Rapid-Control-Prototyping as part of Model-Based Development of Heat Pump Dryers

Abstract

Today’s products are characterized by a highly interdisciplinary level. Likewise, household appliances are affected to this evolution. Mechanical structures, actuators, sensors and distributed control units can be found in modern tumble dryers, as well as in other mechatronic systems. The main challenge in the development process of such systems is to ensure the functionality which contains the proper interaction within the components of the tumble dryer. Mechanical knowledge, thermodynamical expertise, control-engineering competence and knowledge in software have to be managed and brought together. Apart from the interdisciplinary challenge, the rising functionality of modern tumble dryers leads to a further challenge, which appears in the development. Intelligent processes within their components have to be tested intensively, to ensure the benefit they promise. Time-consuming iterations during the development are inacceptable, to guarantee a specified start of production.To face the mentioned challenges in the development process, Miele already applies model-based systems engineering in its development [1]. Using simulation models enables Miele to analyze a lot of different and complex concepts of tumble dryers, to consider innovative and novel ways to dry clothes. As part of these Model-in-the-Loop simulations in early phases of the development, holistic system simulation-models are established. These models basically contain physical and control behavior. Immediately after different concepts are analyzed by the virtual systems, the concepts have to be validated.This work focusses the Rapid-Control-Prototyping (RCP) technology to validate novel innovative heating concepts for tumble dryers. Evaluation different concepts and the integration into home appliance processes is a formidable challenge, accepted in this paper. The RCP technology enables to test first component setups of heating systems, which are controlled by the simulation model of the controller. To set up the Rapid-Control-Prototyping scenario, a testing bench is built up, including equally the software-environment. The controller models are elaborated and simulated within the MathWorks® environment, in detailSimulink®/Stateflow®. This model contains the logical procedure and several safety aspects of a drying process. The simulation model is subsequent integrated into the software environment of National Instruments, to connect the virtual controller with existing and prototypical hardware components of a prototypically heat pump dryer. Within the test bench and the software periphery, the integration of the approach into the development process of Miele is described in this work.