Physics-Based Modeling in Industry: what, why and how?

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1 Physics-Based Modeling in Industry: what, why and how? Maria Henningsson Product Manager, FMI Modelon Modelon

2 The #1 partner for Modelica and FMI technology and system simulation solutions Most complete industry library offerings and unique end-to-end toolchain Active and leading contributor to open standards community Unmatched concentration of expertise in systems simulation technology and applications across industries 5/26/2018 Modelon

3 MODELON Ann Arbor, MI Hartford, CT Gothenburg, SE Lund, SE Hamburg, DE Munich, DE Trichy, IN Tokyo, JP ~70 employees (MSc/PhD) at offices in USA, Sweden, Germany, Japan, India Customers in Fortune 500 in Automotive, Aerospace, Energy and Industrial Equipment ~30% annual growth since /26/2018 Modelon

4 MODELON PRODUCT SUITES Delivering world-class model-based systems engineering solutions 5/26/2018 Modelon

5 MODELON LIBRARY SUITE OVERVIEW IGNITE OPTIMICA Simplorer 5/26/2018 Modelon

6 OUTLINE What? What is a model? Physics-based vs other types of models Why? The business case for modeling How? Organizational aspects Technical aspects: FMI as an open standard Restricted distribution Modelon

7 WHAT? Restricted distribution Modelon

8 WHAT IS A MODEL? A simplified description, especially a mathematical one, of a system or process, to assist calculations and predictions. Oxford dictionary This Photo by Unknown Author is licensed under CC BY-NC-SA This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY This Photo by Unknown Author is licensed under CC BY-SA Restricted distribution Modelon

9 PHYSICS-BASED SYSTEMS MODELING Physics = centuries of ultra-condensed knowledge about the world For example: This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY-ND This Photo by Unknown Author is licensed under CC BY- SA This Photo by Unknown Author is licensed under CC BY-SA Kirchoff Newton Boyle Clausius Restricted distribution Modelon

10 PHYSICS-BASED MODELING USING MODELICA Physical equation based modeling Each icon represents a physical component (electrical resistance, mechanical device, pump,...). A connection line represents the actual physical coupling (wire, fluid flow, heat flow,...). A component consists of connected sub-components (= hierarchical structure) and/or is described by equations. Component Connector Connection

11 PHYSICAL MODELING VS. BLOCK ORIENTED MODELING A-causal modeling Declarative languages just require the developer to define the problem at a higher level and leaves the solution to the simulation tool wr controller PI Vs1 Ra1=0.5 La1=0.05 emf1 Jm=1.0E-3 n=100 Jl=10 G1 wl Block oriented modeling Ra Procedural programs require the developer to define the order that calculations are to be done in Step e PID PI Sum Resistor 1/La Inductor 1 s I n*km emf1 1/(Jl+Jm*n^2) T2wdot 1 s Inertia n*km emf2

12 PHYSICAL MODELING VS. BLOCK ORIENTED MODELING Engineering Problem: Study vibrational effects of the shaft. Engineering Solution: Add flexible shaft to model. Block diagrams are not suitable for large scale physical modeling

13 WHY? The business case for modeling Restricted distribution Modelon

14 DESIGN V Long feedback cycle Requirements & Performance Targets Finished Product System Design System Integration & Validation Module Design Component Design Component Verification Module Integration & Verification

15 CONTINUOUS VALIDATION AND VERIFICATION Continuous feedback on requirements through virtual tests Requirements & Performance Targets Finished Product System Design System Integration & Validation Module Design Component Design Component Verification Module Integration & Verification

16 CONTINUOUS INTEGRATION WITH SIL, HIL, SIMULATORS Requirements & Performance Targets Finished Product System Design System Integration & Validation Module Design Component Design Component Verification Module Integration & Verification

17 SHORTEN THE FEEDBACK CYCLES! Requirements & Performance Targets Finished Product System Design System Integration & Validation Module Design Component Design Component Verification Module Integration & Verification

18 MODELING FOR AUTONOMOUS SYSTEMS Model-based control Simulation-based testing of control algorithms Formal verification Plant design: e.g. evaluate sensor configurations Improve intuition about real-world problems 18

19 HOW? Organizational challenges Restricted distribution Modelon

20 SIMULATION TOOL LANDSCAPE Restricted distribution Modelon

21 CAE TOOLS: THERE ARE A LOT OF THEM! Manage heterogeneity Reality? Multiple physical domains Multiple vendors In-house solutions Legacy tools Individual/group preferences Suppliers Partners Customers Dream? Pragmatic? 21

22 MODELING = INVESTMENT Determine the right level of fidelity Use the correct physics Manage performance vs. accuracy trade-off Parameterize Validate against real-world data Manage model uncertainty Document Restricted distribution Modelon

23 BUSINESS CONSIDERATIONS: CHOOSING THE RIGHT TOOL Capabilities / features Workflows / productivity Existing skill-set in organization Learning curve of tool, need for training Integration into tool-chains Future-proofing? Develop in-house vs. buying off-the-shelf Concern for vendor lock-in Price Restricted distribution Modelon

24 Why do you need a model? To answer questions How do you get maximum return-on-investment on a model? By reusing the same model for many questions Restricted distribution Modelon

25 HOW? Modeling based on open standards Modelica FMI SSP Restricted distribution Modelon

26 MODEL DEPLOYMENT Model deployed (native tool) to support multiple applications Mechanical Mechanical System FMU Electrical Control Systems Thermal Control

27 ALL CONNECTED? 27

28 BACKGROUND TO FMI Standardization Even though many tool suppliers provide their own specific solutions (interfaces) for the model exchange, a standardized tool independent approach is desirable Requirements: The standard should be open Easy to implement both in tools and for end users Safe and seamless deployment - in-house and to suppliers Allow for customization 28

29 WHAT IS A FUNCTIONAL-MOCKUP-UNIT (FMU)? An encapsulated model that is easy to share with others!

30 FMI: A SUCCESS STORY In less than ten years Used across multiple industries Supported by more than 100 tools From European research project to world-wide use Modelon

31 THE POWER OF FMI Use the best tool for each purpose Sizing Take advantage of engineers skills in specific tools Tool 1 Facilitate cross-team use of the same model portfolio Verification Tool 4 Model Modeling tool Quality Tool 2 Control design Tool 3 31

32 What is FMI? 32

33 WHAT IS FMI? 33 FMI Functional Mock-up Interface Open interface standard for model exchange between different modeling and simulation environments. Most often model of a dynamical system that changes with time Consists of Model Interface: Set of C functions for equation evalutation. Model Description Schema: XML Schema defining an XML file containing variable definitions and model meta data. Developed as a part of the MODELISAR project ITEA2 European project to improve the design of systems and embedded software in vehicles. 33

34 34 WHAT IS AN FMU? FMU Functional Mock-up Unit Implementation of the FMI Zip-file with a specific structure consisting of Binary file (usually a DLL-file) XML Model Description file Additional model data (images, documentation) Co-Simulation or Model Exchange Simulator calls FMI functions to create and run the FMU 34

35 FMU DISTRIBUTION An FMU is distributed in a zip-file (with the extension.fmu) which contains: The Model Description File (modeldesrciption.xml). Includes model information (e.g. variables) that is not needed for simulation. The binaries and/or C sources of the Model Interface (including the needed run-time libraries used in the model and/or Dynamic link libraries (DLL) for one or several target machines). Additional model data (like tables, maps) in model specific file formats. 35

36 FMI FLAVORS Model Exchange (ME) Co-Simulation (CS) 36

37 IP PROTECTION FMUs contain compiled code FMU creator controls level of openness Internal variables Parameters Inputs and outputs only Suitable for sharing between OEMs and suppliers 10/18/2016

38 IP PROTECTION FMUs contain compiled code FMU creator controls level of openness Internal variables Parameters Inputs and outputs only Suitable for sharing between OEMs and suppliers 10/18/2016

39 Upcoming: the SSP standard 39

40 GETTING FMI RIGHT: IT S ALL ABOUT WORKING TOGETHER The FMI standard allows a simulation model to be packaged neatly as a piece of a jigsaw puzzle Different teams create their own pieces... The true value comes when it can fit together with other pieces...with different interfaces 5/26/2018 Modelon Restricted distribution 40

41 CHALLENGES Enforcing interfaces Separation of models and parameters Sharing IP in organization Versioning of models and parameters Controller Plant Parameters Organization wide feedback?

42 SYSTEM STRUCTURE AND PARAMETRIZATION (SSP) New standard to address new needs An initiative from the automotive industry and tool vendors Currently under development Describe systems of interconnected FMUs Apply external parameter files

43 SSP, SYSTEM STRUCTURE The.ssp file is a zip file containing System structure description as an xml-file Included FMUs in a resources folder Optionally, additional files as specified by the standard The system structure description file defines Components Inputs and outputs Connections Graphical layout of system Other system meta data All on a fully standardized format

44 MODELON AND FMI: PRODUCTS AND SERVICES Restricted distribution Modelon

45 AN FMI SOLUTION FOR EVERY CONTEXT End-user products Back-end toolkits Customized solutions FMI Library.c PyFMI.py Open source FMI Compliance Checker Open source, owned by MA Upcoming: FMI Composer FMI.NET Toolkit FMI C++ Toolkit.cs.cc Commercial libraries + FMI Course Restricted distribution Modelon

46 FMI COMPOSER FLEXIBLE CO-SIMULATION THE POWER OF OPEN STANDARDS... and simulate in your tool of choice! Build system models in FMI Composer save as ssp export system as FMU... + more than 60 others! Restricted distribution Modelon

47 Using the FMI standard: Two major trends 47

48 FMI TREND #1: SIMULATION DEMOCRATIZATION R&D Model developers using expert tool with steep learning curve Software developers Calibration engineers Test engineers Maximize ROI in model development by spreading and reusing models! Restricted distribution Modelon

49 Example: simulation democratization VIRTUAL K&C: PROJECT WITH TOYOTA MC ticles/virtual-vehiclekinematics-andcompliance-test-rig/ The technical level show by Modelon during the project development was outstanding. Alejandro Ocariz, Engineer, Toyota Motor Europe Restricted distribution Modelon

50 FMI TREND #2: SIMULATION INDUSTRIALIZATION Model development systematic, pervasive Simulation large-scale, automated Regression testing Requirements testing Optimization version controlled development Maximize ROI in model development through Reuse Traceability Maintainability model repository continuous integration build and test server Restricted distribution Modelon

51 Example: simulation industrialization THE HEAVYROAD PROJECT: FMI COMPOSER BUILD THE RIGHT PLANT MODEL FOR EACH TEST HeavyRoad Plant Models combine! ADAPT Autosar Simulation Platform Vehicle Configuration system structure FMU FMU FMU FMU FMU aggregation engine FMI Composer acts as FMU co-simulation engine for ADAPT through a preintegration step Modelon

52 ALL CONNECTED? ALL CONNECTED! 52

53 TAKE-HOME MESSAGE Build up a model portfolio for your applications Take advantage of what is already available Combine physics and data-driven modeling Separate model development from model analysis Use the best tool for each purpose Identify your part within the larger project / organization Opportunities for reuse? Restricted distribution Modelon

54 Delivering world-class model-based systems engineering solutions 5/26/2018 Modelon