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Using of Co simulation ADAMS SIMULINK for Development of Mechatronic Systems Tomas Brezina Zdenek Hadas and Jan Vetiska Faculty of Mechanical Engineering Brno University of Technology Brno Czech Republic e mail brezina fme vutbr cz hadas fme vutbr cz vetiska fme vutbr cz Abstract This paper deals with an efficient technique for the development of mechatronic systems Individual parts of such system as mechanics actuators sensors control system etc are designed in several passes through V model with respects to mutual feedbacks Based on this methodology the developed system is made as a virtual prototype and can be tested and simulated using co simulation technique The ADAMS and SIMULINK co simulation is used and it is based on direct embedding of dynamic model of the mechanical system with sensors and actuators implemented in ADAMS into MATLAB environment to a control system design and a virtual prototype model tuning So the complex model of mechatronic system applies the same implementation for design simulation and testing Keywords Mechatronic development simulation model control ADAMS SIMULINK I INTRODUCTION This paper deals with an efficient technique for the development of mechatronic systems Individual parts of a developed mechatronic system as mechanics actuators sensors control system etc are designed on the base of a mechatronic approach it means the mechatronic design passes several times through development cycles with respects to mutual feedbacks 1 The methodology of a complex mechatronic system design is presented in VDI 2206 2 Based on this methodology the developed cycle contains a model of the mechatronic system which is made as a virtual prototype and it can be tested and simulated using a co simulation technique II BREIFLY ABOUT CO SIMULATION TECHNIQUE The co simulation technique based on ADAMS and SIMULINK cooperation can be useful tool for improving of the development cycle 3 This technique is suitable for a design of a mechatronic system like robots 4 manipulators cars 5 and other mechatronic system with a complex mechanical structure and a dynamic behavior with a control system 6 The co simulation technique is used in a development phase where physical or mathematic model of the mechatronic system and model of a control system is designed This technique is suitable for testing of the mechanical design 7 a setup of system parameters 8 analyses of a whole system behavior and testing of the control system Generally the mechatronic system consists of a mechanical system actuators sensors control systems and a user interface A mechanical design of the mechanical system is designed and assembled in some 3D CAD software This assembly of the mechanical system is imported to ADAMS environment The ADAMS model can be used for a control design or the control design is developed in SIMULINK environment directly State variables of the ADAMS model are connected with the control system in SIMULINK and the whole virtual prototype is tested This system which is based on co simulation techniques is depicted in Fig 1 Fig 1 Co simulation of mechatronic system Efficient using of the co simulation techniques for development of the mechatronic system with respect to mechatronic is demonstrated on an example of a simple manipulator III MECHATRONIC APPROACH The traditional design of a new product consists of several subsystems with different physical nature e g mechanics electrical engineering electronics control and data processing etc These subsystems are developed individually on the base of individual subsystem requirement The mechatronic approach 2 is based on an integration of knowledge from different areas of physics and technical disciplines and then the synergic effect is achieved The mechatronic approach solves the development process as only one task and development task like mechanics electronics electronic control system including software are processed together A new product which is developed with such mechatronic approach has the highest possible technical and economical parameters 9 The development of a new mechatronic system with respect to the mechatronic approach 1 goes through following design cycles Micro level cycle Macro level cycle Recurrent working tasks cycles The modeling and simulation of the mechatronic system and subsystems under development cycles represent very important parts of the development process IV DESIGN OF SYSTEM BASED ON MODEL Models of a system and subsystems of the new mechatronic system in a computer environment are required for the efficient development of models of the systems These models are created for all components of the considered mechatronic structure Very important is an investigation of goals and tasks of the mechatronic system and analysis of requirements for modeling The object of a model design is an appropriate model of the mechatronic system with respects to requirements A Models of Mechatronic System The procedure of a model design is varied for different domains of mechatronics The required quality of the model and the model tasks fundamentally depended on the considered problem In order to describe the model behavior with the required accuracy substitute models of the system are formed on various abstraction levels Topological model Physical model Mathematical model Numerical or Computing model Experimental model Simulation modeling The setup and identification of model parameters and a verification and validation of the complex mechatronic model is very important for successful development of the mechatronic system B Simulations and Analysis The mechatronic system can exist in reality or as the complex system of a simulation model 10 The simulation model is derived from a real system and the real parts and subsystems are interpreted as an ideal behavior of ideal model elements An accordance of the real system and the model affects the accuracy and the model analysis Such created model of the mechatronic system is prepared as the mechatronic system where the simulation model is substituted for the real mechatronic system This system model is used for an investigation of individual subsystem properties e g displacement velocity acceleration load strength etc and the behavior of the basic mechatronic system is simulated and analyzed The model is created as a parametric system Therefore the complex system of the mechatronic model can be improved and expanded during passing through each development cycle C Simulations Tools The development of mechatronic systems requires the use of a large number of computing methods and computer science skills The use of these methods is supported by engineering tools for simulation modeling of individual mechatronic subsystems For complex development of the mechatronic system the mechatronic engineer can use several simulation tools like MATLAB SIMULINK It is complex programmable environment for control systems mathematic modeling optimization study 11 image and signal processing SimScape FEM and other toolbox etc The engineering software represents fundamental tool for an engineering development 12 for example Computer aided design CAD o Catia o ProEngineer o SolidWorks o Inventor o Etc Finite Element Method and Analysis FEM FEA o ANSYS o MARC o NASTRAN o Etc Multi body Systems MBS o ADAMS o Pro Mechanica o DYMOLA o Etc Computational Fluid Dynamics CFD o Fluent o Etc Commonly the broad usage of the computer software to aid in engineering tasks is marked as Computer aided engineering CAE It usually includes CAD stress analysis on components and assemblies FEM kinematic and dynamic of assemblies MBS thermal and fluid flow analysis CFD and usually also the computer integrated manufacturing CIM computer aided manufacturing CAM and computer aided planning CAP The optimization of the product or process is included in the CAE software too The product of Computer aided engineering CEA is distributed by companies PTC MSC I DEAS Etc These engineering and simulation tools are very useful for development of the traditional design of some machine system consists of several subsystems with different physical nature Our aim is a use of the CAE tool and computing or programing environment Matlab LabView etc together with cooperation in the subsystem simulation and an exchange of individual subsystems results Cooperation of such simulation tool is called a co simulation and this simulation tool can create analysis of several subsystems together The whole simulation model of the mechatronic system is simulates and tested as the virtual prototype of the real mechatronic system V EXAMPLE OF MECHATRONIC SYSTEM DEVELOPMENT A Manipulator The presented methodology of the co simulation ADAMS SIMULINK for the development of the mechatronic system is shown on a manipulator with 3 DOF The topological model of this manipulator is shown in Fig 2 and the model consists of a revolving base two arms and holder on an effector The revolving base and arms are driven by DC motors Fig 2 Mechatronic system manipulator with 3 DOF B Model of Manipulator in ADAMS View A simple parametric model of the manipulator was created in ADAMS View and it is shown in Fig 3 The model contains bodies gear boxes DC motors joints gears gravity applied torques and forces damping forces and friction in joints Fig 3 ADAMS View model of manipulator The length of arms is understood as a design variable and these arm lengths can be adjusted to chosen working space The inertia moment mass material and cross section geometry represent parameters of this system and they can be optimized on the base of co simulation results afterwards Such parametric model in ADAMS View can be used for an optimization or sensitivity analysis and the optimal length of arms can be adjusted to a minimal energy demand during operation in working space with a transporting load Additionally ADAMS View environment is able to provide the multi body model MTB for static kinematic and dynamic analysis The MTB model can be driven through a joint motion and kinematic analysis of the manipulator effector can be studied However the bodies can be driven by the applied torque which represent a motor shaft torque and so the dynamic study of the manipulator behavior can be analyzed This mechatronic model of the manipulator contains a model of a DC motor for dynamic study of a manipulator operation 13 and 14 The model of DC motor is described by well known equations 1 and 2 The equation 1 describe an electrical behavior of the DC motor and equation 2 represents a dynamic behavior of the DC motor 1diRc iu dtLLL 1 d Jbc i dt 2 where i is the instantaneous value of the electrical current R is a terminal resistance L the terminal inductance J is the inertia is the shaft velocity b is the linear approximation of a viscous friction in motor bearings c is DC motor constant and u is the instantaneous driving voltage The ADAMS View environment can solve also explicit and implicit differential equations and the DC motor equation 1 is added to the MTB model of the manipulator The left side of the differential equation 2 describes dynamic behavior of the driven manipulator body and this part is used by ADAMS solver automatically during the dynamic analysis The right side of the differential equation 2 is applied as the torque to the MTB model of the manipulator The left side of the real differential equation 2 in the MTB model is more complicated due to applied friction in an arms contact The user does not derive this side of the motion equation The inertia changes of the manipulators arms during moving and frictions are solved automatically by the ADAMS C Model in ADAMS Control Toolkit This electromechanical model of the manipulator is prepared for a feeding by instantaneous voltage The feeding voltage has to be controlled Such controlled system can manipulate with the effector with respect to planning trajectory The control system of the driving voltage can be realized in ADAMS Controls toolkit A control tools with a PID regulator is prepared in the ADAMS Controls toolkit for mechatronic studies The ADAMS Controls toolkit can provide opportunity of the co simulation in SIMULINK The input and output of the MTB model in the ADAMS View were determined as state variables The information exchange between the ADAMS Controls toolkit and the control system in SIMULINK is passed by the state variables of the virtual prototype of the mechatronic system The co simulation of the MTB model of the manipulator with the control system of 3 DC motors in SIMULINK was prepared for presentation of this technique VI CO SIMULATION OF MECHATRONIC SYSTEM A Building of ADAMS model for Co Simulation The MTB model in the ADAMS View is imported into SIMULINK model with defined state variables The ADAMS Control toolkit can import a linearized state space model or nonlinear complex model of mechatronic system with defined state variables for connection in SIMULINK environment We used the second choice with these state variables Inputs state variables to the MTB model driving voltage of the base motor driving voltage of the arm 1 motor driving voltage of the arm 2 motor Outputs state variables from the MTB model position of the motors current of the motors torque of the motors position of effector in global coordinate system B Control in SIMULINK The ADAMS Control toolkit creates m file which connects adams sub system in the SIMULINK environment with a solver of the ADAMS enviroment This adams sub system is shown in Fig 4 and the Control System can be used for a control of the driving voltage of individual DC motors Only a simple control system with PID regulators was designed for this presented example of the manipulator with 3 DOF Fig 4 Control System and ADAMS Connection The co simulation system on Fig 4 opens the MTB model in ADAMS and also the co simulation system call ADAMS Solver The dynamic behavior of the MTB model is calculated by ADAMS Solver in individual steps of the co simulation The output state variables are solved and values of the state variables is provided to SIMULINK model in each step of the co simulation The control system in SIMULINK drives the inputs voltage of DC motors for a required system behavior VII CO SIMULATION RESULTS The results of the co simulation can be shown in SIMULINK environment or the final results file of ADAMS Solver can be used in ADAMS Postprocessor for presentation of results The ADAMS Postprocessor can provide charts and animations of the MTB model behavior with respect to the behavior of the control system in SIMULINK The designed control system can drive the voltage of DC motors of the base arm 1 and arm 2 with respect to required position of manipulator parts The required behavior of manipulator simulates a passage of a manipulator effector movement This movement is shown in Fig 5 The effector of the manipulator passes this trajectory in direction outwards and back Fig 5 Control System and ADAMS Connection The position of the effector in the global coordinate system during the simulation is shown in Fig 6 Fig 6 Effector position X Y Z in global coordinate system This movement is provided by a controlled relative position of DC motors The positions of the individual motor shafts are shown in Fig 7 F ig 7 Positions orientation of individual bodies during simulation The required torque moment of the individual arm motors is shown in Fig 8 These moments of arm motors are measured during simulation of DC motor behavior The behavior of motors depends on the control system and requirements on the effector position or requirements on the angular velocity of arms during simulation On the base of this computer experiment of the manipulator virtual prototype the geometry of arms specification of motors velocity of bodies and more another manipulator parameters can be adjusted Fig 8 Torque moment of individual motor during simulation The aim of paper was not the manipulator design The results shown in this paper have only an illustrative and education character and main aim of the presented simulation was present the modern technique of the virtual prototype design using co simulation ADAMS SIMULINK VIII CONCLUSIONS The presented methodology in this paper creates the simulation model of the mechanical electro mechanical system This model is derived directly from the ADAMS to SIMULINK and the control system in SIMULINK environment can affect behavior of this MTB model The complex behavior of this mechatronic system can be simulated as behavior of the virtual prototype of the manipulator with 3 DOF The co simulation study of the parametric system can by very useful for the development and the optimization of this developed mechatronic system The structural analysis can be included in the MTB model in the ADAMS View environment and the appropriate virtual prototype can be used for several simulation studies of a virtual behavior of the real mechatronic system This technique of the virtual prototyping can be very useful for the design of modern mechatronic systems with respect to development time power consumption accuracy etc ACKNOWLEDGMENT Published results were acquired using the subsidization of the Ministry of Education Youth and Sports of the Czech Republic research plan MSM 0021630518 Simulation modeling of mechatronics systems REFERENCES 1 Z HADAS S V CHET V SINGULE C ONDR EK Development of Energy Harvesting Sources for Remote Applications as Mechatronic systems 14th International Power Electronics and Motion Control Conference Ohrid Macedonia pp 13 19 2010 2 VDI 2206 Design methodology for mechatronic systems Verband Deutscher Ingenieure Association of German Engineers 118 pages 01 Jun 2004 3 D L ZHU J Y QIN Y ZHANG H ZHANG M M XIA Research on Co simulation Using ADAMS and MATLAB for Active Vibration Isolation System Proceedings of the 2010 International Conference on Intelligent Computation Technology and Automation ICICTA 10 Vol 2 IEEE Computer Society W