1 © 2013 ANSYS, Inc. November 6, 2014 ANSYS Confidential © 2013 ANSYS, Inc. November 6, 2014 ANSYS Confidential

Embedded Software System Simulation: Example of Control Simulation of an Electric Drive Design

Aubanel Monnier, Jean-Luc Fock-Sui-Too, Todd McDevitt, Vincent Delafosse ANSYS, Inc.

2 © 2013 ANSYS, Inc. November 6, 2014 ANSYS Confidential © 2013 ANSYS, Inc. November 6, 2014 ANSYS Confidential

ANSYS is a leading provider in simulation software. It is has been known for his 3D simulation capabilities in Mechanical, Fluidic and Electromagnetic domains.

System engineering help designing complex products. It involves multiple disciplines that need to be combined in the more efficient way so that the complexity of the system can be apprehended.

ANSYS also has the vision of providing a system engineering approach, and we aim to briefly introduce our system engineering vision on a particular case: combining Embedded Software simulation with hardware design of an electrical drive.

Introduction

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Electric Drives are a key component in the power conversion chain in between the power sources (the grid, battery, …) and the loads (industrial equipments, traction motors for cars, trains, …)

As the price of energy increases, developing very efficient drives is critical. A system approach has become mandatory to create new generations of drives, as it enables designers to have a global view of their design early on in the development cycle.

Introduction

CPU, ASIC, Memory Controller

Drive

Controller

Power

- +

Load

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ANSYS Systems Engineering Vision

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Detailed 3D Design

Maxwell

Fluent

Mechanical

Simplorer

Software Engineering

ANSYS Systems Engineering Vision System

Validation

Sub-System Integ. & Verification

Component Integration

& Verification

Requirements and Specifications

Sub-System Design

System Functional & Architectural Design

Mechanical Electrical Software

Detailed Design & Optimization

Systems Functional Engineering

Functional Allocations

Detailed Architecture Architecture

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PLM Backbone

Mechanical E/E

Software

System Validation

Detailed Design & Optimization

Requirements & Specifications

Functional & Architectural Design

Sub-System Design Component Integ. & Verification

Sub-System Integ. & Verification

ANSYS System Engineering Solution Map

Simplorer

Mechanical Fluent

Maxwell HFSS

Simplorer

DX HPC

EKM

Apache

Multiphysics Rigid Body Dynamics

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World Class 3D

Physics Mechanical,

Fluids, Thermal, Emag

Our Systems Engineering Strategy

Embedded Software

Simulation & Certified Code

Generation

0D Simulation

VHDL-AMS Modelica Standard

Compilers & Libraries

0D – 3D Co-Simulation

Full or Reduced Order Models

Open & Collaborative Environment

PLM Interoperability

& Support for 3rd Party Tools

HW – SW Co-Simulation HiL, SiL, MiL

Model-Based System Design

Based on SysML

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• Enabling technology built on open standards – SysML for model-based system engineering – VHDL-AMS – standard hardware description language – Modelica – equation based modeling language – FMI/FMU standards for co-simulation – HTML5 & Python for next generation UI

• Interoperability with 3rd Party Tools – Matlab/Simulink – LMS AMESim – Dassault Dymola – NI LabView Veristand – More …

Our Commitment to an Open Platform

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SCADE Suite

PROTOTYPE & DESIGN

Control Software Design

Model Coverage Analysis

VERIFY

Formal Verification

Time & Stack Analysis

Debug & Simulation

Model Checking

Model Diff

SCADE Suite KCG

C & Ada

RTOS & PLC Adaptors

GENERATE

Object Code & Compiler Verification

DO-178B IEC 61508 EN 50128

Certification Kits

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ANSYS Simplorer

Matlab Simulink

Simulation Data Bus/Simulator “0D” Coupling Technology

Co-Simulation

Circuits: States:

VHDL-AMS IF (domain = quiescent_domain) V0 == init_v; ELSE Current == cap*voltage'dot; END USE;

Matlab Real Time Workshop

C/C++ User Defined

Model

ANSYS RBD

ANSYS Maxwell

Blocks:

Electromagnetic (FEA)

Mechanical (FEA)

Model Extraction: Equivalent Circuit, Impulse Response Extracted LTI, Stiffness Matrix

Fluidic (CFD)

Thermal (FEA/CFD)

ANSYS CFD

SCADE Suite

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Practice: Electric Drive with Embedded Software

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Practice: Electric Drive with Embedded Software

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Typical Electrical Drives Development Flow Prototypes/Verification

Hardware Design

Behavioral Level Detailed Level

Software Design

Electrical Design

Open Loop Control Close Loop Control Code Generation

Electrical behavior Losses – EMC/EMI

CAD – Stress Analysis Cooling –Fatigue

?

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Each discipline has independent flow:

-Power electronics designers are only focusing on Semiconductor selections, electrical performances, EMC-EMI effects, efficiency

- Software developers validate codes with elementary and non realistic test cases

-Mechanical and Thermal engineers use approximate values as load cases and boundary conditions

No system validation is realized up until a prototype is build

Takeaways

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ANSYS Electrical Drives Development Flow Prototypes/Verification

Hardware Design

Behavioral Level Detailed Level

Software Design

Electrical Design

Open Loop Control Close Loop Control Code Generation

Electrical behavior Losses – EMC/EMI

CAD – Stress Analysis Cooling –Fatigue

System Validation System Validation

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Each disciple conserves its flow and his design tools. There is no need to sacrifice accuracy to have a common simulation environment

Early validation is possible as system engineers can incorporate simulation models early on in the design process.

The outputs of the system simulation also benefits each discipline: – Power Electronics designers have realistic temperature operating

points – Software developers can test codes also with realistic hardware

models early on – The exact same control model can be implemented as it is in the

hardware plant. – Mechanical and Thermal engineers have knowledge of accurate loss

values and distributions

Takeaways

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Development of a Electric Drive considering the power electronic design and the embedded control development

Electrical Drive Example

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An incremental approach to design the system is used

Electrical Drive Example

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Level 1: Open loop control, behavioral electric

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Level1: system validation

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Level4: Close loop control, Detailed Electrical

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Level4 system validation

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We have illustrated our system strategy, combining Embedded software development with power electronics hardware design.

The SCADE Suite model that is used at the simulation level is the exact same one that is going to be implemented in the controller.

We have yet to implement more detailed models of the different hardware components that are typically designed using 3D simulations

Conclusion