Model-based design of industrial automation solutions using FMI

Abstract: This thesis defined and investigated a general workflow based on model-based design using the Functional Mock-up Interface (FMI), involving Hardware-in-the- Loop (HiL) simulation. The thesis was a direct continuation of Sara Gunnarsson’s master’s thesis "Evaluation of FMI-based Workflow for Simulation and Testing of Industrial Automation Applications", where a Software-in-the-Loop (SiL) simulation of the B&R Reaction Wheel Pendulum was conducted in Automation Studio using a model imported with FMI. A HiL simulation of the pendulum was performed to complete the work done by Sara, thus showcasing the strength and possibilities of using FMI in testing. The performance of the HiL results were evaluated by comparing the settling time with the SiL test and the real process swing-up. In addition to the pendulum work, this thesis also aimed to perform model-based tests of the ABB IRB340 FlexPicker robot, including SiL and HiL simulations. This was done in order to define a general workflow for conducting tests using FMI, and to verify the approach on a more complex process than the pendulum. A MapleSim model of the robot was exported as a Functional Mock-up Unit and imported in Automation Studio, where the testing was done. The results of the pendulum test showed that a HiL simulation with an FMU can be performed. The HiL simulation produced a settling time of 2.55 s at best, compared to 2.46 s of the SiL simulation and 2.28 s of the process. For the FlexPicker, the SiL and HiL tests were never run due to a lack of time. Instead, a recommended approach for implementing the SiL and HiL test—along with two less promising approaches tested—were discussed and evaluated. The conclusion is that the workflow and model-based design using FMI is a promising way of conducting tests, but that there is more implementational work needed before SiL and HiL results of the FlexPicker can be successfully collected.