code generation at mechatronics · philips innovation services, sasg oct 2011 6 dynamics, actuators...
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Oct, 2011
Visit us at www.innovationservices.philips.com
Code Generation at Mechatronics
Philips Innovation Services
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Philips Innovation Services, SASG Oct 2011
Contents
• Introduction Mechatronics
• Mechatronic design challenge
• Control-design ‘old-style’
• Control-design with code generation
• Code details
• Questions
2
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Philips Innovation Services, SASG Oct 2011
Philips Innovation Services Position in Philips
Non-Philips
Customers
Healthcare Consumer
Lifestyle
Lighting
Royal Philips Electronics
Corporate
Technologies
IP&S
Research
Incubators
Philips
Innovation
Services
3
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Philips Innovation Services, SASG Oct 2011
Philips Innovation Services
6 open access labs
> 15,000 electronic instruments
> 19,000 m2 laboratories
Incl. 9,500 m2 clean rooms
High Tech Campus
Eindhoven - NL
Green house
Prototyping & manufacturing
4
Materials
Analysis
Measurement Lab
RF
Thin Film
Clean room
Reliability lab Electronic
Prototyping
Systems
Engineering
Life Science
facility
Device Processing
Facilities
Photonics
Facility
Measurement &
instrumentation
Experience
lab
E-Science
Support
Mechatronics
Competence center
EMC
Center
Consulting Competence
Center
650 technical specialists / 50 consultants
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Philips Innovation Services, SASG Oct 2011 5
Mechatronics
• Provides its customers with drives,
control and mechanical construction for
smooth motion and high accuracy
positioning
• Is both active in equipment and
subsystem design, as well as in
supporting the development of consumer
and healthcare products.
• Staff: 150 Technical specialists,40 %
University degree / Ph.D.s, 50 %
Bachelors & Engineers, 10 % other
education
• Customers:
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Philips Innovation Services, SASG Oct 2011 6
Dynamics, Actuators & Control
Advanced System Design
High precision motion stages
Project management & supply chain
Healthcare systems
Robotics
System architecture
Vibro-Acoustics & Low
Noise Design
Electrical
Systems Design
Metrology
TEMS
Vacuum Mechatronics
Mechanical
Design
Control
Equipment
Design
Product
Development
Tribology/Air
bearings
Electro
Mechanics
Dynamics
Production
Systems
Mechatronics Competences
Motion Control
Software
G
KFB,x
SPGx
Kfay,x
KFB,y
Kfax,x
Kfsy,x
Kfsx,x
snap
acceleration
MIMO FF
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Philips Innovation Services, SASG Oct 2011
Contents
• Introduction Mechatronics
• Mechatronic design challenge
• Control-design ‘old-style’
• Control-design with code generation
• Code details
• Questions
7
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Philips Innovation Services, SASG Oct 2011 8
Reflective electron beam lithography
Challenge
• Rotary stage 1.2 m diameter
• High Accuracy positioning
Results
• MagLev rotary stage
• Performance well within specification
• Prototypes installed at customer
Customer Benefits
• Competitive platform for introduction direct
write technology
• Throughput wph/footprint
• Low energy dissipation (low forces)
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Philips Innovation Services, SASG Oct 2011 9
Design Challenge: measure disc position
N
E
S
X
X
Z
Y
Reference and sensors
ZW
ZN/ZS
ZN
ZS
XE XW
YN
YS
XW XE
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Philips Innovation Services, SASG Oct 2011 10
Design Challenge: Sensor transformations
N
E
S
X
X
Z
Y
Reference and sensors
ZW
ZN/ZS
ZN
ZS
XE XW
YN
YS
XW XE 4 x sensor Axial
4 x sensor Radial
Transformation
5DOF 8 5
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Philips Innovation Services, SASG Oct 2011 11
Design Challenge: Sensor linearization required
4 x sensor Axial
4 x sensor Radial
Transformation
5DOF 8 5
Linearize Axi
Linearize Rad
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Philips Innovation Services, SASG Oct 2011 12
Design Challenge: Ref surface is not flat
4 x sensor Axial
4 x sensor Radial
Transformation
5DOF 8 5
Linearize Axi
Linearize Rad
N
E
S
X
Y
ZN
ZS
XE XW
YN
YS
1e-006
2e-006
3e-006
4e-006
30
210
60
240
90
270
120
300
150
330
180 0
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Philips Innovation Services, SASG Oct 2011 13
Design Challenge: Add calibration table
4 x sensor Axial
4 x sensor Radial
5DOF
Transformation
8 5
Linearize Axi
Linearize Rad
Axi Correction Table
Rad Correction Table
Angle Sensor
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Philips Innovation Services, SASG Oct 2011 14
Design Challenge: Angle linearization required
4 x sensor Axial
4 x sensor Radial
5DOF
Transformation
8 5
Linearize Axi
Linearize Rad
Axi Correction Table
Rad Correction Table
Angle Sensor Linearize Angle
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Philips Innovation Services, SASG Oct 2011 15
Design Challenge: Surfaces change with speed
6 x sensor Axial
6 x sensor Radial
5DOF
Transformation
8 5
Linearize Axi
Linearize Rad
Axi Correction Table
Rad Correction Table
Angle Sensor Linearize Angle
Periodic update Calc new
Corr tables
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Philips Innovation Services, SASG Oct 2011
Implementation: measurement system
16
MAC_PosSensors
2
MAC_COG
1
cos0:0
sin0:0
SurfaceCorrection
DiskAngle SurfaceCorrection
MAC_Sensors
MAC_PosSensors
MAC_RadCor_Sensors
MAC_AxiCorSensors
Gain 1
gpMAC _M_SensorsToSRF * u
Gain
gpMAC _M_SRFtoCOG * u
zeros(3,1)
0:0
gpMAC _M_RotationPointShift0:0
gpMAC _SRF_Offsets0:0
Constant
gpMAC _M_UseSurfaceCorrections0:0
CaptureCorSignals
EQCP Tracer
DiskAngle
1
gsMAC_M_RadCorSensors
gsMAC_M_AxiCorSensors
gsMAC_M_PosSensors gsMAC_M_SensorsAfterSurfCor
gsMAC_M_SurfaceCor
gsMAC_M_Position
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Philips Innovation Services, SASG Oct 2011
Implementation: sensor linearization
17
MAC_AxiCorSensors
3
MAC_RadCor _Sensors
2
MAC_PosSensors
1
Terminate ZN ZE
Terminate XE XW YN
I_Rad330
AnalogIn
I_Rad020
AnalogIn
I_PosZW
AnalogIn
I_PosZS
AnalogIn
I_PosZN
AnalogIn
I_PosZE
AnalogIn
I_PosYS
AnalogIn
I_PosYN
AnalogIn
I_PosXW
AnalogIn
I_PosXE
AnalogIn
I_Axi330
AnalogIn
I_Axi020
AnalogIn
double
double
double
gpMAC _M_DiffSensorOffsets0:0
Ax9
0:0Ax8
0:0Ax7
0:0Ax6
0:0
Ax5
0:0Ax4
0:0
Ax3
0:0Ax2
0:0
Ax11
0:0Ax10
0:0
Ax1
0:0Ax
0:0
gsMAC_M_CorrectedDiff
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Philips Innovation Services, SASG Oct 2011
Implementation: Ref correction
18
SurfaceCorrection
1
mod
mod
Lookup Radial
0:0
Lookup Axial
0:0
double
2*pi
0:0
gpMAC _M_RadSensorPositions0:0
gpMAC _M_AxiSensorPositions0:0
Enable
DiskAngle
1
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Philips Innovation Services, SASG Oct 2011
Contents
• Introduction Mechatronics
• Mechatronic design challenge
• Control-design ‘old-style’
• Control-design with code generation
• Code details
• Questions
19
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Philips Innovation Services, SASG Oct 2011 20
Motion Control Design flow ‘old-style’
Mech Designer Control Designer
User Spec
Concept design
and analysis Control design
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Philips Innovation Services, SASG Oct 2011 21
Motion Control Design flow ‘old-style’
Control model
Signal ▬ PID
Sensor Xform
Plant Filter
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Philips Innovation Services, SASG Oct 2011 22
Motion Control Design flow ‘old-style’
Mech Designer Control Designer
User Spec
Software Spec
Software Designer
Main()
{
doit();
}
Signal
▬
P
I
D
Sensor
Xfor
m
Plant
F
i
l
t
e
r
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Philips Innovation Services, SASG Oct 2011 23
Motion Control Design flow ‘old-style’
Mech Designer Control Designer
User Spec
Software Spec
Software Designer
Main()
{
doit();
}
Language
Barrier!
Signal
▬
P
I
D
Sensor
Xfor
m
Plant
F
i
l
t
e
r
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Philips Innovation Services, SASG Oct 2011
Contents
• Introduction Mechatronics
• Mechatronic design challenge
• Control-design ‘old-style’
• Control-design with code generation
• Code details
• Questions
24
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Philips Innovation Services, SASG Oct 2011 25
Motion Control Design flow using code generation
Mech Designer Control Designer
User Spec
Concept design
and analysis Control design
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Philips Innovation Services, SASG Oct 2011 26
Motion Control Design flow using code generation
Control model
Signal ▬ PID
Sensor Xform
Plant Filter
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Philips Innovation Services, SASG Oct 2011 27
Motion Control Design flow using code generation
Mech Designer Control Designer
User Spec
Software Spec + mdl
Software Designer
Signal
▬
P
I
D
Sensor
Xfor
m
Plant
F
i
l
t
e
r
Signal ▬
PID
Sensor
Xform
Plant
Filter
Main()
{
doit();
}
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Philips Innovation Services, SASG Oct 2011 28
Motion Control Design flow using code generation
Mech Designer Control Designer
User Spec
Software Spec + mdl
Software Designer
Signal ▬
PID
Sensor
Xform
Plant
Filter
Main()
{
doit();
}
Same
Language
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Philips Innovation Services, SASG Oct 2011 29
Motion Control Design flow using code generation
Mech Designer Control Designer
User Spec
Software Spec + mdl
Software Designer
Main()
{
doit();
}
Same model
Allows fast
iterations Signal ▬
PID
Sensor
Xform
Plant
Filter
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Philips Innovation Services, SASG Oct 2011
Contents
• Introduction Mechatronics
• Mechatronic design challenge
• Control-design ‘old-style’
• Control-design with code generation
• Code details
• Questions
30
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Philips Innovation Services, SASG Oct 2011
Code details
• Used in 10+ projects, various applications (RobotArm … REBL)
– Sample rates 500Hz … 20kHz
– # controlled axes 1 – 15
– No defects found yet!
• Control models only, no state diagrams
– General Matlab/Simulink blocks from library
– Hardware inputs and output blocks are custom designed
– Some custom blocks to interface with C++ code
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Philips Innovation Services, SASG Oct 2011
Code details
– Efficiency of the generated code:
• Double precision math by default
• Simulink blocks that are not enabled are not evaluated
• 30k lines at 4kHz on 2.8GHz P4.
– RTW-generated code is not nice to read
• Each block in the model becomes a little code-block
• The program is an ‘endless’ list of code-blocks
• A signal with a name becomes a variable with same name
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Philips Innovation Services, SASG Oct 2011
Code details: conclusion
• Pros
– No language barrier with other mechatronic disciplines
– Fast iterations in integration phase
– No bugs
• Cons
– Toolchain licensing
– Testing
– In Simulink variable scope is flat: use naming convention
• Note
• Some effort required for creating custom IO blocks
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Philips Innovation Services, SASG Oct 2011
Questions
?
34
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Philips Innovation Services, SASG Oct 2011