Mechatronic simulations with NX Motion and MATLAB/Simulink

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Companies today face a growing need for mechatronics i.e., integration of mechanical, electrical and software components as well as systems into a product. Mechatronic simulation can reveal potential problems that may arise when these systems are integrated, allowing multiple iterations on design alternatives and a faster, more efficient development process. This paper describes how NX Motion software can be used to perform controller integrated simulations for complete mechatronic machine analysis.

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Contents
Introduction........................................................................................ 3 Highlights of NX 6 Motion simulation ................................................. 4 Modeling of mechanics in NX Motion ................................................. 5 Co-simulation in NX 6 Motion ............................................................. 7 Controller integrated simulation......................................................... 8 Modal analysis and system identification procedure .......................... 9 Tuning a speed and position controller ............................................. 11 Mechanical design optimization ....................................................... 13 Material change ............................................................................13 Dimension change.........................................................................14 Conclusion and perspective .............................................................. 15 References ........................................................................................ 16

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Introduction
There are many unknowns during the design phase of a machine development cycle. Will the machine meet the requirements? Will it achieve the productivity and precision expected by the end-user? Unfortunately many of the questions can be first answered only when the prototype of the new machine is built. The efforts to develop a prototype which needs changes and design iterations are tremendous compared with the time needed to build a simulation. The question is how accurately can you predict the dynamic behavior of the product using only a simulation model? Is simulation less costly than building and fixing afterwards? What is the probability that, once the machine is optimized, the first prototype will be the final machine? There is no universally true answer. One thing is sure though: simulation can decrease the time-to-market enormously as well as save money in the development phase. Today software companies offer tools which make it easy to build realistic simulations of a motion-based product. One of these tools is NX Motion software, part of the NX suite of Siemens PLM Software. NX Motion simulation has the ability to offer fast and realistic results for the dynamic behavior of a machine modeled in almost any 3D CAD software. With the release of NX 6 the user can integrate the mechanical simulations with the controls and drives by using any Matlab/Simulink control structure in a co-simulation environment. Matlab and Simulink are developed by The Mathworks, a leading provider of software for technical computing and model-based design. Thus, the complete machine dynamics is considered for dynamic analysis and, with that, the machine performance can be easily predicted and analyzed. To reach the maximum performance with a machine, the control system has to be designed and tuned specifically for this machine.
Figure 1: The major cost is defined in the development phase. The highest gain for savings in the final machine costs is during the development phase. Simulations can help to identify the best machine concept faster.

In order to use control optimization theory, the plant dynamics should be first analyzed and converted into a useful model for further solving complex differential equations. The analysis requires the extraction of all important modes and mode-shapes of the mechanical system. This permits a state-space formulation of the system between a vector of torque/force inputs (one for each actuator) and a vector of several speed/position outputs, measured at different points in the system. Once the input-output dynamic representation of the mechanics is completed, it becomes the plant element to be used further for controller optimization in the next steps of the mechatronic design process. A good mechatronic simulation reveals issues in the product early in the development process, allows multiple iterations on design alternatives and helps bring a product faster to the market with less development cost, higher precision and increased productivity. The purpose of this paper is to describe how NX Motion can perform controller integrated simulations for complete mechatronic machine analysis.

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Highlights of NX 6 Motion simulation

To prevent a development disaster, a mechatronic design approach must be used to verify implementation concepts very early in the design phase. NX offers a complete environment to do that seamlessly. The steps of doing mechatronic design with NX could be summarized as follows: a) A mechanical 3D model represents the input in the design process; this model is usually created by mechanical designers and can be executed in the NX Modeling environment. b) Once a 3D model of the machine is completed, the mechatronic engineer switches to the NX Motion environment and builds the functional model by creating bodies and connections between the machine elements in motion. This represents the multi-body-dynamics simulation phase where the machine is supposed to be open-loop controlled under ideally shaped excitation inputs. c) This simulation model is used to run a model identification process in co-simulation with Matlab. The system is identified in a mathematical view by defining the relationships between inputs, outputs and states. It becomes one component of the closed-loop control model which allows running the machine under real production conditions, while optimally tuning the controller for maximizing the performance. d) Finally, a complete controller integrated simulation is run to validate the controlled dynamic behavior of the product. This simulation shows the performance of the product and further development steps can be decided easily. Before NX 6, machine simulation capabilities were ended at step b). Although less complicated, they could offer only a vague and ideal image of how the mechanics would behave in the real world. The overall mechatronic design approach is more complex, but fits the reality much better. The mechatronic engineer now takes charge of the design: he has the know-how and the ability to analyze the connections between different disciplines of mechanics, electronics and controls. With NX 6 Motion and Matlab he can finally produce the real-life simulations and close multiple iterations on the development spiral for approaching the quality needed in product delivery. In summary, a controller integrated simulation with NX Motion offers the following benefits:
Fast overview about the dynamic behavior of a

new machine concept

Decreased time-to-market for new machine designs Fast and easy validation process of the best

controller system
With NX, only one software for modeling, multi-

body-simulation and FE analysis

Fast and realistic simulation results with the NX

Motion environment without complex FE analysis

Reduced installation time for a new machine,

because controller pretuning can be done in advance

To prevent a development disaster, a mechatronic design approach must be used to verify implementation concepts very early in the design phase.

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Modeling of mechanics in NX Motion

the NX Motion simulation model and no adjustments are necessary. Setting up correct stiffness and damping data requires some experience. In very few situations data is available from catalogues, but practice shows that catalogue data is seldom accurate and consistent with real-life measurements. For a reliable simulation result spanning the bandwidth of the motion profile, the low stiffness values responsible for producing the lower mechanical resonances are more important than the high stiffness connections. Flexible bodies are yet to be easily simulated in NX 6 without making some changes in the mechanical structure (this capability will improve in a future version of NX). A designer should identify the elements that present important flexibilities (i.e. low stiffness values) for the system and modify them so those stiffnesses are taken into account as connections between multiple subelements or bodies. If influence of the flexible bodies is significant, the Advanced Simulation environment of NX can be used to perform more complex FE analysis of the part. In short, to build a mechatronic simulation from any 3D CAD data, do the following steps:
1. 2.

Figure 2: Model of the mechatronic demo unit.

For a reliable simulation result spanning the bandwidth of the motion profile, the low stiffness values responsible for producing the lower mechanical resonances are more important than the high stiffness connections.
To illustrate the mechatronic design and simulation process, a real machine example is further presented. This machine is a mechatronic demo unit (Figure 2), which was built by our group for demonstration purposes. It mainly represents a two-mass oscillator built around two motors (one which acts as a pure inertial load) connected axially with a flexible aluminum rod. CAD models are pure geometry. They show an unconnected, surfaces-and-lines representation of an assembly. For a dynamic simulation, elements of the design must become bodies with a precise mass and/or inertia, a certain degree of flexibility (when necessary) and connected by elements that permit movement along the rigid-body designed direction of motion and suppress the appropriate degrees of freedom with the correct rigidity and damping. In dynamic simulations, a successful matching of the simulation to reality is the result of how accurately the following three sets of parameters are defined:
Mass/inertia of links (bodies) Stiffness/damping/friction of the connections

Define links (bodies) of the motion mechanism. Define joints (bearings, mountings, etc.) of the motion mechanisms and degrees of freedom. Set up connections between the links with generalized stiffness objects called bushings. Identify flexibilities (flexible bodies) and split them into smaller rigid bodies to be connected through a bushing element. Include parts (bodies) which are not coming with the 3D model, but may be important for the simulation (e.g. the encoder system which is connected to the motor implicitly).

3.

4.

5.

between bodies
Flexibility of the bodies that cannot be

considered rigid The mass and/or inertia of bodies are inherited from the 3D model. If the correct material properties are set by designers, mass information is transmitted to
Figure 3: Simulation model of the mechatronic demo unit.

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The process is illustrated in the following model. The only degree of freedom (rotation) is handled by two revolute joints which are connected between the rotor and stator on both motors. The suppressed degrees of freedom are made of bushing elements with a defined rotational and Cartesian stiffness. Obviously, only the rotational stiffness matters most. If the geometry of the model is correct and the right material is chosen, NX will calculate the mass and inertias by itself. However, in NX Motion the user can define for each link the mass and inertia, overwriting the calculated data from the geometry. The electric motor presents a special case. Due to its complex construction with multiple materials, the rotor inertia cannot be calculated automatically, using material density data. Therefore, the motor inertia must be entered manually, using the values offered by the manufacturer in its catalogue. In Figure 4, the inertia and stiffness values for the bodies considered in our model are presented. Our observations showed that the first approximation of the system with an automatic calculation of inertias and entering rough stiffness values yields very good results for the low eigenfrequencies of the system, which are critical for our system dynamic analysis. Hence a conclusion can be drawn: the original CAD data, containing just the geometry, would give good results in a complete mechatronic analysis as a first approximation model. This first approximation takes a minimal time, thus the system optimization can be run shortly after finishing the 3D model draft.

The original CAD data, containing just the geometry, would give good results in a complete mechatronic analysis as a first approximation model.
Inertia [106kgm2] 30 820 5100 12 12 5400 850

Element Encoder Motor Chuck_Motor Shaft_Motor Shaft_Load Chuck_Load Load

Connected to Motor Chuck_Motor Shaft_Motor Shaft_Load Chuck_Load Load

Stiffness [Nm/rad] 9 50000 600 70.3 600 50000

Figure 4: Inertia and stiffness values for the mechatronic demo setup (w/o shaft flexibility).

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Co-simulation in NX 6 Motion
The co-simulation function of NX 6 Motion makes it possible to combine the mechanical plant model with the drive and controller model in a mechatronic simulation. With the ability to integrate the controllers into the mechanical NX model, you can optimize the dynamics of the system. To run a controller integrated simulation the following steps are required:
1.

Define the mechanical model as described in the section above. Define the controller scheme file (Simulink file .mdl) in the NX solver parameter dialog box. Define sampling time for the controller in NX. Run the control integration: Drag-and-drop the NX Motion plant block in Simulink into the controller scheme, connect the inputs and outputs and save the file (Figure 5). Solve the co-simulation.

2.

3. 4.

5.

The results of the simulation can be displayed in NX 6 or can be saved during the co-simulation to a Matlab file (.mat) as well. To save the signals for Matlab is a great benefit for the user, because all Matlab functions for controller tuning or signal analysis can be used later, outside the co-simulation environment, without constantly switching between Matlab and NX. This functionality also allows a total modal analysis of the mechanical NX simulation model as described in the next section.

Figure 5: Run the control integration.

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Controller integrated simulation

The major benefit of NX 6 Motion is the ability to accept Simulink-driven inputs and pass system outputs back to the Matlab environment for a controller integrated simulation. The input-output relationship is encapsulated in the plant block which is solved every simulation time step. Once the Matlab simulation is over, the user may observe the results using NX animation and trace capabilities. This implies that every time users change parameters in the control loop, although they never changed the mechanics of the plant, a new Simulink file needs to be created, saved and run in the background, waiting for the results to become available in NX. Many times the mechanics dont change and the purpose of the simulation is to optimize the controller parameters and trace the output behavior under different motion inputs. For this, we would need to permanently have the input-output dynamic behavior of our plant stored in a Simulink block and, without opening NX, run the whole simulation process directly from Simulink. In order to extract the dynamics of the mechanical plant and have it available for simulation purposes exclusively in Matlab, we have to identify and then estimate the mechanics using the following procedure.

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Modal analysis and system identification procedure

also used in the field by Siemens drives to test and plot frequency response functions on machines. We shall reproduce the same procedure of identification via a PRBS type test signal applied to the input of our NX model. The signal shape is created with a tool created in Matlab allowing generation any time a domain vector of various input signals (impulse, step, sinus, square wave, chirp, noise and PRBS). The signal is applied in a co-simulation template file, completed by integrating the NX plant block and by saving output data of the simulation. A system identification and a model estimation are then performed and the frequency response function plotted, as depicted in Figure 6. After running a simulation within the co-simulation environment and collecting the input and output data, the model estimation technique can be used to get a linearized state-space representation from the simulation model. If necessary this can be done for several operation points and a chain of model representations can be created. This allows verifying the controller performance over a wide range of operation. The estimation process with NX Motion and Matlab can be summed up in the following steps (starting after the mechanics are modeled in NX Motion, [see above]):
1.

Figure 6: Model estimation process with NX Motion and Matlab.

To simulate a system, an input-output model must be identified and implemented in a mathematical form. Some identification methods use the time domain input and output data of the system; other methods use the frequency domain input and output data to generate frequency response function representations of the system. The latter process is also known as modal analysis and offers a representation of the dynamic characteristics of a system, its eigenfrequencies and eigenshapes. Modal analysis is generally associated with modal testing. Modal testing is a process to determine the dynamic characteristics of an existing structure/system via measuring its frequency response function (FRF). To produce an FRF the system must be excited with an input signal that encompasses a sufficiently large frequency spectrum and measure the output for further correlation. There are many signal types which can be used for modal analysis, e.g. impulse, noise, chirp, sinus, PRBS, etc. A PRBS (Pseudo Random Binary Signal) is a random sequence of impulse functions and has a white noise-like characteristic which excites all frequencies. PRBS is

Integrate the NX Motion plant block into the Simulink template for system estimation. (Figure 6) Define an input signal and save it in the input1.mat file. Solve the co-simulation in NX Motion; the output.mat file will be created automatically. Estimate a state-space system from the frequency response function of the plant using the input and output data, where: MotorSpeed TFPlant = MotorTorque

2.

3.

4.

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The frequency response can be obtained also from the real system, using the embedded capabilities of Siemens drive systems. Figure 7 shows the real system FRF (blue) versus the simulation model (which is shown in Figure 3) FRF (green). As the simulation model matches very well the characteristics of the real machine, we conclude that it can be used for all further calculation. From the calculated FRF, using simple identification procedures available in Matlab, the system matrices (A, B, C and D) can be obtained for a complete state-space representation.

Figure 7: Bode diagram of the simulation model (green) and the real machine measurement (blue).

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Tuning a speed and position controller

Now, the controller design can be completed either using NX as the main interface and run Simulink in the background, or directly in the Matlab/Simulink environment by exporting the plant model into a discrete state-space block, containing the identified matrices A, B, C and D. To exemplify we designed a simple speed and position control system for our mechatronic demo. This controller scheme contains a proportionalintegral (PI) speed controller and a proportional (P) position controller which are sequenced in a typical cascade structure. Both representations are equivalent, but the advantage of the first one (Figure 8) is that the state-space representation of our system allows controller tuning only in Simulink, without driving the simulation from NX. Once the controller is tuned and the output characteristics meet the requirements, we can animate the whole system by running a co-simulation from NX Motion, using now the optimized parameters of the control structure. Figure 10 compares the differences between the system responses to a similar ramp profile in position using the state-space model (blue) and the NX plant block (red). The two responses superimpose very well thus we can say that the difference between using the state-space model of the plant or the NX plant block is negligible, and the two methods can be used interchangeably with identical results. Mechatronic optimization and tuning of control systems improves the closed-loop characteristics of a machine. Without much detail on tuning principles (outside the scope of this paper) the results of the tuning process are described below. The difference between two controller settings, a good and a bad parameter set, is shown in Figure 11.
Figure 10: Ramp response of the tuned controller with the state-space model and the NX Motion block. Figure 8: Simple position and speed control system in Simulink with the estimated state-space model.

Figure 9: Simple position and speed control system in Simulink with the NX Motion plant block.

Kv [1/s] Poorly tuned Well tuned 12.00 35.00

Kp [Nm*s/rad] 2.00 5.00

Tn [Ms] 30.00 10.00

Figure 11: Controller parameters.

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Figure 12: Frequency response of the speed controller system.

Figure 14: Step response of the speed controller system.

Figure 13: Frequency response of the position controller system.

Figure 15: Ramp response of the position controller systems.

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Mechanical design optimization

Most of the dynamic performance required in the design specifications can be influenced by optimally tuning the controller loops. But, dynamics is not always going to be dramatically improved by tuning. Achieving a specified machine dynamics depends mostly on the mechanical structure and the motion input profiles. During the conceptual phase some changes in the mechanics may be necessary to improve the dynamic result and the overall performance and productivity of the machine. The earlier in the design changes are made, the more effective will these changes be. A model can be re-used and modified in size and structure without incurring almost any manufacturing costs, scrapping parts or building new prototypes. Dynamics, thus performance and productivity, is influenced by the dimensions and the material properties (inertia/mass) of the bodies in motion as well as the connection properties (stiffness and damping) between them. To show how easily we can verify, predict and improve the performance of different concepts we created two case scenarios for our simple demo. In the first case we changed the material of the connecting rod from aluminum to iron and in the second case we doubled its diameter while keeping aluminum as the material. For both concepts the controllers were re-tuned and the performances were analyzed in comparison to the original system.
Figure 16: Effect of the rod material to the first eigenfrequency.

Through the higher eigenfrequency we can increase the Kv gain of the controller and hence increase the performance of the system. New Kv = 48 S
-1

Material change
A material change will affect the both the inertia and stiffness of the rod. NX does the inertia calculation automatically. The rod stiffness, however, with the new material conditions needs to be recalculated and manually updated. The stiffness of a cylindrical rod is proportional to the shear modulus of the material. Between the shear modulus of aluminum and iron is a factor of 2.987 which we can use to recalculate the stiffness. Now we can look at the influence of the material to the first eigenfrequency. Thus the eigenfrequency will increase by 46 percent.

Figure 17: Effect of the rod material to the ramp response performance.

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Dimension change
A change in dimensions will also affect the inertia and the stiffness of the rod. The inertia and the stiffness of a cylindrical rod are proportional to d4, where d is the diameter of the rod. This means that a rod with a double diameter will be 16 times stiffer than the original rod and having 16 times the inertia of the original rod. Now we can recalculate the stiffness and inertia for the rod and investigate the influence to the first eigenfrequency. We can also remodel the rod and let the calculation of the inertia be done by NX. With the diameter change the first eigenfrequency will double.

This system allows us to increase Kv to the following value. New Kv = 70 S

-1

Figure 19: Effect of the double rod diameter to the ramp response performance.

Figure 18: Effect of the diameter of the rod to the first eigenfrequency.

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Conclusion and perspective

The purpose of this paper was to show the capabilities of NX 6 in performing mechatronic design and simulations. Here is a summary of features and functionalities that NX 6 offers to the mechatronic engineer:
A strong Matlab/Simulink co-simulation

environment as the basis for any mechatronic analysis

System identification methods can be applied to

estimate a state-space model of the mechanical plant

Estimated state-space models can be used for

Figure 20: Functions and the derived capabilities of NX 6 in co-simulation with Matlab.

controller design and tuning. This gives the ability to perform the whole tuning process exclusively in Simulink, use Matlab functions for controller tuning and reduce dramatically simulation times, compared to the intrinsic co-simulation feature
Validation and visualization of the controlled

system using NX Motion

Quick validation of mechanical changes and

efficient system optimization

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References
1. H.Gro, J. Hamann, W. Wiegrtner: Elektrische Vorschubantriebe in der Automatisierungstechnik, Siemens AG, 2006 2. J. He, Z.-F. Fu: Modal Analysis, Butterworth-Heinemann, 2001 3. Lunze, Jan: Regelungstechnik 1, Springer-Lehrbuch, 6. Auflage 2007 4. Katayama, Tohru: Subspace Methods for System Identification, Springer-Verlag London, 2005 5. Matlab/Simulink R2007b documentation 6. NX 6.0 documentation

Authors Razvan Panaitescu and Mathias Oppelt, from Siemens Energy & Automation, work in the area of Mechatronic Support. Mechatronic Support is a technical consulting service which is offered to Siemens customers to optimize machine performance using controllers and drives from Siemens.

Contact information: razvan.panaitescu@siemens.com mathiasoppelt@siemens.com

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About Siemens PLM Software

Siemens PLM Software, a business unit of the Siemens Industry Automation Division, is a leading global provider of product lifecycle management (PLM) software and services with nearly 6.7 million licensed seats and 63,000 customers worldwide. Headquartered in Plano, Texas, Siemens PLM Software works collaboratively with companies to deliver open solutions that help them turn more ideas into successful products. For more information on Siemens PLM Software products and services, visit www.siemens.com/plm.

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