OPTIMIZATION
OUR TECHNOLOGICAL FOCUS
The optimization of machine behavior, plant operations, and process control is a driving force for new developments and modernization. The optimization task is often multidimensional and requires consideration of many influencing factors. Our mechatronic system understanding and cross-domain experience open up a wide range of possible intervention points, which we know how to leverage effectively with our modeling and simulation expertise.
PARAMETER OPTIMIZATION
Our extensive experience and expertise in the field of multi-objective optimization (see especially the LCM software platform SyMSpace), automated parameter studies, parameter identification, and sensitivity analyses form a fundamental part of modeling and simulation projects.
PROCESS MODELS
Mathematical models enable the calculation of non-measurable process variables and the prediction of future process behaviors. Validated process models allow for the optimization of plant operations in simulation, without risk and without the time constraints that are always present in real-world testing.
CONTROL ENGINEERING
Effective control ensures rapid achievement of target values, ideally without overshooting and robust against external influences. Varying dynamics at different operating points and nonlinear behavior of actuators make this task challenging. With the right approaches and methods, significant performance advantages can be achieved.
OUR SERVICE OFFER
Knowledge transfer
We support you in establishing virtual commissioning in your company. This can be done by creating a show case for a trade fair, by validating a use case or by virtual commissioning of a customer project.
Development
We develop models and control engineering solutions for you.
In an application-oriented manner, we develop physics-based models of machines, plants or processes for simulation, virtual commissioning and digital twins. The use of suitable methods for model and parameter identification ensures a realistic representation of the real system behaviour by the model. Thus, the advantages of model-based feedforward and feedback control methods as well as the use of models for the estimation of process and state variables can be fully exploited.
Validation
Questions concerning stability and robustness can be systematically investigated by the availability of a suitable model. The examination of the concept for the sequence control of a complex plant and its behaviour in the event of a fault can be carried out within the framework of virtual commissioning without risk. In extensive investigations of a large number of test scenarios, the possibility of automated evaluations and analyses can save a great deal of time. For all these tasks, we are happy to make our know-how available to you.
Optimization
Maximum speed, minimum cycle times, best possible use of the control ranges, minimum energy consumption, reduced load on the system and actuators – with model-based optimization of process and control parameters, we determine the best performance for your system.
APPLICATIONS & BRANCH OF INDUSTRY
Reference Projects
For each of the above services we present here a reference project. See also the collection of projects projects at the top of the page.
PROCESS MODELS – Turbomachines optimal development
The design and development of a customized turbomachine requires the interaction of several specialist domains. While a classic design approach is sufficient in simple cases, it quickly reaches its limits when it comes to more demanding requirements. For example, to achieve an optimized overall system, a holistic approach is recommended that optimizes all relevant sub-aspects while taking mutual dependencies into account:
- Fluid dynamics
- Electromagnetic drive
- Stability and rotor dynamics
- Thermal design and cooling
- Vibrations and acoustics
The SyMSpace development tool allows several of these areas to be optimized as a whole.
PROCESS MODELS – Cement Production
In a project with Cemtec, a model was developed for a grinding process consisting of a mill and a classifier. The identification of model parameters was carried out using plant and laboratory data. The process model allows for the estimation of material fineness through particle size distributions at various points in the process and provides insight into the dynamics of product changeovers. In the form of a Functional Mockup Unit (FMU), the model is also executable on the process computer and thus usable as a virtual sensor (soft sensor) in operation.
Goals, Motivation, Challenges
- Optimize steady state Operation (throughput, energy)
- Faster product change
- Increase product quality
Methods, Technology
- Model-based Estimation of particle size distribution
- Model Calibration with plant data and laboratory results
Solution, Benefits
- Increased System Knowhow
- Virtual Sensor
CONTROL ENGINEERING – Optimization of Setpoint Change
Achieving consistently optimal control quality with a variety of materials and different settings presents a significant challenge in the injection molding process. Additionally, the control system must be easy and reliable to parameterize during machine commissioning. This challenge was addressed and implemented in a project with Engel.
Goals, Challenges
- Reduce overshoot and rise time in pressure control
- Wide range of operation conditions
Methods, Technology
- Model-based control design
- Compensation of nonlinear effects
- Input Shaping for smooth setpoint change
- Pressure dependent control activation
Solution, Benefits
- Standard PID-control extended with compensation and input functions for increased performance
- Simulation studies reduce experimental testing
ADDITIONAL INFORMATION: LINKS & DOWNLOADS
- Modelling, simulation, control engineering: MATLAB/Simulink, SciLab/Xcos, Maple, MapleSim, Mathematica, HOTINT
- Virtual commissioning: Matlab/Simulink, Maple, IndustrialPhysics
- Automation systems: B&R AutomationStudio, Siemens TIA-Portal
- Automatic code-generation: Matlab Coder, MapleSim FMU Export, X2C
- Prototyping: LCM Electronic systems, dSpace, LabView
REFERENCE & REPORTS
Efficient Digital-Hydraulic Control System by LCM
This video demonstrates a highly efficient digital-hydraulic control system called HPC (hydraulic pulse controller) for mobile and industrial applications such as pumps or presses. The hydraulic pulse controller is capable of carrying out short micro dosing resulting...
Leading Indian manufacturer of drive systems for electrically powered vehicles visits LCM
Electromobility is also advancing massively in Asia. Significant growth is expected, especially in the motorcycle segment. The use of optimized drive systems is essential in order to actually achieve the desired goals such as high range, small installation space, low...
Benchmarking Workshop on (active) vibration damping
Benchmarking workshops (also called mechathons when held in the area of mechatronics) can be used to benchmark existing technologies and bring together experts of the same field in order to encourage knowledge transfer and future cooperation. Within the frameworks of...
