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Controls
Hydraulic
Magnetic
Thermal
Pneumatic Electro-
Chemical
Multi-Domain Design
Z Multiple Domains are interconnected and influence
each other
Z The electrical content of vehicles increases
Z More and more controls are involved
Z Electrical systems closely interact with other
domains
Z Electro-Chemical
Z Electro-Mechanical
Z Electro-Magnetic
Z Electro-Thermal
Challenge #2:
Multi-Level Design
Complexity
# of Components
INREG
+
vbus I_main
VBUS>=VSET V D1
VBUS<VSET VM1
EQU
OUTREG
vbus := VM1.V
vset NL1
GAIN2
sp GAIN NL
XY1 I1
engine2generator XY
dψ 1d (t )
v1d (t ) = i1d (t ) ⋅ R1 + − p ⋅ ω (t ) ⋅ψ 1q (t )
dt
dψ 1q (t )
v1q (t ) = i1q (t ) ⋅ R1 + + p ⋅ ω (t ) ⋅ψ 1d (t )
dt
Accuracy
Details
Multi-Level Design
Z Different analyses require different model accuracy
levels
Z Different analyses require different algorithms
Z Different accuracy levels require different modeling
languages
Z Model exchange from one level to the next higher
level requires model extraction
Z Design information must be exchanged between
different design groups
Challenge #3:
Multi-Organizational Design
OEM
System
Tier I
Subsystem
Tier II
Component
Multi-Organizational Design
Analysis Model
Electrical Circuit
Hydraulics
System
Integrator
Control
Mechanical
Component
Tier 1 Supplier
Supplier
Component Magnetic
Need for Integration
System
Component Circuit
Multi-Level
System
Electrical Integration Integrator
Tier 1 Component
Mechanical Control Supplier Supplier
Multi-Domain Multi-Organization
EM Design Environment
Maxwell2D/3D SIMPLORER Simulation Data Bus Simulink
Electromagnetism
Electro mechanics Simulator Coupling Technology
C/C++
MathCad
Interface
Model Database
Electrical, Blocks, States, Machines, Automotive, Hydraulic,
Mechanics, Power, Semiconductors…
Integrated Design Environment
WIN/2000
WIN/XP
WIN/NT
Pentium
>256MB
Compatibility
Z MS-Office compatible
Z Read and write Excel, Access
Z Copy & Paste to and from Word, PowerPoint,
Excel…
Z Windows Printing Support
Z Data Format compatible
Z ASCII
Z Access (*.mdb)
Z Excel (*.xls)
Z CSV (*.csv)
Z Comtrade (*.cfg)
Z SPICE (*.out)
Z TEK – Oscilloscope data (*.dat)
Post Processing
IEEE 488.2 Data
Interface (GPIB)
Graphical and
numerical data
analysis and
representation
Power Module
Channel Calculator
FFT
Presentation Mode
Matlab® and
Mathcad®
Integration
Component Characterization
A
M_LUT1
Data Transfer
• Characteristics Yt
B
M
3~
C
• Stimuli
IM1
• Loads
NL_Charact
Data Acquisition NL
V_LUT
L1 #
Yt
E1
C1 #
Data Processing
State Machines
Event driven
modification of Behavioral Modeling
topologies &
parameters
Online measurement
of characteristic
values
drvm com
Relay.Iin
14.00 Relay.Iout
E1 R1
E2 10.00
8.00
6.00
-2.00
0 0.20 0.40 0.60 t
E6
E5 R1pNoRs1
R3
Final Relay Model
Relay Model
AM1
+
drvp A
no
LCoil CCoil
drvm
com
ON_DIS
lon
• Fast!
EQU
Each block
can be
assigned an
individual
sampling time
or run with
system time
step
DC Motor Drive System
TR
D1 D2 +
D3 AM1
R_R A
L_R
0
0 0 100.00m T 50.00m 100.00m
20.00 N_REF
0 50.00m N
0 0
Motor Speed
-10.00 -10.00
0 50.00m 100.00m T
Automotive System Library
Automotive Library
Power Storages Fuses Spark Plugs PWM Models
Battery - Basic Model Fuse - Single Element Spark Plug PWM
Battery Fuse - Double Element Machines PWM Switch
Fuel Cell Fuse - Advanced Alternator - Transient Model PWM Load
Wires PPTC (Three RC combinations) Alternator - Average Model Flasher Switch
Wire - Thermal static PPTC (Two RC Combinations) Alternator - Current Source Connectors
Wire - Thermal dynamic Lamps Starter Inline Terminal Pair
Wire - Thermal dynamic II Lamp - Filament DC Machine Eyelet Terminal
Wire with Thermal Pin Lamp - Single Filament Mechanical Models Engine Models
Wire - Advanced Lamp - Double Filament Inertia Engine - Speed Source
Wire - Advanced II Lamp - Advanced Friction Engine - Dynamic Model
Gauge based Relays Fan
Wire - Thermal static Relay - Normally Open Ideal Gearbox
Wire - Thermal dynamic Relay - Normally Closed Gearbox with Losses
Wire - Thermal dynamic II Relay - One Pole, Two Throws
Wire with Thermal Pin Relay - Two Poles, Two Throws
Wire - Advanced Relay - Two Poles, Cross-Strap
Wire - Advanced II
Applications: Industries:
• Electrical Distribution • Automotive
System of Vehicles Manufacturer
• Power Management • EV/EHV
• Drive Cycle Analysis • Aerospace
• FMEA • Defense
• Statistical Analyses • Ship Building Industry
Automotive Library Yt
S2
Lamp Switch
Engine Block Ground To Head Lamp Switch
fuse1_5Amp
Yt
Turn Signal
S3 Yt
TS1_HIGH_LOW_Beams_Switch
rlyno1
itp19
Chassis
fuse2_15Amp Low High
Ground itp11
To Hazzard Flasher S1
D1 D2
tY
Tail
- + battery1 Lamps
Battery
QuickGraph1
t
14.00 N0161.V
10.00 60s
6.00
RH HeadLamp
2.00 High Low
-2.00
0 20.00 40.00 60.00 t
Low High
Turn Signal Voltages
LH HeadLamp
7.50
-2.50
0 25.00 50.00 60.00 t
Automotive Library
Z Benefits
Z Easy to use and intuitive graphical modeling
Z Easy parameterization using Wizard technology
Z Statistical analyses, optimization and parameter variations
Z Characterization tool for fuses
Z Multiple model levels for components
Z Web based example database with jump start projects
Z Animated symbols for easy visual inspection
Electro-Chemical Components
- +
Fuel - +
Cell Battery
Boost 0.1m D1
0
Converter VM1
+
V
TR1
RL
Output Voltage
- - RLoad
+ +
Fuel Battery
Cell
LBATT_A2
FUELCELL_A2
0 2.50m 5.00m 7.50m 10.00m 12.50m 15.00m 20.00m t
ICA:
period := 20u
6.10 VM1.V
SET: cs:=1 6.00
ST_r1
Transistor
5.90
On
5.80 Input Voltage
Control modeled ST_r1.VAL>=0.99 and L1.I<I_command 5.70
using state
5.60
L1.I>=I_command 5.50
machines Off
5.40
5.30
5.20
SET: cs:=0 5.10
0 2.50m 5.00m 7.50m 10.00m 12.50m 15.00m 20.00m t
current 12.00
modification
10.00
SET: RL:=5 SET: RL:=10 SET: RL:=5
8.00
0
0 2.50m 5.00m 7.50m 10.00m 12.50m 15.00m 20.00m t
Multi-Domain Design
• Hydraulics
• VHDL-AMS
• Mechanics
• Electro Mechanical
• Magnetics
• …
Hydraulic Library
r1 1 0
50
pk_1
Hydraulic Library
MASS_TRB1
VOL_ACT1
LIMIT_TRB1
PIPE Sharp-Edge
Level1 15.00m LIMIT_TRB1.SUL
Generic
MASS_TRB1.S
PIPE1 OR_SE1
10.00m
P1
0
0 0.50 1.00 t
Power Library
Power Library
Power System and Cable Models Inverter Topologies Applications:
Single Phase Power Supply
Ideal Three Phase Power Supply
Two Level Inverter Equivalent Circuit
Three Phase Two Level Inverter
• AC/DC Converters
Three Phase Power Supply with Impedance
WIRE - Gamma Model
Single Phase Two Level Inverter
Three Phase Three Level Inverter
• Inverters (DC/AC)
Wire T-Model Single Phase Three Level Inverter • Drive Systems
Line-commutated Converters DC Link
B2 Diode Bridge Control Algorithms • Power Quality
B2 Fully Controlled Two Level Square Wave
B2 Half-Controlled, Symmetrical Two Level Natural Sampling • Alternative Power
B2 Half-Controlled, Asymmetrical Three Level Single Phase
B6 Diode Bridge Three Level Three Phase
B6 Thyristor Bridge
B6 Bridges - Inverse Parallel Connection
Three Level Single Phase NS
Three Level Three Phase NS
Industries:
B12 Diode Bridge Four Quadrant Current Control • Industrial Automation
B12 Thyristor Bridge Parallel Connection Four Quadrant Natural Sampling
B12 Thyristor Bridge Cascade Load Models • Drives Manufacturers
B24 Thyristor Bridge Three Phase RL Load
Single Phase A.C. Chopper Logic • EV/EHV
Three Phase A.C. Chopper Dead Time
• Power Conversion
• Power Quality
Power Library
2L3_GTOS
Us1
Direct inverter
g_r2 g_s2 g_t2
Uf
2L_NSAMP
driven squirrel
2-level natural sampling
cage induction
Machine Characteristic Torque
1.60k
1.40k
350.00
300.00 machine with
2-level natural
1.20k
200.00
1.00k
CONST
800.00
KONST1
sampling
100.00 CONST
600.00
ein_aus
400.00 Omega
0
control and
200.00
SPR1
0 -100.00
-200.00 -150.00
-173.34 0 200.00 359.12 0 1.00 1.50
200.00
Stator Current
asm_k_g22.Is_d
asm_k_g22.Is_q
1.40k
Rotor Current
asm_k_g22.Ir_d
asm_k_g22.Ir_q
mechanical
0
-200.00
1.20k
1.00k load
-400.00 800.00
-600.00 600.00
-800.00 400.00
-1.00k 200.00
-1.20k 0
-1.40k -200.00
0 1.00 1.50 t 0 1.00 1.50 t
Power Library
Z Benefits
Z Predefined macro models of frequently used power
electronic topologies
Z Includes common control algorithms
Z Auxiliary elements, such as power grid models and loads
Z System level models for rapid computation of overall
system behavior, power quality and control algorithms
Z Easy and intuitive graphical building blocks
Mechanical Elements Library
Mechanical Systems
Rotational Coordinate Transformation
Mass Rotational-Rotational
Rigidity Rotational-Translational
Torque Source Translational-Rotational
Angular Velocity Source Translational-Translational
Ground Electrical Machines
Translational DCMP DC-Machine Permanent Excitation
Mass ASMS Slip Ring Induction Machine
Rigidity SYMP Synchronous Machine Permanent Excitation
Force Source SYMP Synchronous Machine Permanent Excitation w Damper
Velocity Source
Ground
Applications: Industries:
• Drive Trains • Automotive Suppliers
• Electro-Hydraulic • Drive Manufacturers
Systems
• Industrial Automation
• Electro-Mechanical
Systems • Defense
• Load Variations • Aerospace
Mechanical Elements Library
ET1
Square_wave1.VAL
Motor-generator
M Stf1 M M Stf2
Mas1
J
combination driving a
DCMP STF DCMP DCMP STF
mass with limitations
Dcmp1 Dcmp2 Dcmp3
J := 2m J := 2m J := 2m J := 10m
250.00 Dcmp1.VA
Dcmp2.VA
100.00 Dcmp3.VA
0
-100.00
-250.00
0 0.50 1.00 t
200.00 Dcmp1.OMEGA
100.00 Dcmp2.OMEGA
Dcmp3.OMEGA
0 Mas1.OMEGA
-100.00
-200.00
0 0.50 1.00 t
1.25k Mas1.MACX
500.00
0
-500.00
-1.25k
0 0.50 1.00 t
Mechanical Elements Library
Z Benefits
Z Non-linear friction models incl. stick friction
Z Non-linear rigidity models incl. backlash
Z Fast computing 1D modeling approach based on
SIMPLORER C-Code interface
Z Electrical Machine model implementation with mechanical
pins provide connectivity between electrical and
mechanical world
Z Schematic based graphical modeling with mechanical
building blocks
Multi-Organizational Design
External Simulators
AMS Circuit
Elements
VHDL-AMS
VHDL-AMS Schematic
Z Fully
supported by
SIMPLORER
Schematic
Z Embedded
Editor with
Syntax
coloring
allows to
create models
on sheet and
in the
ModelAgent
VHDL-AMS Code for a Resistor
ENTITY Resistor IS Resistor
PORT (
p m
QUANTITY r : REAL := 1.0e+03; -- Default = 1 K
TERMINAL p,m : ELECTRICAL); r := 1.0e3
END ENTITY Resistor;
Rbehav1
Entity and Architecture
Z Entity Z Architecture
Z Interface description of a Z Behavior description of the
subsystem or physical model
device Z Can be dataflow,
Z Specifies input and output structural, procedural, etc
ports to the model Z Modeling can deal with
both analog (continuous)
and digital (discrete)
domains
CLK C.val
A
CLK
XOR2
Sum
B SUM.y
XOR2
CLK
C
CARRY.y
Carry
AND2
0 2m 4m 6m 8m 10m 12m 14m 16m 18m 20m 22m 24m 26m 28m 30m 32m 34m 36m 38m 40m t
AND2 OR3
AND2
VHDL – Digital Systems
Complete Automotive System Analysis across Domains
• ASICs
• Micro Controller
• FPGAs …
ECU
PTCU
MCU
VHDL
VHDL-AMS Multi Domain Design
vm_rotb ω
+ crank_radius 1/pipe_area
CONST CONST
+ spring_rotb damp_rotb T
v_rotb ω fm_rotb torque force pressure
Spped
40 damp_rotb.omega
25
EQU
mass_rotb
0
pipe_area:= 0.05
Mechanic
-25 crank_radius:= 0.2
-40
0 50 0.1k t [s]
rho := MATH_PI
Fluidic k := 10 dia := 1
len := 1/4
L QuickGraph2
1Meg flow_meter.q
P rhyd1 lhyd1
flow_meter
0
chyd1
-1Meg
vol := 1 0 50 0.1k t [s]
b := 1
VHDL-AMS
Multi Organization Design
System Simulation
OEM Drive Cycles
Fuel Economy
VHDL - AMS
Subsystem Power Train
Providers - Electrical System
Suppliers Sensors …
VHDL - AMS
Component Solenoids, Motors,
Providers Battery, Sensors, Semiconductors,
Fuse …
DC Drive – VHDL-AMS Controller
0 0.1 0.2
TR 4.00e+001
AM1
A
R_R L_R
VHDL-AMS
2.00e+001 DCM.MI [N·m] 1.50e+003
TLoad.VAL
1.00e+003
0
motor torque
and speed and
load torque reference speed
-1.00e+001 0
0 0.1 0.2 t [s] 0 0.1 0.2 t [s]
DC Drive – VHDL-AMS Controller
C/C++ Interface
µ-Controller Electrical
Code Components
ODE
External
Simulators Non-
Electrical
Elements
C/C++ Interface
®
System Simulation
Dynamic
Link Symbol
C/C++ make
Library Library
.dll
Symbol Editor
DC Drive – C-Code Controller
0 0.1 0.2
TR 3.00e+001 DCM.IA [A]
AM1
A
R_R L_R 2.00e+001
DC Link
CONTR_OUT Voltage and
PIC1 LIMITER
Current
PIC LIMIT 5.00e+002
C-Code 1.00e+003
speed and
0
motor torque reference speed
and
load torque
-1.00e+001 0
• Co-Simulation Interface
• Link blocks in both Simulink
packages
• Using SIMPLORER's
external simulator
integration interface and
SIMPLORER
S-function in Matlab
• Co-Simulation Interface
is an open API that can
be used for other
simulation packages
Drive System Control
TR
+
AM1
A
R_R L_R
Bridge1
ET1 10m 0.3m TLoad
R_S L_S M D7
3
ET2
DCM
R_T L_T RA := 1.2
LA := 9.5m
ET3 KE := 0.544
J := 4m
R_R L_R
Bridge1
ET1 10m 0.3m TLoad DCM
R_S L_S M D7
3
ET2
R_T L_T RA := 1.2
LA := 9.5m
ET3 KE := 0.544
SIM2SIM1
J := 4m
SiM2SiM
50
SIMPLORER Link Interface
Drive System Control
Complete Vehicle Simulation
SIMPLORER – Advisor Link
SIMPLORER – Advisor Link
SIMPLORER Single Voltage Electrical Automobile System Template
GAIN
Generator Battery
generator
generator1
50
SiM2SiM
generic
generator
generic +
SIMPLORER Link Interface
generator A
AM1 +Battery-
p p
BatteryPower
GeneratorPower m m
Regulator LoadPower
voltage ® m p
regulator curve
Loads
RadiatorFan +
Engine Misc BrakeLights TurnSignal ExternalLights FrontWipers
V p
Starter
VM1
m
Simulation properties:
Step width max 100m RearWipers RearDefrost FrontHVAC RearHVAC HeatedSeats Radio
Step width min 100u
Simulation end time 1369
Results
Generator Current Speed in RPM
4.00k Speed
100.00 AM1.I
2.50k
0 0
-50.00
0 500.00 793.91 t -2.00k
0 500.00 793.91 t
12.00
-1.00k
-1.50k
0 500.00 793.91 t 11.50
0 500.00 793.91 t
Complete Set of Analyses
OP: -7.9752e-006 V
DC Analysis
OP: -0.00405477 V
NINV +
C1
100p R
OUT
INV -
15916 10k
NSC_LM_7411 OP: -3.98873 V
R1
OP: -0.00100994 V R9 R2 R4
OP: 1 V
OP: 0.999992 V 30k 10k 10k
NINV +
OP: 3.99573 V OUT
NINV + -
Rp INV
E1
15916 C2
OUT
+
INV -
R3 NSC_LM_7413
1n V VM
NSC_LM_7412 10k
R1p 30k OP: 0.000980576 V
10k
OP: 0.998936 V Rfp
R1
Complete Set of Analyses
L1
500m 3.18m
OP: 0.969697 V
OP: 0.969697 V
OP: 1 V R2 16
E1 1 OP: 0 V
C1 132.6u AC Analysis
L2 31.83m
Bode
Gain C1.V
[dB] 100 200 300 400 500 600 700 800 900 1k
20.00 20.00
0.00 0.00
-20.00 -20.00
-28.01 -28.01
100 200 300 400 500 600 700 800 900 1k f [Hz]
Phase
[rad] 100 200 300 400 500 600 700 800 900 1k
3.14 3.14
2.36 2.36
1.57 1.57
0.79 0.79
0.00 0.00
100 200 300 400 500 600 700 800 900 1k f [Hz]
Experiments
Z 1D, 2D & 3D Parameter Sweep
Z Monte Carlo
Z Sensitivity
Z Worst Case
Z Optimization
Z Simplex Algorithm
Z Successive Approximation
Z Genetic Algorithms
Disconnected Technologies
System
Block Diagrams/State Machines
OEM
Sub-System
VHDL-AMS
Circuits
Circuit Supplier
FEA
Component
ne /
hi ms
s
ac ra
Matlab/
M iag
Ci
rc
at D
Simulink
ui
St ock
ts
e
Bl
MathCAD
Simulator
Co-Simulation
Coupling
Advisor
VH
D
…
L-
E A
AM
F
S
Integrated Design Environment
Ac
rd
da
cu
an
rac
St
y
Co m
y
m
n c
u
e
n
i
ic
i c
a
ff
ti
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