On the way to purely virtual simulation and verification of complete heavy equipment, including construction sites
In the development of heavy commercial vehicles such as construction trucks, wheel loaders, excavators, it is extremely expensive, if errors are discovered only at the prototype. Simulations of complete heavy machines and their locations could therefore save time and money.
The simulation of a complete heavy machinery including construction site can be development time and cost savings
The use of electronic and electro-hydraulic systems for heavy equipment is now the one determined by legal requirements such as more stringent emission standards for ANIMAL-4 engines in the United States or regulations for noise emission. Second, the requirements of the customers in terms of increasing performance and productivity of the machines.
Also enables the electronic self-diagnosis of the devices. Through them can be reduced downtime, and utilize numerous security features such as locks.
Customers or machines manufacturers can take advantage of these benefits through the integration of individual electronic systems. This integration also opens the way for autonomous vehicles, eg for agricultural machines, which travel in straight lines, without the operator controls it.
Heavy-duty vehicles operate autonomously soon
The next step will the integration of different kinds of machines in a completely autonomous, site-based system, called a "system of systems". In the future there will be vehicles, for example, automatic handlers, which determine their own next excavation site, or automated trucks that transport their cargo alone at a predetermined location for further processing. Already in 2020, such independent sites or locations are spread as far as now automated tractors.
Increased complexity makes optimization more difficult
In conventional development process, engineers rely on physical devices to optimize design and validate new concepts. The addition of electronic functions in a heavy equipment, which itself represents a nonlinear interaction of different systems and physical domains, increases the complexity of extreme. Machinery and performance optimization predictions thus become extremely difficult tasks.
The more complex the system, the higher the time and costs
The increased design complexity can turn the time and money to test the various possibilities exponentially fast in the air. It is also difficult to determine when enough tests have been carried out to complete verification of the engine performance. At the same time, competition is forcing manufacturers to reduce development costs and shorten development time.
In order to withstand the pressure from both sides, manufacturers are choosing a holistic approach to the development of their machines: put in the machine design and development process amplifies a simulation. They also use virtual prototypes rather than physical prototypes for testing.
Simulations are now an integral part of development
During the past ten years, domain-specific simulations at the component and system level to a common element of the development processes for mechanical, hydraulic and electrical components and systems have become. Since these tools are domain specific, however, it is difficult to estimate the interactions between the different systems. The verification of machine performance without severely limits the use of physical devices.
Correcting errors of physical prototypes is expensive
Previously you could only ensure that a heavy machine works according to the draft by draws physical prototypes of the machines. As anyone can attest to the tests involved engineering, correcting design errors on a prototype of one of the most expensive elements in the design process. If the error during this phase are not detected by tests and get to production phase remain, this can lead to enormous warranty and repair machinery costs and dissatisfied customers.
Errors should be detected as soon as possible
The longer a design flaw in the development process remains undetected, the more expensive it becomes to fix it. Therefore, the detection of errors at the beginning of the process before the metal is cut and the equipment is delivered to develop the most cost-effective means of heavy machinery.
Supplementary + on MATLAB and Simulink in detail
The main features of MATLAB are: advanced programming language for scientific and technical ...
The main features of MATLAB are:
Advanced programming language for technical computing
Development environment for managing code, files and data
Interactive tools for iterative exploration, design, and the solution of problems
Mathematical functions for linear algebra, statistics, Fourier analysis, filtering, optimization, and numerical integration
2D and 3D graphics functions for visualizing data
Tools for building custom graphical user interfaces
Functions for integrating MATLAB based algorithms with external applications and languages like C / C + +, Fortran, Java, COM, and Microsoft Excel
Simulink main features:
Extensive and expandable libraries of prefabricated blocks
Interactive graphic editor for creation and management more intuitive block diagrams
Management of complex designs through hierarchical segmentation models in sub-components
Model Explorer to create, configure, and search all signals, parameters, properties, and the generated code from the model
APIs (Application Programming Interfaces) for integration of other simulation programs and to integrate hand-written code
Embedded MATLAB function blocks for the integration of MATLAB algorithms in Simulink models and implementations of Embedded Systems
Simulation modes (Normal, Accelerator and Rapid Accelerator), which is interpreted or simulations run at the speed of compiled C code can be, this solver available with fixed or variable step size is available
Graphical debugger and profiler to examine simulation results and the subsequent diagnosis of performance and unexpected behavior in draft
Access to all functions available in MATLAB for analysis and visualization of results, to adapt the modeling environment and defining signal, parameter, and test data
Tools for model analysis and diagnoses that ensure model consistency and detect errors efficiently modeling
The simulation shows that the specifications are met
Since the MATLAB and Simulink environments also make it possible to link the machine requirements to the model, test cases can also be defined in accordance with the requirements. Based on the simulation results can be determined if the machine is sufficient or not. The model thus represents an executable system specification for the machine; for
Today, physical and virtual methods used
As the chart shows, developers can now perform some simulations on system level and use the results to a certain level verification, regardless of whether a real test model is available. Given the complexity of the simulation of certain complex dynamics that occur in interactions with earthmoving equipment, we can verify the engine power remains both virtual as well as physical methods.
Virtual verification and validation of autonomous sites
In the autonomous construction sites or sites of the future more of these autonomous machines will be used. This requires a development environment in which the individual power and the interactions between individual machines without the use can be reviewed and validated by physical machines.
This environment provides a platform for rapid design iterations may be different parameters to optimize the overall performance changed simultaneously on the site. In the process engineers an insight into the effects of design decisions on the construction site and power. The result: you see design errors early on and can focus on the impact of the machine to the performance of the construction site.
Simulation of complete machines and their locations
The biggest advantage that comes with it is this early review is that physical machines are only made when the machines and site performance are confirmed by the simulations. This reduces costs and time required for the production of several prototypes. For the year 2020 should be the lofty goal of the industry, the simulation of complete machines and their locations. Then physical machines will be manufactured and used, if all requirements are met virtually secure.
To achieve this great goal, The MathWorks will continue to develop simulation technology that enables this integrated environment. The heavy equipment will thus be possible, on time and within budget to produce machines that provide an optimum combination of safety, productivity and uptime.
* Sameer Prabhu Industry is marketing director at The MathWorks
