Real Time Testing of PMSM Controller using xpc Target Turnkey solution

Transcription

1 Real Time Testing of PMSM Controller using xpc Target Turnkey solution August 08, 2012 Prasanna Deshpande Application Engineering MathWorks India 2012 The MathWorks, Inc. 1

2 What is real time testing Rapid Prototyping Code Generation Execution Host/Target Real-time Wiring and Signal Conditioning xpc Target System Production Plant Hardware 3

3 What is real time testing Hardware in the loop simulation Execution Host/Target/Target Real-time Code Generation Code Generation Wiring and Signal Conditioning ECU or MicroController Real-time System 4

4 Challenges or needs faced by the RP engineer IO Driver in the form of Simulink library Interface the model with a real time kernel Execute the model with a specific sample time A scalable, flexible hardware platform for expansion Robust hardware should be able to sustain in plant noisy environment 6

5 Today s Agenda Converting simulation model to a real time application Configuring I/Os Choosing the right target hardware Preparing the model for code generation Build and Download Interfacing with real time application MATLAB Scripts xpc target explorer Simulink external mode xpc target API Converting a physical system model to real time application for HIL simulation Wrap-up 7

6 Starting point: Simulation Model of PMSM Controller u + s1 s3 s2 y 8

7 Today s Agenda Converting simulation model to a real time application Configuring I/Os Choosing the right target hardware Preparing the model for code generation Build and Download Interfacing with real time application MATLAB Scripts xpc target explorer Simulink external mode xpc target API Converting a physical system model to real time application for HIL simulation Wrap-up 9

8 Converting the simulation model to a real time application: Configuring I/Os I A I B s1 s2 PWM A PWM B s3 PWM C A B Index 10

9 Choosing the right target hardware: Mobile Real-Time Target Machine Performance : 2GHz Dual Core Intel processor 2GB RAM, 100GB HD Gigabit Ethernet Expandable : 5 PCI Slots Digital and Analog I/O, CAN, Serial, etc. FPGA Expansion Card : High-speed PWM and Quadrature generation and decoding High-frequency control loops Programmable with MathWorks HDL Coder This is the xpc Target Turnkey Computer 11

10 Hardware Detailed Block Diagram xpc Target Turnkey Mobile Machine IO 101 AI Card I A I B PWM A PWM B Power Electronics x86 CPU P C I IO 313 FPGA Card PWM C PMSM Motor A B Index Encoder 12

11 Converting the simulation model to real time application: Preparing model for code generation Solver settings - Fixed step Code Generation Settings - xpc target tlc xpc target options - Execution Options Hardware Implementation - HW device type 13

12 Build the application and download to the target hardware 1 2 Simulink Coder Host computer with MATLAB xpc Target Turnkey computer 3 Ethernet or RS 232 An environment that allows the real-time execution of Simulink models on a separate xpc Target Kernel compatible PC. 14

13 Today s Agenda Converting simulation model to a real time application Configuring I/Os Choosing the right target hardware Preparing the model for code generation Build and Download Interfacing with real time application MATLAB Scripts xpc target explorer Simulink external mode xpc target API Converting a physical system model to real time application for HIL simulation Wrap-up 15

14 Interfacing with the real time application: Logging data and tuning parameters From standard MATLAB interface Define signals to log Add file scope without modifying the model Define the parameters to tune Connect and run Tune parameters Stop the application, retrieve data from target and plot 16

15 MATLAB Scripts Example using the tg Object properties >> tg = xpc; % Create xpc Target object >> tg.load('mct_xpcclosedloop'); % Load application >> tg.start; % Start application >> Amp=tg.getparamid('Signal Generator', 'Amplitude'); >> tg.setparam(amp,2) % Change Amplitude value ans = parindexvec: 2 OldValues: NewValues: 2 >> tg.stop; % Stop application >> plot(tg.timelog,tg.outputlog(:,[1 2])) % Plot data 17

16 xpc Target Explorer xpcexplr Example tune parameters, monitor & plot signals Double-click to edit Parameters Signals 18

17 Simulink External Mode Example Simulink model is the interface to the target real-time application External Model 19

18 xpc Target APIs Example Create & Edit Custom UIs.NET, C, COM APIs Drag-and-drop controls Program callbacks with ease using Intellisense Define callbacks and GUI behavior Instant access to all API objects Drag and drop controls Graphical interface design 20

19 3 rd Party Solutions GUI/HMI Tools OpenSim Altia Design VISUALCONNX 21

20 Revisit: What is xpc Target? Host computer with MATLAB Host Computer with MATLAB Ethernet or RS 232 xpc Target Turnkey computer xpc Target Turnkey Computer Ethernet or RS 232 An Environment that 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. 22

21 Revisit: What is xpc Target? 2 Host computer with MATLAB xpc Target Turnkey computer 4 Ethernet or RS An Environment that 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. 23

22 Revisit: What is xpc Target? Host computer with MATLAB xpc Target Turnkey PC computer Ethernet or RS 232 An Environment that provides numerous I/O device driver blocks Blocks are easily configurable within the Simulink model and communicate with actual hardware in real-time. 24

23 Revisit: What is xpc Target? xpc Target Turnkey computer An Environment that provides numerous I/O device driver blocks Blocks are easily configurable within the Simulink model and communicate with actual hardware in real-time. 25

24 xpc Target Turnkey Target Hardware partnership with Speedgoat Hardware customized to fit your performance and I/O needs Saves you time and hassle of acquiring, installing, configuring, and testing Commercial Version : Academia Version : 26

25 Challenges or needs faced by the RP engineer IO Driver in the form of Simulink library Interface the model with a real time kernel Execute the model with a specific sample time A scalable, flexible hardware platform for expansion Robust hardware should be able to sustain in plant noisy environment 27

26 Today s Agenda Converting simulation model to a real time application Configuring I/Os Choosing the right target hardware Preparing the model for code generation Build and Download Interfacing with real time application MATLAB Scripts xpc target explorer Simulink external mode xpc target API Converting a physical system model to real time application for HIL simulation Wrap-up 28

27 Converting a physical system model to real time application for HIL Simulation Must find combination of model fidelity and solver settings that permits real-time execution and delivers accurate results Maximum Possible Step Size Larger step sizes result in poor accuracy and robustness Affected by solver choice, # of nonlinear iterations, and model fidelity Chosen Step Size Small explicit ode14x Step Size Backward Euler Solver Choice Large Trapezoidal Rule Minimum Possible Step Size Smaller step sizes result in overrun Execution Time Affected by solver choice, # of iterations and model fidelity Safety Margin Affected by step size Few # of Iterations Many Simulation Execution Processing I/O and Other Tasks Step Size Idle Low High Model Fidelity 29

28 Steps For Moving to Real-Time Simulation 6 Adjust model to make it real-time capable 1 Obtain reference results and estimate step size with variable-step solver Y 2 Is the solver taking too many small steps? N Flowchart describes steps engineers take 1. Obtain reference results 2. Check if real-time capable 3. Configure for fixed-step, fixed cost simulation 4. Find settings that deliver acceptable results and speed 5. Test on real time platform 6. Adjust if necessary N N N 3 Simulate with fixed-step, fixed-cost solver New results match reference results? Y Acceptable simulation speed? Y 5 Simulate on real-time platform Executes in real time with accurate results? N N Y Increase iterations and/or decrease step size 4 Success Decrease iterations and/or increase step size 30

29 Configuring Local Solvers In Simscape Configure per physical network Choose solver and sample time Sample rates can be different Must be integer multiple of global sample time Backward Euler Designed for robustness Tends to damp oscillations Fixed-step explicit solver Controller Local fixed-step implicit solver #1 Simscape Physical Network Simscape Physical Network Local fixed-step implicit solver #2 Trapezoidal Rule Designed for accuracy Tends to capture oscillations 31

30 Today s Agenda Converting simulation model to a real time application Configuring I/Os Choosing the right target hardware Preparing the model for code generation Build and Download Interfacing with real time application MATLAB Scripts xpc target explorer Simulink external mode xpc target API Converting a physical system model to real time application for HIL simulation Wrap-up 32

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