Model-Based Design for Controls 2011 The MathWorks, Inc. 1
MathWorks at a Glance Headquarters: Natick, Massachusetts US Other U.S. Locations: California; Michigan; Texas; Washington, DC Europe: France, Germany, Italy, Spain, the Netherlands, Sweden, Switzerland, U.K. Asia-Pacific: Australia, China, India, Japan, Korea Worldwide training and consulting Earth s topography on an equidistant cylindrical projection, created with MATLAB and Mapping Toolbox. Distributors in 25 countries 2
Key Capabilities Drive MathWorks Business Verification, Validation, and Test Test and measurement Model checking Code verification Qualification kits Automatic Code Generation Rapid prototyping and HIL Embedded software DSP software VHDL/Verilog PLC code System Modeling and Simulation Simulink DSP designs State charts Physical Communication systems modeling Discrete-event modeling Video processing Data Analysis and Algorithm Development Control design Signal processing Optimization Statistics Image processing Computational finance Computational biology Technical Computing MATLAB Application deployment Student version Instrument and database connectivity Distributed and parallel computing MATLAB Mobile for iphone 1985 1990 1995 2000 2005 2010 Founded in 1984 3
MathWorks Today Revenues ~$600M in 2010 Privately held More than 2000 employees worldwide Worldwide revenue balance: 45% North America, 55% international More than 1 million users in 175+ countries 1984 1989 1994 1999 2004 2009 4
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Deeply Rooted in Education 3500+ universities around the world 1200+ MATLAB and Simulink based books Academic support for research, fellowships, student competitions, and curriculum development Benefits for Industry: Everyone that comes in as a new hire already knows MATLAB, because they all had it in college. The learning curve is significantly lessened as a result. Jeff Corn, Chief of Engineering Projects Section, U.S. Air Force Every year, tens of thousands of engineers enter the workforce with MathWorks product skills and experience. Students learn theory and techniques while using MATLAB and Simulink. 6
Core MathWorks Products The leading environment for technical computing The industry-standard, high-level programming language for algorithm development Numeric computation Data analysis and visualization Toolboxes for signal and image processing, statistics, optimization, symbolic math, and other areas Foundation of MathWorks products 7
Core MathWorks Products The leading environment for modeling, simulating, and implementing dynamic and embedded systems Linear, nonlinear, discrete-time, continuous-time, hybrid, and multirate systems Foundation for Model-Based Design, including physical-domain modeling, automatic code generation, and verification and validation Open architecture for integrating models from other tools Applications in controls, signal processing, communications, and other system engineering areas 8
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MathWorks Product Overview Simulink Product Family View full product list Application-Specific Products MATLAB Product Family 15
What are we doing today? 16
xpc Target runs Simulink in hard real-time 1 2 Host computer with MATLAB xpc Target on Target Computer 3 Ethernet or RS 232 Environment allows the real-time execution of Simulink models on a separate PC-based target computer 17
Today s Agenda Introduction to Simulink Plant Modeling Control and Real Time Testing Closing remarks 18
Traditional Development Process RESEARCH REQUIREMENTS SPECIFICATIONS Requirement Documents Difficult to analyze Difficult to manage as they change DESIGN Paper Specifications Easy to misinterpret Difficult to integrate with design EDA Electrical Components Algorithm Design Embeddable Algorithms MCAD/ MCAE Mechanical Components Physical Prototypes Incomplete and expensive Prevents rapid iteration No system-level testing IMPLEMENTATION Manual Coding Time consuming Introduces defects and variance Difficult to reuse C/C++ Embedded Software Traditional Testing Design and integration issues found late Difficult to feed insights back into design process Traceability INTEGRATION AND TEST 19
Model-Based Design- Describe the system dynamics DESIGN Model-Based Design uses block diagrams to mathematically model the system behavior. Electrical Components Embedded Software Control Algorithms Mechanical Components You design the way the system should perform. 20
Model-Based Design- Design and test using simulation RESEARCH DESIGN REQUIREMENTS Requirements are linked to the model. Environmental Models Mechanical Electrical Control Algorithms Supervisory Logic Detail is added from specific domains to refine the model. Intellectual property and engineering data are reused from existing designs and CAE tools, such as CAD, FEA, and SPICE models. Design and test control algorithms using the model. 21
Model-Based Design- Test and validate in real-time RESEARCH REQUIREMENTS DESIGN Environmental Models Mechanical Electrical Control Algorithms Supervisory Logic Automatically generate code from the simulation model for real-time testing of the control algorithms. Automatically generate code from the simulation model for real-time system simulation of hardware for testing the real microcontroller, FPGA, or PLC REAL-TIME TESTING C, C++ VHDL, Verilog Structured Text MCU DSP FPGA ASIC PLC 22
Model-Based Design- Implement embedded software RESEARCH C, C++ DESIGN Environmental Models Mechanical Control Algorithms Supervisory Logic Electrical IMPLEMENTATION VHDL, Verilog REQUIREMENTS Structured Text TEST & VERIFICATION Automatically generate code from the simulation model for implementing directly on production targets: Microcontrollers FPGAs PLC IDEs MCU DSP FPGA ASIC PLC INTEGRATION 23
Model-Based Design Plant Modeling Control Design Testing SolidWorks SimMechanics Simscape SimElectronics SimPowerSystems Simulink Design Optimization Optimization Toolbox Simulink Control Design Control System Toolbox Simulink Design Optimization Optimization Toolbox xpc Target MATLAB Coder Simulink Coder DSP System Toolbox 24
MAN Roland Develops High-Precision Commercial Printing Press Controller with MathWorks Tools Challenge To implement a new design process to support development of a precision controller for a state-of-the-art commercial printing press Solution Use MathWorks products for Model-Based Design to design and model the controller, run real-time simulations, and deploy a production system Results Development time reduced by one year Design iterations completed in minutes, not weeks Error analysis streamlined for MAN Roland customers Link to user story MAN Roland s state-of-the-art printing press. MathWorks tools made it easy for us to test ideas, introduce new algorithms, and compare one controller against another... We could quickly change the structure of the controller and immediately see the results. The ability to perform rapid iterations enabled us to optimize quality and functionality while greatly reducing development cycle time." Thomas Debes MAN Roland 25
We can import the entire mechanical design directly from a CAD tool SolidWorks Model SimMechanics Model The translator automatically generates the SimMechanics model using CAD information 28
Now, for our robot to be of any use, it has to be able to move We can include the effects of actuator and sensor dynamics in the simulation model 29
And we can test and verify the overall system performance in simulation reference + S1 S2 - S3 controller Generate test vector arrays and verify the controller design against the performance specifications given for the system 30
Modeling Dynamic Systems: two approaches Data-Driven Modeling Use system test data to derive a mathematical representation 1.4e9 G( s) e 1 2.8e7s 0.1s 31
Modeling Dynamic Systems: two approaches First-Principles Modeling Use an understanding of the system s physics to derive a mathematical representation V+ V- 32
Both have advantages & disadvantages Data-Driven Modeling Complete Modeling Environment First-Principles Modeling Advantages: Fast Accurate Disadvantages: Requires plant Requires data acquisition system Advantages: Insight in behavior Physical parameters Disadvantages: Time-consuming Requires expertise 33
Tools that span both modeling approaches Complete Modeling Environment Data-Driven System Identification Toolbox Test and Measurement Tools Simulink Design Optimization First-Principles Simulink Physical Modeling Tools 34
SimMechanics SimDriveline SimElectronics SimPowerSystems SimHydraulics SimPowerSystems SimMechanics SimDriveline SimHydraulics SimElectronics Physical Systems in Simulink Simscape Simscape MATLAB, Simulink Electrical power systems Multidomain physical systems Fluid power and control Mechanical dynamics (3-D) Drivetrain systems (1-D) Electromechanical and electronic systems 35
Estimation of DC Motor Parameters Untuned Parameters Resistance Inductance Damping Intertia Tune Parameters with Optimization 36
Break 2011 The MathWorks, Inc. 37
DC Motor Controller Design 38
Or we can fine tune our controller gains by optimizing the system response reference + S1 S2 - S3 controller Use Simulink Design Optimization to set graphical constraints on relevant signals and optimize the controller gains against the nonlinear system response 39
From Simulation to Real-Time Testing Models designed in Simulink and Stateflow You want to run, test, and prove your Simulink design with your hardware under test at its normal operating frequency, speed, or timing. But how can you do this testing in real-time?? 40
How can you do this testing in real-time? Use xpc Target! xpc Target and xpc Target Turnkey systems create a hard real time environment for testing your Simulink models. 41
Real-Time Testing Scenarios: Functional Rapid Prototyping Code Generation Execution Host/Target Real-time Wiring and Signal Conditioning Real-Time Target Computer Production Plant Hardware 42
Real-Time Testing Scenarios: Hardware-in-the-Loop (HIL) Simulation Execution Host/Target/Target Real-time Code Generation Code Generation Wiring and Signal Conditioning ECU or MicroController Real-Time Target Computer 43
xpc Target runs Simulink in hard real-time 1 2 Host computer with MATLAB xpc Target on Target Computer 3 Ethernet or RS 232 Environment allows the real-time execution of Simulink models on a separate PC-based target computer 44
xpc Target enables tuning parameters in real-time Host computer with MATLAB Host computer with MATLAB Ethernet or RS 232 xpc Target on Target Computer xpc Target on Target Computer Ethernet or RS 232 Environment provides interactive access between the real-time application and the host computer Allows live parameter tuning, control from the original Simulink model and offline analysis support in MATLAB. 45
xpc Target enables quick data analysis with MATLAB 2 Host computer with MATLAB xpc Target on Target Computer 4 Ethernet or RS 232 3 1 2 Environment provides interactive access between the real-time application and the host computer Allows live parameter tuning, control from the original Simulink model and offline analysis support in MATLAB. 46
xpc Target enables quick data analysis with MATLAB Host computer with MATLAB xpc Target on Target Computer Ethernet or RS 232 Environment provides numerous I/O device driver blocks Blocks are easily configurable within the Simulink model and communicate with actual hardware in real-time. 47
xpc Target provides I/O driver blocks in Simulink xpc Target on Target Computer Environment provides numerous I/O device driver blocks Blocks are easily configurable within the Simulink model and communicate with actual hardware in real-time. 48
Why xpc Target Turnkey? Complete, fully assembled, real-time testing solution Combines xpc Target (software) with a real-time target machine and IO modules (hardware) Optimized for Simulink and xpc Target xpc Target Turnkey 49
What is xpc Target Turnkey? Portfolio of real-time target machines Assembled to meet your performance and I/O requirements Various form factors for office, lab, and field use Made and optimized for the use with Simulink and xpc Target 50
What is xpc Target Turnkey Wide range of I/O modules installed in your target machine and fully tested IO Type Analog Digital Serial Protocols Audio/Speech Shared Memory Various Configurable FPGA Functionality High-resolution, high-speed, simultaneous sampling TTL, 12V, 24V, high-drive, opto-coupled RS232, RS422, RS485, SDLC, HDLC SPI, I2C, SSI, CAN, Ethernet, UDP, J1939, ARINC 429, MIL-STD-1553 Audio/Speech optimized analog IO modules, XLR panels Reflective Memory for high speed data transfer in multi-processor systems LVDT/RVDT, Synchro/Resolver, 3 phase motor control Pulse train (PWM, capture, quadrature decoding, hall effect) Event based interrupts Analog I/O with lowest latency and/or special synchronization schemes Algorithmic implementations for very fast inner control loops 51
FPGA Programming for xpc Target Programming FPGA boards for xpc Target Turnkey real-time target machines using Simulink HDL Coder Workflow Advisor. Execute high-speed algorithms on an FPGA connected to a model running in real time with xpc Target. Automatically program the FPGA without needing to know HDL code - ideal for functional testing and verification. Quick reconfiguration of FPGA IO promotes a flexible real-time testing environment. Compatible with both new and existing xpc Target Turnkey systems. 52
Next Steps Visit www.mathworks.com Product literature MATLAB Central Live and recorded webinars Use the eval form to request more information Passcodes to for evaluation of products Follow-up meeting or phone call Pricing and licensing Training; public and on-site classes Feel free to ask questions afterwards 53