PROVIDING WORLD-WIDE INTRANET ACCESS TO PRODUCT LIFETIME CALCULATIONS USING MATLAB PRODUCTION SERVER - Dirk Twisk Bosch Transmission Technology ...
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PROVIDING WORLD-WIDE INTRANET ACCESS TO PRODUCT LIFETIME
CALCULATIONS USING MATLAB PRODUCTION SERVER
Dirk Twisk
Bosch Transmission Technology
Using Matlab production server for product lifetime calculations
Contents
1. Bosch Transmission Technology
2. The CVT
3. Modelling
4. Implementation with Matlab
5. Server based calculations
6. Matlab Production Server solution
7. Next steps
2 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Engineering calculations at Bosch Transmission Technology BTT
All engineers should use the same tools.
Many tools are developed in house – what is the latest version?
Quality procedures are used to develop and verify software tools.
Use versioning systems and (unit) tests.
Everybody uses the same data
Multiple channels of communication internally and externally.
App 1 data
Data can be shared between applications. App 2
App 3
Effective use of computational resources.
3 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Tilburg
BTT Locations Netherlands
China
Shanghai
Schwieberdingen
Germany
Yokohama
Japan
Ho Chi Minh
Vietnam
San Luis Potosi
Mexico
Production
Engineering
4 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduction to the CVT
5 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Model calculations for Push Belts
Designs are made by engineers, based on user requirements:
Maximum torque and power, expected lifetime (kms), ratio coverage, package size.
Detailed calculation results are shared with the customer.
Bosch designs and produces the push-belt only.
All other transmissions components are made by the customer.
Integration engineering.
Calculations are made during all stages of the development process.
Initial offering to customer
Product Development.
Verification in Laboratory.
6 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Engineering calculations Secondary speed Variogram
Geometrical calculations
Achieve a large Ratio Coverage.
OD
‒ Deep LOW is for take-off performance
‒ OD is required for fuel efficiency LOW
Determine build size. Smaller and less weight is better.
Primary speed
Forces and Stresses
Effective stress
Calculate forces and stresses acting on the system. σeff
SN curve
Calculate expected lifetime of the push belt
‒ Number of stress cycles before most critical part fails.
L10
cycles
7 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Pulley ± 400 elements
Pulley
Element
Loops
Situation for Overdrive
8 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Force balance model
Loop set part Element string part Pulley sheave part
9 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Solving the problem in Matlab
Call to fsolve
[R1,R2,exitflag] = fsolve(@(SolvVec) FuncName(SolvVec,ConstVec),InitVec,options); Target function
Differential equations
% ------------------------------------------------------------------------- %--------------------------------------------------------------------------
function [F] = Fdsec(phi,fdmax,fstrek,b_s)
function [F] = Calc_Solution_Above_Transition(x,y)
if (model == BOVEN)
fdmax = x(1); F = (fdmax+Csch-(fstrek-Csn)*exp(-mu_lr*(alphas-b_s)))*exp(con10b*(phi-(alphas-b_s)))+(fstrek-Csn)*exp(-mu_lr*phi)-Csch;
fstrek = x(2); else
beta_s = x(3); F=( Csch-(fstrek-Csn)*exp(-mu_lr*(alphas-b_s)))*exp(con10b*(phi-(alphas-b_s)))+(fstrek-Csn)*exp(-mu_lr*phi)-Csch;
end
faxs = y(1);
end
F = [Fdsec(alphas,fdmax,fstrek,beta_s)
FaxsA(fdmax,fstrek,beta_s)+FaxsB(fdmax,fstrek,beta_s)-faxs %--------------------------------------------------------------------------
function [F] = FaxsA(fdmax,fstrek,b_s)
Msecf(fdmax,fstrek)-Ms]; if alphas-b_s < COMPZERO
end F = 0.0;
% ------------------------------------------------------------------------- else
scale = 10000;
F = scale*quadl(@(phi) dFaxsA(phi,fdmax,fstrek,scale),0.0,(alphas-b_s));
function [F] = Calc_Solution_Below_Transition(x,y) end
fdmax = x(1); end
fstrek = x(2);
beta_s = x(3); %--------------------------------------------------------------------------
function [F] = FaxsB(fdmax,fstrek,b_s)
faxs = y(1); con20 = 0.5*(1-tan(lambda_sec)*mu_lf*sin(gammalfb))./(tan(lambda_sec)+mu_lf*sin(gammalfb));
if model == BOVEN
F = [Fdsec(alphas,0.0,fstrek,beta_s)-fdmax F = con20*((-1/con10b)*(fdmax+Csch-(fstrek-Csn)*exp(-mu_lr*(alphas-b_s))))*(exp(con10b*b_s)-1);
FaxsA(0.0,fstrek,beta_s)+FaxsB(0.0,fstrek,beta_s)-faxs else
F = con20*((-1/con10b)*( Csch-(fstrek-Csn)*exp(-mu_lr*(alphas-b_s))))*(exp(con10b*b_s)-1);
Msecf(-fdmax,fstrek)-Ms]; end
end end
10 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.How to Implement
Tilburg
Netherlands BTT - Tilburg
Mechanical Engineering
Transmission Design (CVT)
Modelling
Matlab
RBEI - Bangalore
Software Systems Design
Databases
Java
Bangalore
Matlab
India
11 Internal | C/CCB, C/CCD | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.System Design
• Server stores inputs and outputs for
several applications
• Start with complete variator models:
BCP and VBL
• Data can be accessed by all users
(engineers)
• Different interfaces and business logic
for different applications.
12 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.System Implementation
Front End/Business Java Database SQL
Calculations Matlab Reporting Report Server
13 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Development – traditional design
PS-CT/EAC RBEI/ETC PS-CT/ICT
Product Development Software Development Maintain computer systems
Model Development Information Systems Install Software
1. Write Code 1. Write Code
2. Test Code 2. Test Code
3. Compile Code 3. Compile Code
4. Jar File(s) 4. Create Executable 1. Upload to Software Server.
2. Install JAR on users’ PC.
3. [ Install Matlab runtime ].
14 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Local installation
Local install servers
Tilburg Netherlands Vietnam Japan
Netherlands
15 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Drawbacks of the traditional design
Complicated release process:
• Updates not synchronized due to the use of different install servers.
• Every user needs to have (correct) Matlab runtime installed.
• High maintenance costs (technical support).
• Sending data over the network is slow, so the performance is not acceptable.
• Changes to the Matlab code requires rebuild of the complete code.
After the second major release, it was decided to change the design
Switch to a web-based approach
16 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Web-based Approach
Netherlands
Vietnam
Web-server
http://BCP
Japan
17 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Improved Solution
Make the application web-based:
All required components run on a single server.
Only inputs and outputs are sent over the network.
Users do not have to install any software on local computers
The database itself is used to store user data and grant access to users.
Use NT login credentials
Updating software is required at only 1 location
Synchronized updates of software and database.
Minimal disruption of service.
Maximum of 1 hour downtime for major updates.
18 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Architecture
Tomcat
BCP Java applet
Matlab
19 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Initial Implementation
network
Server (machine) Server (machine) only 1
SQL databases VM (4 cores) process !
BCP production Tomcat
Testing
BCP MCR
Training
App 2
Tilburg - NL App 3
Tilburg - NL
20 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Limitations …
Tomcat Server Matlab
Incoming Job 1 MCR Matlab module (*.m)
Requests Job 2
by users Job 3
(200+) Job 4 Jobs 2-5 are waiting
Job 5 for execution
Calculation Times: Queue 1 2
3 3
Shortest : 2 seconds 4 4
Longest : 24 hours Proc. 1 Job 1 Job 2 Job 3 Job 4
Proc. 2 Unused …..
Proc. 3 Unused …..
21 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Infrastructure with Production Server – Final Design
network
Server (machine) Server (machine)
SQL databases VM (4+ cores)
BCP production Tomcat Worker
Testing Worker
BCP MPS
Training Worker
Worker
Tilburg - NL
Tilburg - NL
22 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Main Benefits of MPS
Multiple Matlab jobs run simultaneously: Worker 1 1
Tomcat
Each up to 24 hours per job (vehicle duty cycles). Worker 2
BCP MPS 1 Worker 3
Worker 4
Scalable:
Add more cores to the server.
Worker 1 2
Assign different machines for different tasks.
Worker 2
MPS 2
Utilize available (unused) computational resources. Worker 3
Worker 4
Decoupled updating of main BCP code and Matlab code.
Define inputs/outputs between systems.
Independent updates of Java and Matlab code.
Log output is used to verify communication between the
components.
23 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.Next Steps
Server
Tomcat
Three developments: BCP
App 2
1. Make existing standard programs web-based: App 3
• Model-Viewer-Controller type applications.
2. Create a library of common functions, allow calling from: Function
MPS
Library
• Java (web)
• Excel Matlab
• Matlab
3. Provide functionality to non-Matlab departments
• Production, Quality, Inspection, …
24 Internal | PS-CT/EAC3 | 2018-03-05
© Robert Bosch GmbH / Bosch Transmission Technology B.V. 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.You can also read
