摘要
当前，机电产品中融入了越来越多的嵌入式技术，系统构成日趋复杂，形成了由机械、电子、液压、控制等多领域子系统构成的综合体，并逐渐发展为一种具有信息化、网络化和智能化的新型复杂系统——信息物理系统（CPS，Cyber-PhysicalSystem）。因此，必须研究适应产品新特征的数字化设计，以提高设计效率、降低开发成本、缩短研发周期。本文针对具有“信息”和“物理”融合特征的当前机电产品和未来CPS，结合产品设计流程，研究产品数字化设计，在国家“863”和自然科学基金项目以及中国商飞相关产品研发项目的支持下，围绕数字化建模与仿真以及半物理仿真技术，对相关关键技术进行了深入研究。主要包括以下工作：
(1).归纳了机电产品数字化设计从“瀑布”模型到“V模式”模型、“建模-设计-分析”循环迭代模型的演变过程，分析了各设计模型的特征与特点。针对CPS特性，提出了覆盖机电产品方案设计、详细设计及测试与验证各阶段，以多领域统一建模与仿真为基础，支持产品数字建模与仿真分析及半物理仿真验证的数字化设计流程框架。
(2).针对CPS数字建模与仿真，采用基于多领域统一建模语言Modelica及工具软件MWorks，提出了从基础模型库、综合模型库到系统级多领域统一模型的层次化建模方法。并以飞机液压起落架系统为应用对象，建立了液压、机械、控制等综合模型库，针对起落架的收放控制、前起转弯控制、刹车控制和液压能源综合管理等具体应用建立了系统级多领域模型，并进行了数字仿真与分析。
(3).提出了半物理仿真系统中界定“模型－模型”或“模型－实物”的“电信号优先分断”原则，并分析研究了构建半物理仿真系统的三个关键技术：针对硬件板卡与软件模型之间交联问题，提出了可以实现从模型到仿真目标机板卡接口无缝连接的RTI接口技术；针对CPS中多控制单元并行运行需求以及层次化物理模型到高效率模型实时代码之间映射问题，提出了适于多目标机的代码生成技术；针对不同控制单元的实时代码到相应目标机的配置管理、协调运行及监控反馈，提出了适于多目标机的代码下载技术。
(4).提出了由数字仿真系统、综合管理系统及仿真目标机系统构成的机电产品通用数字化设计平台框架：基于Modelica多领域建模语言与MWorks工具软件构建数字仿真系统，支持从基础模型库、综合模型库到系统级嵌入式机电产品的层次化开发过程。基于RTI接口、支持多目标机代码生成和代码下载等半物理仿真关键技术，开发了综合管理系统，提供模型代码下载、运行控制、参数调整、变量监视等功能。采用实时操作系统VxWorks，通过目标机与硬件板卡的配置，开发了仿真目标机系统，响应控制指令，接收仿真目标代码，执行模型实时运算，返回运行状态、监控变量等。
(5).以液压起落架系统为工程实例，基于通用数字化设计平台框架，建立了液压起落架数字化设计平台，支持起落架的收放控制、前轮转弯控制、机轮刹车控制、液压能源综合控制等子系统的设计与试验。在系统方案设计阶段，为总体设计提供参考依据并进行匹配优化；在详细设计阶段，采用半物理建模与仿真技术，提供软硬交联的可靠验证；在试验与验证阶段，实现系统级、高置信度的仿真分析与试验。该平台有效的提高了液压起落架系统的研发效率，缩短了研发周期；目前，其已成功应用于中国商飞的ARJ21和C919两型号飞机液压起落架的相关技术研发过程。
Nowadays, more and more embedded technologies are applied in the mechatronicproducts, which lead the system to become the complex muti-domain system includingmechanics, electronics, hydraulics, control etc. Moreover, the system has graduallyevolved into a new kind of complex system with information, network and intelligence.This is so called as Cyber-Physical Systems (CPS). It is necessary to study the digitaldesign methods for the new products to match the news characteristics, improve the designefficiency, reduce the research costs and shorten the development cycle. Based on thedigital modeling and simulation and the hardware-in-the-loop (HIL) simulationtechnologies, this paper deeply researched the key technologies of digital design in thedesign process for the current mechatronic products and prospective CPS with thecombination feature of Cyber and Physical. This research is conducted with the support ofNational863projects, natural science funds and the relevant research projects of COMAC.The research can be summarized as follows:
(1). Analyzing and summarizing the current digital design of mechatronic productsincluding waterfall model, V model and modeling-design-analysis model, with thepointing of the problems in current product design process. By this way, the digital designmethods for the current mechatronic products and prospective CPS are discussed to statethat the key technologies and two main phases of the methods are digital modeling andsimulation and the HIL simulation. Based on muti-domain modeling and simulation, themethods could be applied into project design, detailed design and test.
(2). As to the design of CPS, the modeling and simulation of it based on the Modelicalanguage and MWorks software becomes the better choice with the realization ofhierarchical modeling from the base model, synthesize model to system model. Moreover,the landing gear system is taken as an example that the model libraries of hydraulics,mechanics, electronics and control are established based on Modelica. Then the model ofsubsystems including retractable landing gear, nose-wheel steering, wheels brakes andenergy management are designed.
(3).The principle of “electric-signal priority sub-section” is presented to divide thesystem into model and physics. In the HIL simulation, the key problems and keytechnologies are analyzed, including the RTI (Real-Time Interface) technology (ex: thecommunication between the model and hardware), code automatically generation formulti-target machine technology (ex: the efficient transferring from the model code tomachine code), and code automatically download for multi-target machine technology (ex:realizing the setting, running control and monitoring of the target machine).
(4).Based on the researches on the digital design, a general digital design platformhas been implemented, which includes the digital simulation system, the simulation targetsystem and the integration management system. The digital simulation system is based onthe Modelica language and MWorks software to realize the hierarchical modeling. Theintegration management system is composed by the RTI and the code generation anddownload technologies. The simulation target system is based on the VxWorks toreal-time calculate the model.
(5).For the landing gear system as a living example, the digital and HIL designplatform is established based on the general digital design platform with the additionaldevelopment of the signal simulation system and the dash board system. The subsystemsof retractable landing gear, nose-wheel steering, wheels brakes and energy managementcould be designed by the platform. Then the project design, detailed design and test couldbe optimized, verified, and analyzed respectively. The platform has been successfullyapplied into the landing gear system of ARJ21and C919in COMAC, which improves thedesign efficiency and shortens the development cycle.
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