Model-based Development Approach Research Articles

Design of a Hierarchical-Type Control System Based on Smart MBD Approach and its Application to Hydraulic Excavator

Model-based development (MBD), which utilizes system models to design complex products, has received increasing attention. However, an advanced control system design scheme is required to accurately control the developed products under harsh conditions for practical usage. This paper proposes a control system that integrates a data-driven compensator (DDC) with a model-based control (MBC) system design. The proposed method considers a hierarchical control structure comprising an upstream control system based on the MBC design approach and a downstream control system that includes a plant control loop with a DDC. The proposed system can always maintain the desired performance by driving the MBC based on an ideal model because the downstream control system, DDC, maintains the characteristics of the ideal model even if the plant properties change owing to changes in operational and/or environmental conditions. In this study, the design scheme for unifying models and data in the MBD process is called smart MBD (S-MBD), and the proposed control system design scheme is based on the S-MBD approach. The effectiveness of the proposed hierarchical control system is verified by applying it to a hydraulic excavator.

A Model-Based Approach for the Methodical Development and Configuration of Modular Product Families

This paper shows how a methodical development and configuration of modular product family concepts and their effects on economic targets can be implemented in SysML. For this purpose, different sources of inconsistency between different methodical tools are highlighted and the need for research is shown. As a solution approach, a methodical framework is presented, which can be used to implement product development methods for the developing of modular product family modeling by means of Model-Based Systems Engineering (MBSE) in the modeling language SysML. By applying the framework, it is shown on the one hand how a product family of vacuum cleaner robots as a simple example can be modularized in a methodical, model-based manner. On the other hand, a configuration system and an impact model of modular product families are connected with the system model and applied to a product family of laser systems as an industrial use case. This made it clear that the framework can be used to model various methodical topics of product family modeling in a consistent manner, to enable higher-level analyses with the use of MBSE tools. This can reduce errors, decrease effort and increase traceability across different methodical tools.

Mathematical modelling for prediction of Young’s modulus in compositionally complex alloys

A generic mathematical model-based bottom-up approach for high throughput materials development of compositionally complex alloys is established in this study. A general bottom-up technique, in contrast to a top-down approach, entails property selection, element screening, structure identification, and fabrication. The application is used to guide the property selection. The alloy design depends on the screening of contributing elements depending on the necessary property. The usage of mathematical models could help with element screening to meet the property requirement. The properties of the resulting compound alloys may be determined by the attributes of compositionally complex alloys. As a result, developing a model that links the needed attribute to the most important aspects of compositionally complex alloys is critical. The Young’s modulus, which is the considered attribute, is predicted using a predictive mathematical modelling approach based on its relationship with the features: valence electron concentration and average melting temperature. Monte Carlo Simulation is also used to discover the optimum feasible composition in order to improve Young’s modulus.

Application of the Steric Mass Action formalism for modeling under high loading conditions: Part 2. Investigation of high loading and column overloading effects

The application of a model-based approach for industrial chromatography development requires the capability of the model to describe protein elution under high loading and overloading conditions. In a previous work, an extensive dataset was created to model the elution behavior of a bispecific antibody (bsAb) on the strong cation exchange resin POROS™ XS. Thereby, the pH-dependence of the model parameters in the Steric Mass Action (SMA) model could be examined and described over a pH range of 4.5 to 8.9. However, discrepancies between simulated and experimental data were observed under high loading and overloading conditions, particularly in the lower pH range (pH 4.5 to 5.3) and in the higher pH range (pH 6.0 to 9.0). In this work, these discrepancies are studied by performing new experiments which show that these differences were primarily not caused by limitations of the SMA model. At lower pH values, overloading phenomena such as protein breakthrough during the loading phase, additional peaks, and peak shoulders occurred. The application of various experiments performed with different Na+ concentrations and different loading times during sample loading revealed that intraparticle diffusion effects and conformational changes of the bsAb are responsible for these overloading phenomena at low pH. The applied lumped rate mass transfer model is not adequate and should be extended to consider these effects. At higher pH, the assumption of describing the bsAb's elution behavior with only one simulated species was insufficient to predict complex peak shapes that arise because of multi-component elution of the bsAb's charge variants. The extension of the model to a simple multi-component system consisting of two variants allowed the prediction of a majority of the complex elution profiles.

Mechanical Design and a Novel Structural Optimization Approach for Hexapod Walking Robots

This paper presents a novel model-based structural optimization approach for the efficient electromechanical development of hexapod robots. First, a hexapod-design-related analysis of both optimization objectives and relevant parameters is conducted based on the derived dynamical model of the robot. A multi-objective optimization goal is proposed, which minimizes energy consumption, unwanted body motion and differences between joint torques. Then, an optimization framework is established, which utilizes a sophisticated strategy to handle the optimization problems characterized by a large set of parameters. As a result, a satisfactory result is efficiently obtained with fewer iterations. The research determines the optimal parameter set for hexapod robots, contributing to significant increases in a robot’s walking range, suppressed robot body vibrations, and both balanced and appropriate motor loads. The modular design of the proposed simulation model also offers flexibility, allowing for the optimization of other electromechanical properties of hexapod robots. The presented research focuses on the mechatronic design of the Szabad(ka)-III hexapod robot and is based on the previously validated Szabad(ka)-II hexapod robot model.

Using a Model-based Material Sparing Approach for Formulation and Process Development of a Roller Compacted Drug Product.

The present work details a material sparing approach that combines material profiling with Instron uniaxial die-punch tester and use of a roller compaction mathematical model to guide both formulation and process development of a roller-compacted drug product. True density, compression profiling, and frictional properties of the pre-blend powders are used as inputs for the predictive roller compaction model, while flow properties, particle size distribution, and assay uniformity of roller compaction granules are used to select formulation composition and ribbon solid fraction. Using less than 10g of a model drug compound for material profiling, roller compacted blend in capsule formulations with appropriate excipient ratios were developed at both 1.4% and 14.4% drug loadings. Subsequently, scale-up batches were successfullymanufactured based on the roller compaction process parameters obtained from predictive modeling. The measured solid fractions of roller compaction ribbon samples from the scale-up batches were in good agreement with the target solid fraction of the modeling. This approach demonstrated considerable advantages through savings in both materials and number of batches in the development of a roller-compacted drug product, which is of particular value at early development stages when drug substance is often limited and timelines are aggressive.

How to create a Ni-free corrosion protecting deposit on basis of ZnFe-X

ABSTRACT ZnNi-deposits are currently used for corrosion protection especially in the automotive industry. With current REACH 1 regulations there is a demand for Ni-free coatings. The objective of this research project was the design of a REACH-compliant ternary zinc alloy based on ZnFe-X (X= Cu, In, Mn, Sn, Mo, Cr) with superior coating properties compared to Ni-free alternatives such as binary Zn-alloys. Using a model-based electrolyte development approach both thermodynamic and kinetic phenomena were included in the simulations. The implementation of a robot assisted experimental set-up enabled an effective, resource-saving research on different electrolyte systems in parallel and on choosing optimum pulse plating parameters. Optimum results were obtained by incorporating Mo at up to 1.5% into the ZnFeMo alloy.

Development of Air Supply Controller for FCV Based on Model-Based Development Approach

<div class="section abstract"><div class="htmlview paragraph">In Toyota’s 2nd generation FCV, an electric turbo-type air compressor has been adopted for downsizing and cost reduction. Automotive Fuel Cell applications present several challenges for implementing a turbo-type air compressor. When operating a fuel cell in high-temperature or high-altitude locations, the FC stack must be pressurized to prevent dry-up. The flow rate vs pressure conditions that the FC must pass through or in some cases operate at are typically within the surge region of a turbo-type air compressor. Additionally, Toyota requires quick air transient response (< 1 sec) for power generation, energy management, and FC dry-up prevention. If the turbo-type air compressor is not precisely controlled during quick transients, it can easily enter the surge region. To solve the above issues, we developed a new air supply controller which can avoid compressor surge by controlling 3 variables, ‘FC stack air flowrate’, ‘FC stack air pressure’, and ‘FC stack air Bypass’ independently with high accuracy. The controller was designed using a model-based development approach. At first, the physical characteristics of the air systems compressor, valves, pipes, and FC stack were modeled and integrated into a system level simulation that can run real-time on-board the vehicle Engine Control Unit (ECU). Next, the feedforward and feedback (PI) control were developed by implementing inverse models of the air system component equations. We confirmed that this control development approach could achieve Toyota’s air supply control performance requirements and prevent turbo-type air compressor surge.</div></div>

Model-Based Test Case Prioritization Using an Alternating Variable Method for Regression Testing of a UML-Based Model

Many test case prioritization (TCP) studies based on regression testing using a code-based development approach have appeared. However, few studies on model-based mutation testing have explored what kind of fault seeding is appropriate or how much the code-based results differ. In this paper, as automatic seeding for the mutation generation, several mutation operators were employed for the UML statechart. Here, we suggest mutation testing employing the model-based development approach and a new TCP method based on an alternating variable method (AVM). We statistically compare the average percentage of the fault detection (APFD) results of the new method to other TCP methods such as a greedy algorithm for code coverage or fault exposure possibility. Finally, in empirical studies, the model-based TCP results for a power window switch module, a body control module, and a passive entry and start system are derived; these are real industrial challenges in the automotive industry.

A Surrogate Modeling Approach for the Development of Biorefineries

Biorefining processes are still struggling with commercial flowsheeting softwares. Challenges include the lack of property data, complexity of raw materials, and the constant influx of new processes and technologies. Surrogates are gaining attention due to their ability to exploit black-box nature problems and their attractive computational simplicity. However, existing surrogate modeling methodologies are deprived of property-based parameters and deviate from engineering principles that are useful to retain in the model. This paper introduces a new iterative model-based approach for the systematic development of low granularity models for biorefining processes. The approach develops regressed models in the context of existing commercial packages. Degrees of freedom include the selection of listed components, property methods, and process models. Stages include the selection of property and process models, the optimization of the model parameters, and regression with experimental data. The framework is applied for the modeling of a real-life biorefinery. Three case studies demonstrate the potential of the suggested procedure. The first case study has fixed options for the property and process models, while the second one has them as a degree of freedom. The third case study extrapolates the resulted metamodels to different capacities and six different feedstock types (wheat and rice straw, wood, sugarcane bagasse, banana stem, and miscanthus). Metamodels produced with more degrees of freedom for selecting and modifying the process and property models gain in accuracy, flexibility, and simplicity. The suggested framework can be integrated with artificial intelligence tools to automatize the link with commercial software.

Online Reconfiguration of Distributed Robot Control Systems for Modular Robot Behavior Implementation

The use of autonomous robots in areas that require executing a broad range of different tasks is currently hampered by the high complexity of the software that adapts the robot controller to different situations the robot would face. Current robot software frameworks facilitate implementing controllers for individual tasks with some variability, however, their possibilities for adapting the controllers at runtime are very limited and don’t scale with the requirements of a highly versatile autonomous robot. With the software presented in this paper, the behavior of robots is implemented modularly by composing individual controllers, between which it is possible to switch freely at runtime, since the required transitions are calculated automatically. Thereby the software developer is relieved of the task to manually implement and maintain the transitions between different operational modes of the robot, what largely reduces software complexity for larger amounts of different robot behaviors. The software is realized by a model-based development approach. We will present the metamodels enabling the modeling of the controllers as well as the runtime architecture for the management of the controllers on distributed computation hardware. Furthermore, this paper introduces an algorithm that calculates the transitions between two controllers. A series of technical experiments verifies the choice of the underlying middleware and the performance of online controller reconfiguration. A further experiment demonstrates the applicability of the approach to real robotics applications.

Biomechanical Model-Based Development of an Active Occupational Upper-Limb Exoskeleton to Support Healthcare Workers in the Surgery Waiting Room.

Occupational ergonomics in healthcare is an increasing challenge we have to handle in the near future. Physical assistive systems, so-called exoskeletons, are promising solutions to prevent work-related musculoskeletal disorders (WMSDs). Manual handling like pushing, pulling, holding and lifting during healthcare activities require practical and biomechanical effective assistive devices. In this article, a musculoskeletal-model-based development of an assistive exoskeleton is described for manual patient transfer in the surgery waiting room. For that purpose, kinematic data collected with an experimental set-up reproducing real patient transfer conditions are first used to define the kinetic boundary conditions for the model-based development approach. Model-based analysis reveals significant relief potential in the lower back and shoulder area of the musculoskeletal apparatus. This is corroborated by subjective feedback collected during measurements with real surgery assistants. A shoulder–arm exoskeleton design is then proposed, optimized and evaluated within the same simulation framework. The presented results illustrate the potential for the proposed design to reduce significantly joint compressions and muscle activities in the shoulder complex in the considered patient transfer scenarios.

Development of an Adaptive Learning Support System based on Model-Based Development (MBD) Approach

Education is of the highest importance to the world we live in. If ways can be found to elevate the level of education within any given country, the individuals of that country will naturally benefit, but so too will the country as a whole, as it increases its competitiveness on a global scale across a broad range of areas. For example, in Japan there are general guidelines for learning that state the ways in which students are educated should be adjusted according to the needs of each individual. Dr Shin Wakitani is a control engineering specialist with a particular interest in data-driven controller design and model-based development (MBD) education. Wakitani leads a team based at Hiroshima University in Japan, which is investigating a means of establishing an adaptive learning support system development method.

Development and first use of an experimental device for fission-induced spectrometry applied to neutron flux monitoring

In order to provide dependable neutron flux instrumentation for Generation IV Sodium-cooled Fast Reactors (SFR), the French Atomic and Alternative Energies Commission (CEA) is investigating the feasibility of an innovative technology based on the optical signal produced within a fission chamber. In such gaseous detectors, neutrons interact with fissile material releasing heavy ions in the MeV-range, eventually leading to spontaneous photon emission in the ultraviolet-to-infrared range thanks to gas excitation and ionization. In this paper, the process of light generation is analyzed through semi-empirical models and custom-developed codes. A specific instrumentation has been defined and manufactured to emulate optical fission chambers and collect basic spectroscopic data required for model-based development approach. That testing device was named PSEG, which stands for Prototype of Scintillator Electrodes-Gas. Experimental validations have been carried out: the ionized argon gas exhibited no local thermodynamic equilibrium. Furthermore, the broadening of selected argon emission lines due to pressure change offers a promising self-diagnosis capability for future optical fission chambers.

An Integrated model-based Approach for FMECA Development for Smart Manufacturing Applications

Qualtech Systems, Inc. (QSI)’s integrated tool set, consisting of TEAMS-Designer® and TEAMS-RDS® provides a comprehensive model-based systems engineering approach that can be deployed for fault management throughout the equipment life-cycle – from its design for fault management to condition-based maintenance of the equipment. The TEAMS® failure-cause effect dependency model is a digital twin representation of the equipment in its failure-space and allows for various types of analyses such as testability, serviceability, failure propagation and others that facilitate fault management design of the equipment. The same model is deployed through TEAMS-RDS® for condition monitoring, prognostics, real-time health assessment, failure impact analysis, guided troubleshooting and others that facilitate condition-based maintenance as well as ensure efficient and rapid maintenance actions. In this paper, we present an overview of QSI’s integrated toolset, with a focus on a systematic model-based approach towards an automated development of Failure Effects and Criticality Analysis (FMECA) and other relevant analyses for the equipment, for an improved understanding of failure effects and their causality at the system-level. The eventual objective here is improved equipment design as well as designing improved failure detection, failure isolation and failure mitigation. The paper will also discuss examples of such real-world applications for smart manufacturing in major depot maintenance facilities in the US. A subsequent paper will focus on the development and integration of process-level and equipment-level FMECAs for Smart Manufacturing applications.

A scalable model based approach for data model evolution: Application to space missions data models

During the development of a complex system, data models are the key to a successful engineering process, as they contain and organize all the information manipulated by the different functions involved in the design of the system. Moreover, these data models evolve throughout the design, as the development raises issues that have to be solved through a restructuration of data organization. But any such data model evolution has a deep impact on the functions that have already being defined.Recent research tries to deal with this issue by studying how complex industrial data models evolve from one version to another and how their data instances co-evolve. Complexity and scalability issues make this problem a major scientific challenge, leading to huge gains in development efficiency. This problem is of particular interest in the field of aeronautics and space systems. Indeed, the development of these systems produces many complex data models associated to the designed systems and/or to the systems under design, hence on the one hand data models are available. On the other hand, it is well known that these systems are developed in the context of collaborative projects that may last for decades. In such projects, specifications together with the associated data models are bound to evolve and engineering processes shall take into account this evolution.Our work addresses the problem of data model evolution in a model-driven engineering setting. We focus on minimizing the impact of model evolution on the system development processes in the specific context on the space engineering area, where data models may involve thousands of concepts and relationships, and we investigate the performance of the model-based development (MBD) approach we propose for data model evolution over two space missions, namely PHARAO and MICROSCOPE.

Pressurized hot water extraction of 10-deacetylbaccatin III from yew for industrial application

In this study a systematic and model-based approach for a process development focusing on pressurized hot water extraction (PHWE) is investigated, considering potential thermal degradation of high-value compounds. For extraction of 10-deacetylbaccatin III (10-DAB) from yew as a representative test system, water at 120 °C provided the best compromise between extraction yield and thermal degradation. A yield of almost 100% with regard to the overall amount of 10-DAB was reached in only 20 min. Each experiment for model parameter determination was carried out with 1.9 g of plant material at a flowrate of 1 mL/min and an applied pressure of 11 bar. All experimental values are assessed by a physico-chemical (rigorous) extraction model with experimental values and simulation results showing high conformity. In order to demonstrate the usability of the extraction model and model parameter determination a scale-up prediction was calculated. The scale-up experiments were predicted precisely and thus the model validated. The experiments and the simulation results for a column with a volume of 104 mL and a mass of 22 g yew needles were consistent with the milli-scale used for model parameter determination.

System Lifecycle Management - An Approach for Developing Cybertronic Systems in Consideration of Sustainability Aspects

Contemporary technological products are systems based on multiple engineering disciplines. Requirements, risen due to global competition and legislation, lead to complexity explosion especially with regard to the information flow within the product development process. Embedded intelligence and interconnectivity used for an autonomous decision-finding by the products increases complexity furthermore. This paper presents an approach and framework for model-based development of Cybertronic Systems supported by System Lifecycle Management for provision of data availability and traceability. An example based on eco-design of a Cybertronic Element – wheeled excavator – within a Cybertronic System – autonomous construction area – is presented.

2E11 社会人を対象としたモデルベース開発型アプローチによる制御系設計教育((19)産学連携教育-II/(20)MOT教育,口頭発表)

2E11 社会人を対象としたモデルベース開発型アプローチによる制御系設計教育((19)産学連携教育-II/(20)MOT教育,口頭発表)

A Hardware-in-the-Loop Facility for Integrated Vehicle Dynamics Control System Design and Validation

Abstract: Due to the increased number and the complexity of the embedded systems in today’s vehicle, there is ever increasing pressure to reduce the development cost and time to market of such systems. In recent years, Model based Development (MBD) is becoming a main stream in the development of automotive embedded systems, and Hardware-in-the-Loop (HiL) testing is one of the key steps toward the implementation of MBD approach. This paper presents the recent HiL facility that has been developed at Cranfield University. The HiL setup includes real steering and brake smart actuator, high fidelity validated vehicle model, complete rapid control prototyping tool chain, and driver-in-the-loop capability. The applications of HiL setup are including but not limited to: smart actuators system identification; rapid control development and early validation of standalone and/or integrated vehicle dynamics control systems. Furthermore, the facility can be employed for investigation on driver-vehicle interaction at the presence of standalone active steering and/or brake systems as well as various Advanced Driver Assist Systems (ADAS), such as lane keeping or adaptive cruise control systems. The capability of the HiL facility for validation of a several newly developed vehicle dynamics control systems is presented.