1 © 2011 The MathWorks, Inc.

Model-Based Design for

Controls

2

MathWorks at a Glance

Headquarters:

Natick, Massachusetts US

Other U.S. Locations:

California; Michigan;

Texas; Washington, DC

Europe:

France, Germany, Italy,

Spain, the Netherlands,

Sweden, Switzerland, U.K.

Asia-Pacific:

Australia, China, India,

Japan, Korea

Worldwide training

and consulting

Distributors in 25 countries

Earth’s topography on an equidistant cylindrical

projection, created with MATLAB and Mapping Toolbox.

3

Key Capabilities Drive MathWorks Business

Founded in 1984

1985 1990 1995 2000 2005

• Rapid prototyping and HIL

• DSP designs • State charts • Physical modeling

• Discrete-event modeling

• Model checking

• Test and measurement

• Code verification

• Embedded software

• VHDL/Verilog

MATLAB

Simulink

• Control design

• Signal processing

• Image processing

• Computational finance

• Computational biology

• Application deployment

• Distributed and parallel computing

• Student version

• Optimization

• Statistics

Technical

Computing

Data Analysis

and Algorithm

Development

System

Modeling and

Simulation

Automatic

Code

Generation

Verification,

Validation,

and Test

• Instrument and database connectivity

• DSP software

• Communication systems

• Video processing

2010

• Qualification kits

• PLC code

• MATLAB Mobile for iPhone

4

1984 1989 1994 1999 2004 2009

MathWorks Today

Revenues ~$600M in 2010

Privately held

More than 2000 employees worldwide

Worldwide revenue balance: 45% North America, 55% international

More than 1 million users in 175+ countries

5

Key Industries

Aerospace and defense

Automotive

Biotech and pharmaceutical

Communications

Education

Electronics and semiconductors

Energy production

Financial services

Industrial automation and

machinery

6

Deeply Rooted in Education

Benefits for Industry:

Every year, tens of thousands of engineers enter the workforce with

MathWorks product skills and experience.

Students learn theory and techniques while using MATLAB and Simulink.

3500+ universities around the world

1200+ MATLAB and Simulink based books

Academic support for research, fellowships, student competitions, and curriculum development

“Everyone that comes in as a new

hire already knows MATLAB,

because they all had it in

college. The learning curve is

significantly lessened as a result.”

Jeff Corn,

Chief of Engineering Projects Section,

U.S. Air Force

7

Core MathWorks Products

The leading environment for

technical computing

The industry-standard, high-level

programming language

for algorithm development

Numeric computation

Data analysis and visualization

Toolboxes for signal and image

processing, statistics, optimization,

symbolic math, and other areas

Foundation of MathWorks products

8

Core MathWorks Products

The leading environment for modeling,

simulating, and implementing dynamic

and embedded systems

Linear, nonlinear, discrete-time,

continuous-time, hybrid, and

multirate systems

Foundation for Model-Based Design,

including physical-domain modeling,

automatic code generation, and

verification and validation

Open architecture for integrating models

from other tools

Applications in controls, signal processing,

communications, and other system

engineering areas

9

Migration Planning

Component Deployment

Full Application Deployment

Co

nti

nu

ou

s Im

pro

ve

me

nt

Consulting Services Accelerating return on investment

A global team of experts supporting every stage of tool and process integration

Supplier Involvement Product Engineering Teams Advanced Engineering Research

Advisory Services

Process Assessment

Jumpstart

Process and Technology

Standardization

Process and Technology

Automation

10

Training Services Exploit the full potential of MathWorks products

Flexible delivery options:

Public training available worldwide

Onsite training with standard or

customized courses

Web-based training with live, interactive

instructor-led courses

Self-paced interactive online training

More than 30 course offerings:

Introductory and intermediate training on MATLAB, Simulink,

Stateflow, code generation, and Polyspace products

Specialized courses in control design, signal processing, parallel computing,

code generation, communications, financial analysis,

and other areas

11

MATLAB Central

Community for MATLAB and Simulink

users

Over 1 million visits per month

File Exchange – Upload/download access to free files

including MATLAB code, Simulink models,

and documents

– Ability to rate files, comment, and ask questions

– More than 12,500 contributed files, 300

submissions per month, 50,000 downloads

per month

Newsgroup – Web forum for technical discussions about

MathWorks products

– More than 300 posts per day

Blogs – Commentary from engineers who design, build,

and support MathWorks products

– Open conversation at blogs.mathworks.com

Based on February 2011 data

12

Connections Program

More than 400 add-on products and services that

complement and extend MathWorks products:

Specialized third-party toolboxes for MATLAB

Interfaces to third-party software and hardware products

Specialized training courses and consulting services

System integrators and suppliers that incorporate

MathWorks products

13

Book Program

More than 1200 books for educational and professional

use, in 26 languages

Mathematics

Aerospace engineering

Environmental sciences

Chemistry

Finance

Electronics

Controls

Signal processing

Image processing

Biosciences

Communications

Mechanical engineering

14

Technical Support

Resources

Over 100 support engineers

– All with MS degrees (EE, ME, CS)

– Local support in North America,

Europe, and Asia

Comprehensive, product-specific Web

support resources

High customer satisfaction

95% of calls answered

within three minutes

70% of issues resolved

within 24 hours

80% of customers surveyed

rate satisfaction at 80–100%

15

MathWorks Product Overview

Simulink Product Family Application-Specific Products

View full product list

MATLAB Product Family

16

What are we doing today?

17

Host computer

with MATLAB

xPC Target on

Target Computer

xPC Target runs Simulink in hard real-time

Ethernet or RS 232

1

2

3

Environment allows the real-time execution of Simulink models on a

separate PC-based target computer

18

Today’s Agenda

Introduction to Simulink

Plant Modeling

Control and Real Time Testing

Closing remarks

19

Mechanical

Components

MCAD/

MCAE

Electrical

Components

EDA

INTEGRATION AND TEST

SPECIFICATIONS

DESIGN

RESEARCH REQUIREMENTS

Embedded

Software

C/C++

IMPLEMENTATION

Requirement Documents

• Difficult to analyze

• Difficult to manage as they change

Paper Specifications

• Easy to misinterpret

• Difficult to integrate with design

Manual Coding

• Time consuming

• Introduces defects and variance

• Difficult to reuse

Traditional Testing

• Design and integration issues found late

• Difficult to feed insights back into design

process

• Traceability

Embeddable

Algorithms

Algorithm

Design Physical Prototypes

• Incomplete and expensive

• Prevents rapid iteration

• No system-level testing

Traditional Development Process

20

DESIGN

Embedded

Software

Control

Algorithms

Mechanical

Components

Electrical

Components

Model-Based Design- Describe the system dynamics

Model-Based Design uses

block diagrams to

mathematically model the

system behavior.

You design the way the system

should perform.

21

Model-Based Design- Design and test using simulation

DESIGN

Environmental Models

Control Algorithms

Mechanical Electrical

Supervisory Logic

Requirements are linked to the

model.

Detail is added from specific

domains to refine the model.

Intellectual property and

engineering data are reused

from existing designs and CAE

tools, such as CAD, FEA, and

SPICE models.

Design and test control

algorithms using the model.

RESEARCH REQUIREMENTS

22

REAL-TIME TESTING

Model-Based Design- Test and validate in real-time

DESIGN

Environmental Models

Control Algorithms

Mechanical Electrical

Supervisory Logic

Automatically generate code

from the simulation model for

real-time testing of the control

algorithms.

RESEARCH REQUIREMENTS

Automatically generate code

from the simulation model for

real-time system simulation of

hardware for testing the real

microcontroller, FPGA, or PLC

MCU DSP FPGA ASIC

Structured

Text

VHDL,

Verilog C, C++

PLC

23

INTEGRATION

IMPLEMENTATION

TE

ST

& V

ER

IFIC

AT

ION

Model-Based Design- Implement embedded software

DESIGN

Environmental Models

Control Algorithms

Mechanical Electrical

Supervisory Logic

Automatically generate code

from the simulation model for

implementing directly on

production targets:

• Microcontrollers

• FPGAs

• PLC IDEs

RESEARCH REQUIREMENTS

MCU DSP FPGA ASIC

Structured

Text

VHDL,

Verilog C, C++

PLC

24

Plant Modeling Control Design Testing

SolidWorks

SimMechanics

Simscape

SimElectronics

SimPowerSystems

Simulink Design Optimization

Optimization Toolbox

Simulink Control Design

Control System Toolbox

Simulink Design Optimization

Optimization Toolbox

xPC Target

MATLAB Coder

Simulink Coder

DSP System Toolbox

Model-Based Design

25

MAN Roland Develops High-Precision

Commercial Printing Press Controller with

MathWorks™ Tools

Challenge To implement a new design process to support

development of a precision controller for a state-of-the-art

commercial printing press

Solution Use MathWorks products for Model-Based

Design to design and model the controller, run

real-time simulations, and deploy a production system

Results Development time reduced by one year

Design iterations completed in minutes,

not weeks

Error analysis streamlined for MAN Roland

customers

“MathWorks™ tools made it easy for us

to test ideas, introduce new algorithms,

and compare one controller against

another... We could quickly change the

structure of the controller and

immediately see the results. The ability

to perform rapid iterations enabled us

to optimize quality and functionality

while greatly reducing development

cycle time."

Thomas Debes

MAN Roland

MAN Roland’s state-of-the-art printing

press.

Link to user story

28

We can import the entire mechanical design

directly from a CAD tool…

The translator automatically generates the SimMechanics model using CAD information

SolidWorks Model

SimMechanics Model

29

Now, for our robot to be of any use, it has to be

able to move…

We can include the effects of actuator and sensor dynamics in the simulation model

30

And we can test and verify the overall system

performance in simulation…

Generate test vector arrays and verify the controller design against the performance specifications given for the system

reference +

-

controller

S1 S2

S3

31

Modeling Dynamic Systems: two approaches

Use system test data to derive a

mathematical representation

Data-Driven Modeling

sese

esG 1.0

78.21

94.1)(

32

Modeling Dynamic Systems: two approaches

Use an understanding of the

system’s physics to derive a

mathematical representation

First-Principles Modeling

V+

V-

33

Both have advantages & disadvantages

Data-Driven Modeling First-Principles Modeling Complete Modeling Environment

Advantages: Insight in behavior

Physical parameters

Disadvantages: Time-consuming

Requires expertise

Advantages: Fast

Accurate

Disadvantages: Requires plant

Requires data acquisition system

34

Tools that span both modeling approaches

Simulink Design

Optimization Simulink

First-Principles

System Identification

Toolbox

Data-Driven

Physical Modeling Tools

Complete Modeling Environment

Test and Measurement

Tools

35

Physical Systems in Simulink

Sim

Mech

an

ics

Mechanical dynamics (3-D)

Sim

Dri

ve

lin

e

Drivetrain systems (1-D)

Sim

Hyd

rau

lic

s

Fluid power and control

Multidomain physical systems

Electrical power systems

Sim

Po

we

rSys

tem

s MATLAB, Simulink

Sim

Po

werS

yste

ms

Simscape

Sim

Mech

an

ics

Sim

Dri

velin

e

Sim

Hyd

rau

lics

Sim

Ele

ctr

on

ics

Sim

Ele

ctr

on

ics

Electromechanical and

electronic systems

Simscape

36

Estimation of DC Motor Parameters

Untuned Parameters • Resistance

• Inductance

• Damping

• Intertia…

Tune

Parameters

with

Optimization

37 © 2011 The MathWorks, Inc.

Break

38

DC Motor Controller Design

39

Or we can fine tune our controller gains by

optimizing the system response…

Use Simulink Design Optimization to set graphical constraints on relevant signals and optimize the controller gains against the nonlinear system response

reference +

-

controller

S1 S2

S3

40

Models designed in Simulink and Stateflow

You want to run, test, and prove your Simulink design with your hardware under test at its normal operating frequency, speed, or timing.

But how can you do this testing in real-time?

?

From Simulation to Real-Time Testing

41

… How can you do this testing in real-time?

Use xPC Target!

xPC Target and xPC Target Turnkey systems create a hard

real time environment for testing your Simulink models.

42

Real-Time Testing Scenarios:

Functional Rapid Prototyping

Wiring and

Signal Conditioning

Real-Time Target Computer Production Plant Hardware

Code

Generation Execution

Host/Target

Real-time

43

Real-Time Testing Scenarios:

Hardware-in-the-Loop (HIL) Simulation

Wiring and

Signal Conditioning

ECU or MicroController

Code

Generation

Code

Generation Execution

Host/Target/Target

Real-time

Real-Time Target Computer

44

Host computer

with MATLAB

xPC Target on

Target Computer

xPC Target runs Simulink in hard real-time

Ethernet or RS 232

1

2

3

Environment allows the real-time execution of Simulink models on a

separate PC-based target computer

45

Ethernet or RS 232 Host

computerwith

MATLAB

xPC Target on

Target Computer

xPC Target enables tuning parameters in real-time

Ethernet or RS 232

Environment provides interactive access between the real-time

application and the host computer

Allows live parameter tuning, control from the original Simulink

model and offline analysis support in MATLAB.

Host computer

with MATLAB

xPC Target on

Target Computer

46

Ethernet or RS 232

3

1

2

4

2

Environment provides interactive access between the real-time

application and the host computer

Allows live parameter tuning, control from the original Simulink

model and offline analysis support in MATLAB.

Host computer

with MATLAB

xPC Target on

Target Computer

xPC Target enables quick data analysis with MATLAB

47

xPC Target on

Target Computer

Ethernet or RS 232

xPC Target on

Target Computer

Environment provides numerous I/O device driver blocks

Blocks are easily configurable within the Simulink model and

communicate with actual hardware in real-time.

Host computer

with MATLAB

xPC Target enables quick data analysis with MATLAB

48

Environment provides numerous I/O device driver blocks

Blocks are easily configurable within the Simulink model and

communicate with actual hardware in real-time.

xPC Target on

Target Computer

xPC Target provides I/O driver blocks in Simulink

49

Complete, fully assembled, real-time testing solution

Combines xPC Target (software) with a real-time target

machine and IO modules (hardware)

Optimized for Simulink and xPC Target

xPC Target Turnkey

Why xPC Target Turnkey?

50

Portfolio of real-time target machines

Assembled to meet your performance and I/O requirements

Various form factors for office, lab, and field use

Made and optimized for the use with Simulink and xPC Target

What is xPC Target Turnkey?

51

Wide range of I/O modules installed

in your target machine and fully tested

What is xPC Target Turnkey

IO Type Functionality

Analog High-resolution, high-speed, simultaneous sampling

Digital TTL, 12V, 24V, high-drive, opto-coupled

Serial RS232, RS422, RS485, SDLC, HDLC

Protocols SPI, I2C, SSI, CAN, Ethernet, UDP, J1939, ARINC 429, MIL-STD-1553

Audio/Speech Audio/Speech optimized analog IO modules, XLR panels

Shared Memory Reflective Memory for high speed data transfer in multi-processor systems

Various LVDT/RVDT, Synchro/Resolver,

Configurable FPGA • 3 phase motor control

• Pulse train (PWM, capture, quadrature decoding, hall effect)

• Event based interrupts

• Analog I/O with lowest latency and/or special synchronization schemes

• Algorithmic implementations for very fast inner control loops

52

FPGA Programming for xPC Target

Execute high-speed algorithms on an FPGA connected to a model

running in real time with xPC Target.

Automatically program the FPGA without needing to know HDL code

- ideal for functional testing and verification.

Quick reconfiguration of FPGA IO promotes a flexible real-time

testing environment.

Compatible with both new and existing xPC Target Turnkey systems.

Programming FPGA boards for xPC Target Turnkey real-time target machines using Simulink HDL

Coder Workflow Advisor.

53

Next Steps…

Visit www.mathworks.com – Product literature

– MATLAB Central

– Live and recorded webinars

Use the eval form to request more information – Passcodes to for evaluation of products

– Follow-up meeting or phone call

– Pricing and licensing

– Training; public and on-site classes

Feel free to ask questions afterwards