Vintecc使用基于模型的设计开发用于多轴收获机的PLC系统

解决方案

Use Model-Based Design to develop controller and plant models, verify designs with MIL and HIL simulations, and generate production Structured Text for PLC deployment

结果

在可用硬件之前已验证了90％的设计
开发时间表缩短了几个月
New features implemented within days

“基于模型的设计SPED开发非常大，因此可以提供其他功能，几乎没有其他工作，并使我们对所交付的软件具有很高的信心。没有建模和仿真，我们可能仍在努力使系统启动并运行。”
Vincent Theunynck, Vintecc

Harvester incorporating the Vintecc control system.

比利时咨询公司Vintecc的主要客户最近重新设计并建造了具有高度定制建筑的收割机。借助780hp发动机驾驶三个独立的后轴和两个独立的车轮在前桥上，收割机能够在单个负载中收集和拖运100吨农产品。

VINTECC使用Simulink设计并实施了整个收割机的控制系统，包括动力总成，收集器以及所有其他机械和液压组件金宝app^®和基于模型的设计。

“With any huge machine, safety and reliability are critical,” says Vincent Theunynck, founder and principal engineer at Vintecc. “By modeling and simulating the control software as well as the powertrain and other core components in Simulink, we could see how it all worked. We verified that the software performed as intended—first in model-in-the-loop simulations, then in hardware-in-the-loop simulations—before testing on the actual machine.”

挑战

先前的收割机版本更小且易于控制，仅需要简单的电子控件，而无需软件。新的收割机具有更多的功能和更大的容量，需要更加复杂的控制系统。Theunynck需要准确地对收割机的动力总成和液压组件进行建模，以便在可用硬件之前对控制器进行基于模拟的调试和验证。

尽管Theunynck在C中具有开发控制器的经验，但他以前在结构化文本（ST）方面几乎没有经验。为了帮助确保整个系统的行为能够按预期进行，Theunynck希望避免手工编码PLC并在实际机器上调试控制代码。取而代之的是，他想通过仿真进行调试和验证其设计，然后自动生成PLC系统的IEC 61131-3 ST源代码。

解决方案

Vintecc使用MATLAB建模，模拟和实施了完整的收割机控制系统^®，S金宝appimulink和SimScape™。

Theunynck partitioned the overall control system design into three major application programs, each implemented on a separate PLC and communicating with one another over a CAN network.

Vintecc created a model for each controller that included Stateflow^®charts to manage execution modes and Simulink elements such as PID Controller blocks to control the harvester’s hydraulic and mechanical systems.

Vintecc使用SIMSCAPE开发了包括轮胎和车身元素在内的植物模型。液压泵，电动机和气缸；动力总成组件；和机械链接。

为了验证牵引力控制，自动轴对准，巡航控制，自动反向以及其控制设计的其他功能，theunynck在simulink中对控制器和植物模型进行了模型（MIL）模拟模拟。金宝app

生成密码后^®由Simulink PLC Coder™的Controller模型中的ST符合符合性ST，金宝app他在Codesys环境中编辑了该应用程序，并将其控制设计部署到IFM Ecomat Mobile产品家族的三个PLC中。

使用车辆网络工具箱™,Theunynck implemented a CAN interface on the plant models, enabling the models to send and receive messages via a CAN bus. He conducted hardware-in-the-loop (HIL) simulations in which the PLC controllers communicated via CAN messages with the Simulink plant models, which he ran in real time with Simulink Desktop Real-Time™.

Throughout development, Theunynck used MATLAB to postprocess and visualize simulation results.

Having verified and validated 90% of the software via simulation, the only remaining step was to test the PLC control system on the actual hardware to ensure correct parameter tuning before the completed system was delivered to the client.

结果

在可用硬件之前已验证了90％的设计。“These machines are deployed in a very short timeframe, so they have to be extremely reliable,” says Theunynck. “Our rigorous verification and validation process reduced the number of potential errors to an absolute minimum, ensuring that the machine will remain fully operational, with no downtime or disruption of the client’s business.”

开发时间表缩短了几个月。Theunynck说：“基于模型的设计将开发缩短了两到三个月，因为它使我们能够自动生成生产软件并通过仿真验证功能行为。”“因此，我们能够开发出比最初预期的更多自动功能，从而为客户提供了他的软件投资的回报。”

New features implemented within days。Theunynck说：“在项目中，客户要求提供两个新功能：巡航控制和自动逆转。”“通过常规的手工编码方法，这些更改将至少花费10天的时间来实施。借助基于模型的设计，我在短短两天内就实施并测试了这两个功能。”

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