1. High-Fidelity Physical Modeling for Aerospace Mechatronics Applications
Paul Goossens, VP of Application Engineering
Dr. Orang Vahid, Senior Modeling Engineer

2. Agenda Introduction Case Studies:
Quadrotor – Quanser
Planetary Rover – University of Waterloo and Canadian Space Agency
Challenges in Model-based design and development
Maplesoft Engineering Solutions

3. Physical Model-based Development
“Virtual” Prototyping through Model-based Design and Development plays an increasingly key role in system design, commissioning and testing.
Increasing adoption of MBD and simulation
Reduce prototyping cycles and costs
Increase end-user functionality, quality, safety and reliability
Deterministic, repeatable testing platform
Connection to real components with virtual subsystems through Hardware-in-the-Loop (HIL) Testing is critical to this strategy
Validation of subcomponents and/or controllers before integrating into the vehicle reduces errors and costs
Validation of model against the real thing improves the whole process, dramatically reducing development cycles and time-to-market in the future
Greater demand for greater model fidelity…

4. Emerging Challenges... Scalability Capacity Tasks
Number of functions (Complexity)

5. Emerging Challenges... Scalability Multi-domain Modeling Capacity
Tasks
Capacity
Number of functions (Complexity)
Engine/ Powertrain
Torque/Speed
Inputs
Chassis/Tire
Outputs
Apply Load???
Driveline

6. Emerging Challenges... Scalability Multi-domain Modeling
Real-time Performance
Tasks
Capacity
Number of functions (Complexity)
Engine/ Powertrain
Torque/Speed
Inputs
Chassis/Tire
Outputs
Apply Load???
Driveline

7. Qball-X4 Development

8. Qball-X4 Development Plant Model in MapleSim Paper Concept for Product
Rough Feasibility Study Paper Calculations, Low fidelity Simulations
Plant Model in MapleSim

9. Qball-X4 Development Plant Model in MapleSim Paper Concept for Product
Rough Feasibility Study Paper Calculations, Low fidelity Simulations
Plant Model in MapleSim
Export Plant to Simulink Dev RT Controller in QUARC Include Visualization
Modify Model Structure, and Fidelity
Evaluate Performance Trade various Concepts
*Simulink is a registered trademark of The Mathworks, Inc. Quarc is a registered trademark of Quanser Consulting, Inc.

10. Qball-X4 Development Plant Model in MapleSim Paper Concept for Product
Rough Feasibility Study Paper Calculations, Low fidelity Simulations
Plant Model in MapleSim
Export Plant to Simulink Dev RT Controller in QUARC Include Visualization
Modify Model Structure, and Fidelity
Build Subsystem Prototypes for Technically Risky Subsystems
Evaluate Performance Trade various Concepts
Parameter Identification
*Simulink is a registered trademark of The Mathworks, Inc. Quarc is a registered trademark of Quanser Consulting, Inc.

11. Qball-X4 Development Plant Model in MapleSim
Paper Concept for Product
Rough Feasibility Study Paper Calculations, Low fidelity Simulations
Plant Model in MapleSim
Export Plant to Simulink Dev RT Controller in QUARC Include Visualization
Modify Model Structure, and Fidelity
Build Subsystem Prototypes for Technically Risky Subsystems
Evaluate Performance Trade various Concepts
Prototype Full System Deploy with Sim Controller
Parameter Identification
Parameter Identification
Deploy Final Product, Controllers Curriculum

12. Qball-X4 Development
Multibody Modeling

13. Qball-X4 Development
Multibody Modeling

14. Qball-X4 Development
Multibody Modeling

15. Qball-X4 Development
Multibody Modeling

16. Qball-X4 Development
Multibody Modeling

17. Qball-X4 Development
Multibody Modeling

18. Qball-X4 Development
Multibody Modeling

19. Qball-X4 Development
Multibody Modeling

20. Qball-X4 Development MapleSim Model:
Multibody Quadrotor Model + Controller

21. Qball-X4 Development MapleSim Model:
Multibody Quadrotor Model + Controller

22. Qball-X4 Development
MapleSim Model:
Multibody Quadrotor Model

23. Qball-X4 Development
MOVIE #1

24. Qball-X4 Development QUARC®/Simulink® Model
Generated s-function from the MapleSim plant model
Physical plant imported into Quarc model
Rapid control prototyping can begin
Fidelity of model improved in Quarc
Sysid techniques used to get accurate model of actuator dynamics
Limitations and sensors, electronics, and computation considered now.
Processor fundamental sample time
Sensor resolution, bandwidth, etc
Non linearities
Cad Model visualization used to aid in understanding
*Simulink is a registered trademark of The Mathworks, Inc. Quarc is a registered trademark of Quanser Consulting, Inc.

25. Qball-X4 Development
Flight Test
MOVIE #2

26. Planetary Rovers

27. Planetary Rovers Rover Modeling: A Multi-disciplinary Approach
System Components
Rover dynamics
Wheels
Solar cells
Wheel motors
Battery
Power electronics
Heaters
Robotic arms, other peripherals
Terrain
Environment

28. Angular velocity input
Planetary Rovers
Six-wheeled Rocker-Bogie Rover
Modeling Environment
Angular velocity input
Steering angle input
Visualization Environment

29. Planetary Rovers
Rigid Wheel Model

30. Planetary Rovers
Visualization in MapleSim
MOVIE #3

31. Planetary Rovers
Rover Kinematics

32. Planetary Rovers Rover Kinematics
Automatic Generation of the Constraint Equations in Maple

33. 27 Constraint Equations of 36 variables
Planetary Rovers
Rover Kinematics
Automatic Generation of the Constraint Equations in Maple
-2.*l1x-1.*ySL*cos(xi)*sin(eta)*sin(zeta)+ySR*cos(xi)*sin(eta)*sin(zeta)+zSL*cos(xi)*sin(eta)*cos(zeta)-1.*zSR*cos(xi)*sin(eta)*cos(zeta)-1.*cos(xi)*cos(eta)*xSL+cos(xi)*cos(eta)*xSR-1.*ySL*sin(xi)*cos(zeta)+ySR*sin(xi)*cos(zeta)-1.*zSL*sin(xi)*sin(zeta)+zSR*sin(xi)*sin(zeta)
-1.*l1y+sin(xi)*cos(eta)*xSL-1.*sin(xi)*cos(eta)*xSR-1.*ySL*cos(xi)*cos(zeta)+ySR*cos(xi)*cos(zeta)-1.*zSL*cos(xi)*sin(zeta)+zSR*cos(xi)*sin(zeta)+ySL*sin(xi)*sin(eta)*sin(zeta)-1.*ySR*sin(xi)*sin(eta)*sin(zeta)-1.*zSL*sin(xi)*sin(eta)*cos(zeta)+zSR*sin(xi)*sin(eta)*cos(zeta)+l1y*cos(phi)-1.*l1z*sin(phi)
-1.*l1z+cos(eta)*sin(zeta)*ySL-1.*cos(eta)*sin(zeta)*ySR-1.*cos(eta)*cos(zeta)*zSL+cos(eta)*cos(zeta)*zSR+l1y*sin(phi)-1.*sin(eta)*xSL+sin(eta)*xSR+l1z*cos(phi)
-1.*cos(xi)*cos(eta)*xSL+cos(xi)*cos(eta)*xBL-1.*ySL*cos(xi)*sin(eta)*sin(zeta)-1.*ySL*sin(xi)*cos(zeta)+yBL*cos(xi)*sin(eta)*sin(zeta)+yBL*sin(xi)*cos(zeta)+zSL*cos(xi)*sin(eta)*cos(zeta)-1.*zSL*sin(xi)*sin(zeta)-1.*zBL*cos(xi)*sin(eta)*cos(zeta)+zBL*sin(xi)*sin(zeta)-1.*l3x
sin(xi)*cos(eta)*xSL-1.*sin(xi)*cos(eta)*xBL+ySL*sin(xi)*sin(eta)*sin(zeta)-1.*ySL*cos(xi)*cos(zeta)-1.*yBL*sin(xi)*sin(eta)*sin(zeta)+yBL*cos(xi)*cos(zeta)-1.*zSL*sin(xi)*sin(eta)*cos(zeta)-1.*zSL*cos(xi)*sin(zeta)+zBL*sin(xi)*sin(eta)*cos(zeta)+zBL*cos(xi)*sin(zeta)+l3y
-1.*sin(eta)*xSL+sin(eta)*xBL+cos(eta)*sin(zeta)*ySL-1.*cos(eta)*sin(zeta)*yBL-1.*cos(eta)*cos(zeta)*zSL+cos(eta)*cos(zeta)*zBL+l3z
-1.*cos(xi)*cos(eta)*xSR+cos(xi)*cos(eta)*xBR-1.*ySR*cos(xi)*sin(eta)*sin(zeta)-1.*ySR*sin(xi)*cos(zeta)+yBR*cos(xi)*sin(eta)*sin(zeta)+yBR*sin(xi)*cos(zeta)+zSR*cos(xi)*sin(eta)*cos(zeta)-1.*zSR*sin(xi)*sin(zeta)-1.*zBR*cos(xi)*sin(eta)*cos(zeta)+zBR*sin(xi)*sin(zeta)+l3x
xSR*sin(xi)*cos(eta)*cos(phi)-1.*xSR*sin(eta)*sin(phi)-1.*xBR*sin(xi)*cos(eta)*cos(phi)+xBR*sin(eta)*sin(phi)+ySR*cos(phi)*sin(xi)*sin(eta)*sin(zeta)-1.*ySR*cos(phi)*cos(xi)*cos(zeta)+ySR*cos(eta)*sin(zeta)*sin(phi)-1.*yBR*cos(phi)*sin(xi)*sin(eta)*sin(zeta)+yBR*cos(phi)*cos(xi)*cos(zeta)-1.*yBR*cos(eta)*sin(zeta)*sin(phi)-1.*zSR*cos(phi)*sin(xi)*sin(eta)*cos(zeta)-1.*zSR*cos(phi)*cos(xi)*sin(zeta)-1.*zSR*cos(eta)*cos(zeta)*sin(phi)+zBR*cos(phi)*sin(xi)*sin(eta)*cos(zeta)+zBR*cos(phi)*cos(xi)*sin(zeta)+zBR*cos(eta)*cos(zeta)*sin(phi)+l3y
-1.*xSR*sin(xi)*cos(eta)*sin(phi)-1.*xSR*sin(eta)*cos(phi)+xBR*sin(xi)*cos(eta)*sin(phi)+xBR*sin(eta)*cos(phi)-1.*ySR*sin(phi)*sin(xi)*sin(eta)*sin(zeta)+ySR*sin(phi)*cos(xi)*cos(zeta)+ySR*cos(eta)*sin(zeta)*cos(phi)+yBR*sin(phi)*sin(xi)*sin(eta)*sin(zeta)-1.*yBR*sin(phi)*cos(xi)*cos(zeta)...
27 Constraint Equations of 36 variables

34. Planetary Rovers Rover Kinematics Additional Constraints and Forces
Differential Joint
Steering
Wheel/soil forces

35. Planetary Rovers MOVIE #4 Rover Kinematics
Quasi-static Simulation using MATLAB®
MOVIE #4
*Matlab is a registered trademark of The Mathworks, Inc.

36. Planetary Rovers
Rover Path Planning
Energy Optimization

37. Planetary Rovers Rover Component Library Software Component Library
Modeling Workspace

38. Planetary Rovers
Hardware Components
Lighting System
Solar Arrays

39. Planetary Rovers Hardware Components Battery Motor Flywheel
Load simulator
PXI
Sensors
Rover weight? 200 kg
Equivalent kinetic energy representation

40. Planetary Rovers HiL Implementation NI® PXI Software
Hardware (Test Bench)
Component Modeling
Solar Panels
Battery
Motor
Irradiation Model
Lighting System
Solar Panels
Charge Controller
NI® PXI
Battery
Inverter
Load Simulator
LabVIEW™ 2009
Rover Model HiL Graphical User Interface
Motor
Flywheel

41. Planetary Rovers
HiL Implementation

42. Planetary Rovers
HiL Implementation

43. Planetary Rovers HiL Implementation – Sample Results
Summer Full Load - Pure Hardware vs. Solar Panel, Motor, Load Simulator in the loop
Summer Full Load - Pure Hardware vs. Solar Panel in the Loop

44. What is MapleSim? MapleSim is a truly unique physical modeling tool:
Built on a foundation of symbolic computation technology
Handles all of the complex mathematics involved in the development of engineering models
Multi-domain systems, plant modeling, control design
Leverages the power of Maple to take advantage of extensive analytical tools
Reduces model development time from months to days while producing high- fidelity, high-performance models

45. Maplesoft Engineering Solutions
Multi-domain physical modeling
-dSPACE®
-LabVIEW™
-NI® VeriStand™
-MATLAB® & Simulink®
-B&R Automation Studio
Driveline Component Library
More Libraries
*Simulink and MATLAB are registered trademark of The Mathworks, Inc. All other trademarks are property of their respective owners.

46. The Symbolic Advantage
Automatic
Equation
Generation
Advanced analysis
Parameter optimization
Sensitivity etc
Multibody kinematics and dynamics
Greater insight into system behavior
Symbolic model simplification
Optimized code generation
Best performance
~10x faster than similar tools
Equation-based Model Creation
Enter system equations
Test/Validate model
Easy component block generation

47. Hardware in the Loop Simulation
Equation and code generation
Controller implementation (and design) Realtime management
Embedded controller
Data acquisition
Plant model Analysis Controller design
-dSPACE®
-LabVIEW™
-NI® VeriStand™
-MATLAB® & Simulink®
-B&R Automation Studio
System HIL Simulation
*Simulink and MATLAB are registered trademark of The Mathworks, Inc. All other trademarks are property of their respective owners.

48. Key Takeaways...
Physical modeling: increasingly important – and increasingly complex – in systems design, testing and integration.
Symbolic technology: proven engineering technology that significantly improves model fidelity without sacrificing real-time performance.
MapleSim: ideal tool for rapid development of high-fidelity physical models of mechatronics systems to help engineers achieve their design goals.
With the drive for greater fuel efficiency, quality and safety, physical modeling is becoming increasingly important – and increasingly complex – in automotive systems design, testing and integration
Symbolic technology is a proven engineering technology that significantly helps to improve model fidelity without sacrificing real-time performance
MapleSim is the ideal tool for rapid development of high-fidelity physical models of automotive systems to help engineers achieve their design goals...

49. Thank You! Questions?
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