MATLAB Modeling of Complex

Mechanical Systems

George Holling
Rocky Mountain Technologies Inc.
 Overview
Problem Definition

Different Solving Methods

Our Project Path

Outlook

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
We had to implement a magnetic bearing
system for a customer

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
Key performance parameters

Passive magnetic bearing

350 KRPM

>20 N bearing force

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
Mechanical System

6 degrees of freedom

> 100 KHz mechanical frequency

> > 1MHz control bandwidth

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
Other challenges

Requires accurate, no contact sensor

feedback
> >.25 mil resolution
> > 250 kHz bandwidth

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
Simplifications for this paper

We only model x-y motion

Z-axis is fixed
Z position will still move
Z axis is centered in center of flywheel

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
What are the simulation problems

High rotational speed

Small simulation timestep
High control bandwidth
Small simulation timestep
High but lower mechanical time constants
x, y
Long simulation times
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Problem Definition
What are the simulation problems

Small airgap
Many small elements in airgap for good
accuracy and conversion
We make 80% of the airgap available for
motion by design
Only a small portion of the 1.5 mm gap is available
for VIRTUAL AIR
Results in many, very small elements
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Problem Definition
What are the simulation problems

Large flywheel diameter

Ratio of OD/airgap is large
Many elements in simulation
Very slow to simulate

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
What are the simulation problems

We need to develop and test control

algorithms
Requires many simulation runs
Fast solutions are preferred

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Problem Definition
Since we develop control algorithms we want to
model the system in MATLAB Simulink

MATLAB Simulink is a graphic modeling

environment for system design and analysis
Widely used in academia and industry
Many specialty toolboxes support the simulations
Many customer require us to provide MATLAB models

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Modeling of the system

Model the complete mechanical system

via 3-D FEA with 6 degrees of freedom
We only model 5 degrees
X motion
Y motion
X tilt
Y tilt
Z rotation (RPM)
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Different Solving Methods
Modeling of the system

For completeness we bring out the Z

motion even though its value will always
be 0 (zero)

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
We have the following solving methods
available to us
Direct solving
Reduced order models

Parallel solving
A combination of the above
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Different Solving Methods
Direct solving

We model the complete mechanical

system via a 3-D FEA analysis

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
3-D mechanical model - Direct solving

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
System block diagram - Direct solving

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Modeling of the system - Direct solving

We never attempted to solve this system

in its direct form
Just simulating a single bearing can take 24
hours or more
We consider this approach to be not
practical

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Reduced order model solving

Convert the complete mechanical system

into an equivalent MATLAB function block
Linearization
Higher order approximation

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Reduced order model solving- Higher order
approximation

A response function is developed by applying a

range of control inputs over the operating range
of the mechanical system
Good results have been achieved with this approach
Still slow due to the large amount of data that must be
simulated

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Reduced order model solving - Linearization

The system is highly nonlinear as forces

are a function of ~ 1/(1-x) where x is the
displacement in % of airgap (1 mm)

We do not believe that linearization will

yield meaningful results especially when
cuurents are applied to the stabilizer
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Different Solving Methods
Parallel solving Subsystems

The complete mechanical system is

comprised of 5 components that can be
solved individually
Components are physically connected
There will be a delayed response that
requires a smaller simulation timestep than
the direct solve

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Parallel solving Subsystems

Some components can be approximated

as 2-D structures
Some forces will not be modeled in 2-D
Tilt forces generated by each component
Tilt moment is small compared to radial and
axial forces
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Different Solving Methods
Parallel solving Subsystems

The magnetic bearing can not be modeled

in 2-D
No return path for the flux -> 0 force

The magnetic bearing can potentially be

represented as a reduced model block

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
Parallel solving Subsystems

This is a great feature of MAGNET

Licenses to run multiple instances of the
solver are typically included in the standard
software license

Solving times will improve by orders of

magnitude
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Our Project Path
We selected the parallel solving method for
our analysis

To develop the algorithms we also decided

to only model of the system

For demonstration purposes we will show

the full model for this talk
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Our Project Path
We now replace the full model with a model
comprised of multiple sub-systems

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
We now replace the full model with a model
comprised of multiple sub-systems

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
Each subcomponent receives its position
input from the mechanical equivalent

With these inputs we can accurately model

the performance of the system

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
The equivalent mechanical system
Inputs
Moments
Forces
Mechanical Properties
Inertia
Outputs
Position
Velocity
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Different Solving Methods
3-D mechanical model - Direct solving

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
The sub-system components
Inputs
Position
Velocity
Component behavior
FEA (2-D or 3-D or reduced model as applicable)
Outputs
Moments
Forces

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
3-D mechanical model - Direct solving

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
The sub-system components
Inputs
Position
Velocity
Component behavior
FEA (2-D or 3-D or reduced model as applicable)
Outputs
Moments
Forces

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Different Solving Methods
3-D mechanical model - Direct solving

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
System MATLAB Diagrams

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
System MATLAB Diagrams

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
System MATLAB Diagrams

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Our Project Path
The sub-system components
The flywheel is modelled directly via its
mechanics
No real reason to run a magnetic FEA
We may want to run mechanical FEA but
that is a separate talk
The flywheel can ba adequatly described
through its basic mechanical equations

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Results
Using the Parallel Solving method we were able
to model the system and to develop control
algorithms
Reasonable simulation times
Overnight to show stability
Especially if stabilizer is modeled in 2-D
System simplification
We can develop insights into each components
separately
We can implement, optimize and test each
component separately
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV
 Outlook
The ability to run multiple subsystem FEAs is a
very powerful feature in MAGNET

This ability has made it feasible for us to

accurately analyze a very complex mechanical
system and to develop and test the control
algorithms

Many competitors problems do not have this

capability

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Outlook
You may have similar applications where
you can improve the performance of your
simulation and analysis

Model feedback sensors and motors

Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV

 Outlook
If you have a complex problem that can
benefit from this approach feel free to
contact us with any questions

Rocky Mountain Technologies Inc

www.RockyMountainTechnologies.com
sales@RockyMountainTechnologies.com
406-552-4260
Infolytica Engage 2016 Nov, 9, 2016 Las Vegas, NV