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美卓使用基于模型的设计开发用于节能数字液压系统的控制器，用于使用基于模型的设计

Challenge

精确控制压延机辊的速度，位置和压力​​在纸张整理设备中

Solution

Simulate, prototype, and implement advanced controls for a digital hydraulic system using Model-Based Design

Results

  • Months of design time saved
  • Weeks of customer startup time eliminated
  • 系统可靠性增加

“Using Model-Based Design with MATLAB and Simulink, we achieved multiple goals simultaneously. We developed a sophisticated controller for digital hydraulics that is more reliable, accurate, and efficient than previous systems, and we accelerated development, which gives us a competitive advantage.”

Kari Leminen, Metso
美卓造纸设备。机器的压电区由数字液压系统控制。

In industrial papermaking equipment, the calender rolls must be precisely controlled to achieve the right degree of smoothness and glossiness in the paper. Typically, roll positions must be maintained within a tolerance of 0.1 millimeters, and the pressure at the nip—the line of contact between rolls—must be within 0.2 bar of its set value.

使用基于模型的设计，美容开发了一种符合这些要求的数字液压系统，消耗98％的能量，需要更少的占地面积，并且比传统上用于扼流带控制的比例液压系统更可靠。

“Model-Based Design with MATLAB and Simulink was instrumental in helping us reduce costs and improve quality because it enabled us to test and tune a complex controller design via simulation, rapidly implement a real-time prototyping system, and generate code for a production industrial controller PLC,” says Kari Leminen, general manager of automation technology at Metso.

Challenge

Metso wanted to streamline the development, testing, and production of controls for its first digital hydraulic system for advanced papermaking machinery.

While digital hydraulic systems require less energy and floor space than proportional hydraulic systems, they require much more complex controls. A digitally operated hydraulic cylinder can have 30 to 40 valves, and a single machine 20 or more cylinders, creating significant control requirements.

“With a proportional hydraulic system, it’s easy to set up a PID controller to adjust the valve position as needed,” says Ville Hopponen, technology engineer for automation at Metso. “A digital hydraulic system requires much more complicated mathematics in the controller, and programming mistakes are common when you are developing such a complex system.”

美卓需要一种有效的方法来生产实时原型制作系统，客户试验实施和数字液压控制器的生产版本。

Solution

Metso engineers used Model-Based Design to develop a controller for the digital hydraulic system that precisely follows predefined targets for roll position, roll velocity, and nip pressure.

初步控制设计是与坦佩雷科智能液压和自动化部门的合作开发的。

大学研究人员建模了Simulink中的控制系统和数字阀金宝app®。它们用Simsce Multibody™建模了电容器框架和工厂的其他方面，并在Simulink中进行了闭环模拟，以验证设计的可行性。金宝app

美容工程师增强了研究人员的初始模型，适应商业用途和添加容错，诊断和状态报告功能。在Simulink中验证增强设计后，METSO工程师使用Simulink Co金宝appder™从其模型生成C代码，它们部署到DSPACE®模拟器®hardware for real-time testing.

在Matlab中分析了测试结果®并用于指导设计改进。

要生产第一个客户试点版本，METSO将从DSPACE切换到Simulink Real-Time™。金宝app在此过程中，核心Simulink模型不变;金宝app仅更新输入和输出模块以适应与实际硬件的实时通信。

在成功的试点计划之后，Metso工程师再次将目标转换为贝克霍夫®可编程序逻辑控制器(PLC)使用C代码。The same core controller module was reused, with small changes made to I/O modules. Metso engineers are now using Model-Based Design for several other digital hydraulics projects.

Results

  • Months of design time saved。“By simulating the hydraulic systems and controls with our Simulink model instead of on hardware, we could explore fault conditions, valve configurations, and other design options much faster,” says Hopponen. “We shortened development further by reusing the model to generate code for testing prototypes and production PLCs.”

  • Weeks of customer startup time eliminated。“In the past it took weeks to tune parameters directly on the system at the customer site,” says Leminen. “With Model-Based Design we tune parameters in the model and on a real-time prototype, so when we get to the site we can start running the system almost immediately.”

  • 系统可靠性增加。“使用Simulink实时模拟和金宝app实时测试的模拟有助于我们提供一个异常可靠的控制系统，”Leminen说。“我们的控制器已证明比传统系统更可靠，并且在生产中造成了不时的时间，这很重要，因为停电可能每小时耗费5,000欧元或更多。”

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