUDyn K SwitchAgility TSet2 * 1 SignalAusgang1 Sign SwitchSpeed 3 V2R fSpeed2 Prod8 S8 2 RackLoad VR2 SignalAusgang4 NOT1 1 2 2 2 V2 UBY Prod1 PressContr 1 K VL2 Plus12 CV PressContr2 Pressure Control pAct TSet1 x K Ratio TorqueOffset Prod2 SetSign Actuator VOne KOne TorqueLimit Prod3 1 Sw2 USV4 SignalEingang3 p_p BitSign Up V2p fPos3 xSensor TorqueVsLoad SignalAusgang5 p Motor Pump Unit SwitchPosition Sum5UpR Steering Actuator * dpAct Accu 1 3 Prod7 1 2 xSet K SWPos La pSensorR 2 UpL Div2 UFS 1 UDeltaStgAng AimX dpSign U2Stroke * * * * 2 VTdeltadot 1 fSpeed3 Plus12 xPos Driver Model YTrack AimSearch TFric TPump 1 TU SignalEingang5 yPos ValveOffset Track Sum6 vDiff K nPS2 * 2 Torque 1 Tdeltadot deltaSensor Prod2 Sw2 2 PT11 fVeh 123 vRectangle Ux fPos1 v2freq Freq2Value1 SwitchSpeed nPS1 UOffset PumpSU StgSpeed VTU xOffset1 Sw1 USU AimSearch RatoVsPos 1 VTdeltadot UDeltaStgAng StgRate StgAngle Norm Prod5TorqueMot AimX SignalEingang1 SWPos Friction 3 vContr Manifold I SV nPWM StgSpeed SignalEingang4 2 1 vVehSet vSet PlusOnly longitudinal SignalEingang6 Max Driver Model PT2 Fail Safe Sum4 USV MPUDyn Manifold I UOffset VZero Steering Unit StgAngle Sw1 3 SV xPos V5 Pipe K PumpS DT12 PumpS xOffset1 2 PT2 USV Sum4 Min K Min ValveOffset nPS0 PWMUnit nMax V5 Pipe SignalEingang1 StgRate nPWM xOffset2 PRV PRV nPWM Max K 1 Q_p FailKSafe SignalAusgang3 VR1 1 yPos 2 vVeh VR1 V2L VL1 Q_p 1 V2L SignalEingang7 VL1 MPUChar V2R 3 MPUDyn V2R UMPU vDiff MPUChar Min Min nPS0 PWMUnit nMax SignalAusgang1 RackLoad 2 VR2 SignalAusgang4 * VR2 x 1 UpCont S8 RackLoad VL2 Actuator v SignalAusgang4 VL2 * 2 2 1 S1 * USV4 SignalEingang3 1 1 * VS UpCont MPUDyn xOffset2 Agility Offset Min SwitchAgility Min DT12 nPS0 SwAgility S8 NOT1 V1 K Diff1 Diffp 2 2 SignalEingang5 Steering Actuator 1 Prod1 Torque Prod8 3 xSensor Sum6 2 K SwitchAgility 2 V2 1 S1 VS * 2 2 pS 1 1 1 pSet SignalAusgang5 NOT1 pS pSet Prod1 PressContr MPUChar CV 1 p_p Q Hydro2Signal2 PressContr 3 v Sum5UpR UBY vContr p Motor Pump Unit 1 3 Prod7 SignalEingang2 pSenso pSensorR 2 UpL vVehSet1 Accu pSensor Up V2p K Hydro2Signal2 vSet x Actuator Udp pSensorL 2 Up PressContr2 PlusOnly V2 longitudinal BY p_p Q USV3 USV4 SignalEingang3 p Pressure Control ValveLimit USV2 CV ActRatio SignalEingang4 SignalAusgang5 SignalAusgang3 Motor Pump Unit Steering Actuator fVeh * dpSign Accu U2Stroke xSensor v2freq 1 USV1 pSensorR 1 Zaehler StgAngle1 ontr Chassis SignalEingang7 Div1 AND1 V2dp TorqueVsLoad TorqueLimit Prod3 TorqueOffset VB S6 & dpAct TSet1 2 * TSet2 TSet3 V4 Sign Range V1R xRange S3 sign() 2 * StgRateSign RangePress xRange p Q Lock Detection SRPress RangeErr ULV Torque Control PlusMin V1R S3 1 Range H p_l Hydro2Signal3 Decis BitSign Prod4 SignalAusgang7 1 PlusMin Prod4 1 Reset p_r NOT3 Torque Control Signum1 SWReset p Q Hydro2Signal1 SetSign BitSign K Sign SignalAusgang6 Range 1 Signum1 1 2 * Decis ULV Prod4 StgRateSign FSFlipFlop SRErr Prod6 1 RangeAngle 2 3 SRAng 4 RangePos 5 * * * * S NOT4 SFS1 1 SFS2 R Diagnosis SRPos RangeLoad SRLoad Kett 9 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON 2. Step: Code Generation Control Unit Steer-by-Wire System Real Time Operating System Vehicle Code Export Controller + I/O Blocks Controller + I/O Blocks -RT U2Stroke Position Control xAct U2StgAngle PT12 Chassis ValveOffKomp ValveLimit 1 StgAngle1 deltaSet xSet 2 3 Sum3xdiff USV1 SignalAusgang1 SignalEingang1 D/A V2p A/D UDeltaStgAng pAct UBY Up X-DAD-4 Prod1 PressContr 1 1 D Out USV3 PressContr2 Pressure Control Ux USV2 PosControl ActRatio K D In XDAD4 pS 2 2 3 pSet Diff1 Diffp UMPU * UpCont D/A xOffset2 X-DAD-4 Agility Offset SwAgility A/D K DT12 VZero D Out KZero Udp D In XDAD5 OffsetGains StgRate dOut dIn SWPos xOffset1 Norm Sw1 RatoVsPos Plus11 fPos3 xActN fPos1 fPos2 Prod2 Sw2 1 2 Bit2Dec Dec2Bit SwSpeed Freq2Value1 123 vRectangle PT11 RatioVsSpeed fSpeed3 Plus12 3 4 frequ vAct fSpeed1 Ratio Control fSpeed2 K VOne KOne V2dp TorqueVsLoad TorqueLimit Prod3 Sw3 K 5 * * * * ConstRatio Ratio TorqueOffset 1 dpAct TSet1 2 TSet2 * TSet3 USU SetSign Sign Torque Control BitSign Range xRange PlusMin Prod4 1 Signum1 SWReset sign() 2 * Decis StgRateSign RangePress Lock Detection SRPress RangeErr FSFlipFlop SRErr Prod6 RangeAngle 2 3 SRAng 4 RangePos 5 SRPos * * * * S NOT4 1 SFS1 1 SFS2 R UFS Diagnosis RangeLoad SRLoad Kett 10 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON ULV 3. Step: Controller HIL Test Control Unit I/O Steer-by-Wire System Vehicle v2freq SpeedSensor Co-Simulation fVeh Ux dpSign Controller Udp pSensorL Settings pSensorR 2 UpL non real-time non real-time 1 3 Sum5UpR xSensor Prod7 Steering Actuator 1 USV3 SignalEingang2 * 2 x Accu USV4 SignalEingang3 Motor Pump Unit pSensor Actuator v 1 SignalAusgang1 F 2 VL2 Up V2 UMPU VS 1 V2R * VL1 SignalAusgang4 1 S8 V2L SignalAusgang3 Prod8 Fail Safe 2 3 Sum4 USV PT2 SV V1 HIL1 K SwitchPosition PRV MPUDyn SwAgility PWMUnit nMax SWPos Min Min nPS0 Pipe Prod5 * Sum6 TorqueMot vContr Torque vDiff yPos xPos Track Steering Unit YTrack StgSpeed Friction deltaSensor 1 VTdeltadot Dec2Bit UDeltaStgAng Tdeltadot TFric TPump 1 3 Sum1 S4 1 3 3 Zaehler Nenner 2 AngX1 tan(x) 1 1 3 Sum7 Psi AngX3 2 3 Diff3 SteerDelay AimDist Sum2 AngX2 Diff2 DeltaX AimY K 2 2 DeltaY 2 La VTU TU arctan Div2 AimSearch PumpSU AimX USU SignalEingang6 Driver Model DT11 SWReset Bit2Dec 3 longitudinal SignalEingang1 Reset BitSign PlusOnly vVehSet1 ValveOffset PumpS dOut StgAngle vRectangle Manifold I vSet K UOffset nPS2 nPWM dIn V5 1 nPS1 2 Max SwSpeed SwitchSpeed K 1 Q_V SignalEingang5 2 VR1 2 MPUChar K K S1 SignalEingang4 p_P Q Hydro2Signal1 NOT1 SwitchAgility SignalEingang7 vVeh p UBY K VR2 SignalAusgang5 CV SteerAmpl 1 2 3 Sum8 StgAng2 StgAng1 THandwheel lateral UFS StgAng3 StgWheel NOT2 V1L S2 1 V3 Fail Safe SignalAusgang2 StgAng Manifold II AND1 VB S6 SignalAusgang6 & p Q V4 p_r Hydro2Signal2 SignalAusgang7 NOT3 V1R S3 1 p Q p_l Hydro2Signal3 ULV Kett 11 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON 4. Step: Operation Control Unit Vehicle I/O Steer-by-Wire System Vehicle Controller Settings real-time real-time Monitoring Settings Fail-safevalve block Steering torque simulator Starting up and monitoring of the controller Steering actuator Details of the Steer-by-Wire system Kett 12 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON Conclusion • The presented combination of domain specific fluid power simulation with HIL simulation is not only interesting for research and development but it could be very interesting for several industrial applications. • If an existing controller has to be adapted to a new application, the new parameter setting can be precisely developed by non-RT-HIL simulation. • Integrating the fully developed control units into the simulation of the detailed virtual prototype under DSHplus and Virtual.Lab will lead to very exact results and offer time and cost saving potentials. Kett 13 This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence. It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH LMS Conference Europe 2006 © 2006 FLUIDON
