Virtual Prototyping of Aerospace Systems Using Integrated LMS Virtual.Lab and IMAGINE AMESim

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1 Virtual Prototyping of Aerospace Systems Using Integrated LMS Virtual.Lab and IMAGINE AMESim Joel Tollefson Imagine Inc. Aerospace Business Development Hans Van den Wijngaert LMS Product Manager Motion LMS 2006 USER CONFERENCE 1

2 Abstract: LMS and IMAGINE S.A. have announced a partnership to develop an integrated virtual prototyping solution for mechatronic system analysis based on LMS Virtual.Lab Motion and IMAGINE AMESim. The combination of AMESim's dynamic systems modelling and simulation capabilities with Virtual Lab Motion's 3-D multi-body dynamics and kinematics will provide an integrated solution that will improve product development of complex mechanical systems. This integrated environment delivers interoperability between LMS Virtual.Lab and IMAGINE AMESim. It enables engineers to use AMESim to build high fidelity models of hydraulic, pneumatic, mechanical, electric drive, and control systems and seamlessly interface this with 3-D mechanical models and run the simulations and analyses all within the common environment of LMS Virtual.Lab Motion, which also integrates CAD geometry from CATIA, and structural dynamic data from CATIA FEA, Nastran, ANSYS, Permas,.... This presentation shows the many advantages in using the combined tools including, coupling the dynamics of controls and mechanical systems, providing full 3-D motion with animation, and using design of experiments and optimization tools to improve product design and performance. As time permits, several examples will be given to illustrate the application of the integrated software products to aerospace, automotive, and heavy machinery systems. LMS 2006 USER CONFERENCE 2

3 Presentation Topics! Aerospace product development needs and issues! Solution: LMS and IMAGINE partnership for the integration of V.L Motion and AMESim and application to product development! Overview of AMESim! Example of an integrated AMESim and V.L Motion environment for complete virtual systems modeling and simulation of aerospace systems LMS 2006 USER CONFERENCE 3

4 Aerospace Product Development Lower Use of CAE Tools Higher Conceptual Preliminary Final Verification # of problems solved Industry Needs! Shorten design cycle! Reduce cost! Improve quality! Reduce risk & liability Increase application of CAE tools Hardware Testing Design process LMS 2006 USER CONFERENCE 4

5 Industry Process Iron Bird Physical Testing Flight Controls & Actuation Sizing & layout Sizing & layout Kinematics & Dynamics Kinematics & Dynamics Iron Bird: Systems Integration & Functional Test Real-time Environment LIMITATIONS: - Limited to ground testing - Late in design cycle - Extreme cost (>$1B) Control System Control System External Loads External Loads LMS 2006 USER CONFERENCE 5

6 Industry Process Landing Gear Development Conceptual Preliminary Final Verification Design Virtual Test Lab Verification Full Aircraft Full Aircraft Full LG Simulation Full LG Simulation Flight Tests Flight Tests Subsystem Subsystem Virtual Drop Virtual Drop Drop Tests Drop Tests Component Component Stress Analysis Stress Analysis Component Tests Component Tests Correlation Correlation LMS 2006 USER CONFERENCE 6

7 Modeling & Simulation Requirements! High fidelity physicsbased models Jack Model! Multi-Domain! Multi-Disciplines Power Actuation Power Actuation Multi-body Dynamics Controls Electric Drives Electromechanical Hydraulics Pneumatics Mechanical Control Systems Structural Dynamics Aero Loads Fluid Power Actuation Electric Power Actuation LMS 2006 USER CONFERENCE 7

8 Example of Modeling Requirements Application: simulate oleo-pneumatic landing gear for generating ground loads High Fidelity Multi-Disciplines Multi-Domain! Controller Model! Oleo-pneumatic strut! Gas/pneumatic dynamics! Fluid dynamics with compressibility! Thermal effects Schematic view of Oleo strut Gas Oil! Mechanical model! Mechanical dynamics! Multi-body dynamics! Forces/torques! Structural dynamics Oil Oil LMS 2006 USER CONFERENCE 8

9 LMS and IMAGINE Partnership LMS Virtual.Lab Motion! Strategic partnership to integrate tools for complete systems modeling! Towards 1D - 3D integration for functional modeling! Data models AMESim Virtual.Lab DS s V.5 PLM (CATIA, SIMULIA )! Combined modeling environment! LMS Motion: common platform for integrating domains and tools! CAD CATIA V5, Pro-E, etc.! FEA structural dynamics NASTRAN, ANSYS! Controls Simulink! Systems (Mech., Elec., Hydraulic, Pneumatic, Thermal) AMESim LMS 2006 USER CONFERENCE 9

10 What is AMESim? 1-D Modeling & Simulation Lumped Parameter Time and Frequency Domains Simulation Platform (1D) LMS 2006 USER CONFERENCE 10

11 Collaborative System Simulation (CSS)! The simulation model is an assembly of components! Each component represents a function of the system (system dynamics)! The behavior of the component is described with analytical (mathematical) models! Multidisciplinary / Multilevel approach! We are mainly looking for dynamic responses and system performance LMS 2006 USER CONFERENCE 11

12 Advantage: AMESim Multi-Disciplinary Libraries Mechanical Hydraulics Pneumatics Thermal Electric Drives Electromechanical Cooling Air conditioning 2-Phase Flow Powertrain Engine Drive Exhaust 2500 Physical Models LMS 2006 USER CONFERENCE 12

13 How is AMESim different from Simulink? AMESim complements Simulink s control system modeling by providing high-fidelity physics-based plant models of multi-disciplinary systems. Primary use Strength Niche applications Matlab Simulink Control System Matlab/Simulink Control systems design and analysis tool Linear systems & finite state machine Real-time code generation AMESim Plant Model AMESim Physics-based plant modeling tool Highly non-linear & discontinuous systems Simulation of fluid power and mechanical systems AMESim AMESim Advantage Advantage Multi-disciplinary Multi-disciplinary libraries libraries better better suited suited to to plant plant models models Industry Industry proven provenlibraries built built by by experts experts for for nonexpertexperts non- Large Large development development & support support staff staff specialized specialized in in multi-disciplines multi-disciplines Model Model schematic schematic matches matches physical physical system system LMS 2006 USER CONFERENCE 13

14 AMESim in aeronautics LUBRICATION INJECTION ECS THRUST ACTUATORS BREATHING SYSTEM ENIGNE CONTROL STEERING BRAKING LANDING GEAR FLIGHT COMMAND LMS 2006 USER CONFERENCE 14

15 AMESim in aerospace VIBRATION PROPULSION COMBUSTION CONTRÔLE Hydrogen tank VIBRATOIRE STRUCTURE/FLUID COUPLING THRUST CONTROL Turbopump LOX Turbopump LH2 Gas Generator Regenerative Circuit SAFETY PROCEDURE HYDRAULIC ACTUATORS Combustion Chamber LMS 2006 USER CONFERENCE 15

16 History & Strategy of IMAGINE Multi-Physics & Optimization CAD & CAE Integration & Partnership Multi-Fluid & Interfaces Fluid Power Hydraulic Component Design Hydraulic Simulation Component Simulation System Simulation Collaborative System Simulation LMS IMAGINE PARTNERSHIP LMS 2006 USER CONFERENCE 16

17 Multi-Level/Multi-Disciplinary Solutions Lower Level of Model Fidelity Higher Conceptual Preliminary Final Verification Conceptual Level Functional Level Geometric Level Hardware Level LMS 2006 USER CONFERENCE 17

18 Multi-Level/Multi-Disciplinary Solutions Lower Level of Model Fidelity Higher Conceptual Preliminary Final Verification Conceptual Level Simple low-order systems-level approximation algebraic equations empirical data (tabular data) used to approximate performance S-function approach (LaPlace domain) to model dynamic response LMS 2006 USER CONFERENCE 18

19 Multi-Level/Multi-Disciplinary Solutions Lower Level of Model Fidelity Higher Conceptual Preliminary Final Verification Functional Level Detailed functional model of systems physics-based equations dynamics modeled using ODE and DAE component-based schematic matches real system Open Model LMS 2006 USER CONFERENCE 19

20 Multi-Level/Multi-Disciplinary Solutions Lower Level of Model Fidelity Higher Conceptual Preliminary Final Verification Geometric Level Multi-body dynamics kinematics capability mechanical motion and animation AMESim Animation Open Model LMS 2006 USER CONFERENCE 20

21 Multi-Level/Multi-Disciplinary Solutions Lower Level of Model Fidelity Higher Conceptual Preliminary Final Verification Geometric Level For complete geometric definition, interface AMESim with CAE tools for mechanical motion, LMS Virtual.Lab Motion include structural dynamics LMS 2006 USER CONFERENCE 21

22 Drop Test Example Integrated AMESim/V.L Motion Conceptual Preliminary Final Verification! Create detailed oleo-pneumatic strut model in AMESim! Specify and optimize orifice sizing and pneumatic & hydraulic data! Import AMEsim model as dll into V.L Motion! In V.L Motion, create rigid or flexible assembly! Specify drop height and impact angles! Use spun or stationary tire! Run virtual drop to determine energy absorbed! Calculate ground loads on aircraft structure AMESim Drop Test V.L Motion LMS 2006 USER CONFERENCE 22

23 Landing gear application : oleo-strut design Design Objective : design landing gear oleo strut that meets aircraft acceleration & loads specifications Challenges Accurate models of the 3D mechanical system can be built in Virtual.Lab Motion but without detailed hydraulics of the oleo-strut Hydraulics models can be be built in AMESim but to get the motion and force inputs right, a detailed 3D mechanical model is required Solution : Coupled MBS and hydraulics simulation with LMS Virtual.Lab Motion and AMESim LMS 2006 USER CONFERENCE 23

24 Hydraulics model oleo strut Schematic view of Oleo strut Gas Oil Oil The oleo strut contains 3 different chamber connected with orifices: 1) Cylinder chamber = Gas + Oil, gas = spring 2) Snubber chamber 3) Piston chamber Snubber orifices Main orifice Gas Cylinder Volume Oil Snubber Volume Piston Volume AMESim Oleo Strut Model LMS 2006 USER CONFERENCE 24

25 1D AMESim model of Landing Gear + Oleo Strut Starting Point : 1D AMESim Model of Landing Gear 3D Motion model with linear springdamper model for oleo strut Objective : connect AMESim oleo strut to 3D mechanism LMS 2006 USER CONFERENCE 25

26 Coupled simulation Actuator LMS Virtual.Lab Motion Master-Slave Simulation with Motion as master solver AMESim exports equations and LMS Virtual.Lab Motion solves AMESim equations Sensor Actuators Forces/Torques from hydraulics / electrical / 1D mechanical systems Mass & Inertia changes Sensors Translational displacement, velocity, acceleration Angular displacement, velocity, accelerations Motion curves, force elements LMS 2006 USER CONFERENCE 26

27 AMESim model modification Model modifications : Remove mechanical elements for Aircraft mass and tire spring-damper Insert VL Motion Interface Block and reconnect oleo-strut AMESim 1D Landing Gear Model AMESim Oleo Strut with Motion Interface Block LMS 2006 USER CONFERENCE 27

28 Compile AMESim model Compile AMESim model with the Microsoft Visual C++ compiler A *.dll model file is created in the working directory model parameters are written in the model directory Animation Open Model LMS 2006 USER CONFERENCE 28

29 LMS Virtual.Lab Motion model modifications Dist, Veloc Force Force Steps : Disable Oleo Spring-Damper element Define Sensor Values (Plant Output) RelativeDistance Relative Velocity of oleo-strut connection points Define Actuator Value (Plant Input) Action Reaction Force acting on oleo-strut connection points Define AMESim connection element = Define same inputs & outputs LMS 2006 USER CONFERENCE 29

30 Select AMESim model *.dll and run Motion solver Reference AMESim model *.dll Run the Motion Solver The Motion solver solves both 3D mechanical equations + AMESim hydraulics equations The Motion BDF (Implicit / DASSL ) solver is suitable for solving stiff hydraulics equations Regular AMESim results are stored during the motion run Animation LMS 2006 USER CONFERENCE 30

31 Motion animation Animation Motion results all Motion results are available : displacement velocities accelerations reaction forces tire forces the Input and Output nodes to AMESim can be displayed in the Motion 2D Displays LMS 2006 USER CONFERENCE 31

32 Visualize AMESim Results Animation LMS 2006 USER CONFERENCE 32

33 LMS IMAGINE Partnership Industries and applications! Automotive! Chassis controls! Steering systems! Closures Sliding doors, sunroofs!! Engine! Drive train!! Aerospace! Flight controls! Landing systems! Closures Cargo bays, doors!.! Construction and Agricultural Equipment!... LMS 2006 USER CONFERENCE 33

34 Summary! Integrated AMESim and V.L Motion provides a complete environment for virtual product development:! Multi-level modeling and simulation! Multi-disciplinary capability! Integration with V.L Motion provides 3-D geometry, multibody dynamics, structural dynamics and optimization! Advantage! Implement computer-based modeling, simulation and analysis earlier in design process to reduce risk and uncover problems! Less physical tests virtual iron-bird, landing gear drop tests! Reduces development time and cost LMS 2006 USER CONFERENCE 34

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