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1© 2012 The MathWorks, Inc.
Model-Based Design for Automation Systems
November 2012
Design and test your designs using simulation and automatically implement it on Allen-Bradley PLCs
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Mechatronic Systems
Robotic arms
Web applications– Printing presses– Steel rolling mills
Machines– Packaging machines
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Mechatronics integrates mechanical, electronic, control, and embedded software systems
Mechatronics
Mechanics Electronics
SoftwareControls
“Mechatronics is really all about design of any physical system, where you integrate controls, electronics, and computers from the very start of the design process.”
Prof. Kevin CraigMechanical Engineering, Marquette University
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Challenges of Designing Mechatronics
Source: System Design: New Product Development for Mechatronics, January 2008, Aberdeen Group
Problems uncovered
late
Multi-discipline
complexity
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As errors propagate through a project they become more expensive to fix in later phases
Requirements Design Coding Integration & Testing
Relative cost to fix an error
Project phase where error is fixed
Type of error: - requirements- design- coding
Source: Return on Investment for Independent Verification & Validation, NASA, 2004
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Engineers struggle to integrate multiple disciplines into mechatronic systems
Development challenges Optimizing the system across multiple
technical disciplines Detecting integration problems before
prototyping electromechanical systems
Integrating more software to provide improved features and performance
Mechatronics
Mechanics Electronics
SoftwareControls
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manroland Develops High-Precision Commercial Printing Press Controller
http://www.mathworks.com/company/user_stories/manroland-Develops-High-Precision-Commercial-Printing-Press-Controller.html
Video:
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Model-Based DesignDesign and test using simulation
DESIGN
RESEARCH REQUIREMENTS Modeled Physical Behavior of paper web
Environmental Models
Control Algorithms
Mechanical Electrical
Supervisory Logic
Designed controller and implemented it
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REAL-TIME TESTING
DESIGN
Control Algorithms
Supervisory Logic
Environmental Models
Mechanical Electrical
RESEARCH REQUIREMENTS
MCU DSP FPGA ASIC
Structured Text
VHDL, VerilogC, C++
PLC
Control Algorithms
Supervisory Logic
Model-Based DesignTest and validate in real-time
Modeled Physical Behavior of paper web
Designed controller and implemented it
Tested the controller in real-time on the press
10INTEGRATION
IMPLEMENTATION
TEST & VER
IFICATIO
N
DESIGN
Control Algorithms
Supervisory Logic
Environmental Models
Mechanical Electrical
RESEARCH REQUIREMENTS
MCU DSP FPGA ASIC
Structured Text
VHDL, VerilogC, C++
PLC
Control Algorithms
Supervisory Logic
Model-Based DesignImplement embedded software
Modeled Physical Behavior of paper web
Designed controller and implemented it
Tested the controller in real-time on the press
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Manroland
Overcame 3 challenges:– Modeled Physical Behavior of paper web– Designed controller and implemented it– Tested the controller in real-time on the press
Results:– Shortened development time by 50 percent– Ensured software for customers are error free– Saved time and money
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Problem to Solve
Logic for luggage conveyor belt at an airport
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Problem to Solve
Simplistic representation
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Today’s Workflow
RSLogixLD, FB, SFC, STManual Programming
Control Algorithms
Code compiled to
PLC
Validation is done using hardware
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Model-Based Design WorkflowDesign and test using simulation
Simulink & Stateflow
LD, FB, SFC, STManual Programming
Code compiled to
PLC
RSLogix
Control Algorithms
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Model-Based Design WorkflowTest and validate in real-time
Simulink & Stateflow
LD, FB, SFC, ST
Control Algorithms
Manual Programming
Code compiled to
PLC
Structured Text
Simulink PLC Coder
RSLogix
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Model-Based Design WorkflowTest and validate in real-time
Simulink & Stateflow
LD, FB, SFC, ST
Control Algorithms
Manual Programming
Code compiled to
PLC
Structured Text
ANSIC-Code
Simulink Coder
Hardware-in-the-Loop
Simulink PLC Coder
RSLogix
Real-TimeSystem
Machine Model
Validation is done using real-time
simulation
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Model-Based Design WorkflowImplement embedded software
Simulink & Stateflow
LD, FB, SFC, ST
Control Algorithms
Manual Programming
Code compiled to
PLC
Structured Text
Simulink PLC Coder
RSLogix
Machine Model
Final validation is done using hardware
