Method of off-line hybrid system assessment for test monitoring and modification

• US 10,061,278 B2
• Filed: 09/09/2014
• Issued: 08/28/2018
• Est. Priority Date: 09/09/2013
• Status: Active Grant

• Current Assignee: MTS Systems Corporation (Illinois Tool Works Inc.)
• Original Assignee: MTS Systems Corporation (Illinois Tool Works Inc.)
• Inventors: Fricke, David M.
• Primary Examiner(s): Lo, Kenneth M
• Assistant Examiner(s): Shafayet, Mohammed
• Application Number:
  US14/481,670
• Publication Number:
  US 20150081045A1
• Time in Patent Office: 1,449 Days
• Field of Search: 700 30
• CPC Class Codes: G01M 17/00 Testing of vehicles testing fluid tightness G01M3/00; testing elastic properties of bodies or chassis, e.g. torsion-testing, G01M5/00; testing alignment of vehicle headlight devices G01M11/06; testing of engines G01M15/00
• CPC Class Codes: G05B 13/04 involving the use of models or simulators
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30

Abstract

A method and an arrangement of controlling simulation of a coupled hybrid dynamic system comprising a component under test and a virtual model includes driving the physical component under test of the system on a test rig over a period of time to conduct a test by applying an initial test drive signal input to the test rig to generate a test rig response. At least a portion of the test rig response is inputted into the virtual model of the system to obtain a model response of the system. A condition of the physical component under test is assessed during at least a portion of the period of time to conduct the test based on comparing another portion of the test rig response with the model response where an output relating to the assessment is recorded or rendered.

Claims

1. A system, comprising:

a physical test rig configured to drive a physical component under test on the physical test rig;

a storage device; and

a computer processor operable with the storage device to store a virtual model of the system less the physical component under test, wherein an interface is defined where the physical component interfaces with the virtual model to form a complete system, the processor configured to, prior to conducting a test;

drive the physical test rig and store in the storage device a first portion of a test rig response and a second portion of the test rig response;

apply the first portion of the test rig response to the virtual model and store a response of the virtual model to the first portion of the test rig response and compare the response of the virtual model to the first portion of the test rig response with the second portion of the test rig response so as to form a difference, the difference being used by the processor form a system dynamic response model and store said system dynamic response model in the storage device;

generate a first test drive signal using an inverse of the system dynamic response model; and

the processor further configured to, during the test;

drive the physical test rig with the first test drive signal over a first period of time to control the physical test rig and generate a first test rig response of the test;

receive at least a portion of the first test rig response into the virtual model of the system less the physical component under test;

obtain a first model response at the interface of the system resulting from the at least a portion of the first test rig response received;

assess a changing condition of the physical component under test during at least a portion of the first period of time to conduct the test based on comparing another portion of the first test rig response at the interface with the first model response at the interface due to continued application of the first test drive signal input to the physical test rig;

record or render an output corresponding to the changed condition of the physical component under test; and

generate a new test drive signal from data corresponding to the assessed changes in the physical component under test and the first test drive signal; and

drive the physical test rig over a second period of time subsequent to the first period of time by applying the new test drive signal as input to the physical test rig to generate a second test rig response.

2. The system of claim 1, wherein the first test rig response comprises a first component and a second component as a result of applying the first test drive signal input to the physical test rig;

wherein the computer processor is configured to receive the first component of the first test rig response and generate the first model response at the interface of the system based on using the first component of the first test rig response and a virtual drive as inputs during the first period of time to conduct the test;

wherein said at least a portion of the first test rig response comprises the first component;

wherein said another portion of the first test rig response comprises the second component;

wherein the computer processor is configured to compare the second component of the first test rig response with the first model response at the interface to form a difference; and

wherein the output is based on the difference.

3. The system of claim 2, wherein the computer processor is configured to obtain the difference at intermittent intervals during a period of time to conduct the test.

4. The system of claim 2, wherein the computer processor is configured to obtain the difference continuously during the period of time to conduct the test.

5. The system of claim 2, wherein the computer processor is configured to generate the new test drive signal to use to conduct the test instead of the first test drive signal input to the physical test rig when a parameter based on the difference reaches a selected threshold.

6. The system of claim 2, wherein the computer processor is configured to repeatedly generate a new drive signal input to use to conduct the test when a parameter based on the difference reaches a selected threshold.

7. The system of claim 5, wherein the parameter is a result of the difference comparing the second component of the first test rig response with the first model response.

8. The system of claim 5, wherein the parameter is based on a rate of change of the difference.

9. The system of claim 5, wherein the computer processor is configured to limit an extent of adjustment of a later obtained drive signal with respect to an earlier drive signal.

10. The system of claim 9, wherein the computer processor is configured to generate the new test drive signal using the first test drive signal input to the physical test rig.

11. A method of controlling simulation of a coupled hybrid dynamic system comprising a physical component under test in a physical test rig and a virtual model of the system less the physical component under test, the method comprising:

prior to conducting a test, driving the physical test rig and using responses from the virtual model and responses from physical test rig to obtain a system dynamic response model and using the system dynamic response model to obtain an initial test drive signal input;

during a first period of time during an actual test of the physical component, initially driving the physical test rig by applying the initial test drive signal input to the physical test rig to generate a first test rig response;

during the first period of time, through a computer processor,

inputting at least a portion of the first test rig response into the virtual model of the system and obtaining a first model response of the system; and

generating a new test rig drive signal based selectively on the initial test drive signal and an output of comparing another portion of the first test rig response with the first model response, wherein the output of the comparison corresponds to changes in the physical component under test; and

during a second period of time of the test subsequent to the first period of time, driving the physical test rig by applying the new test rig drive signal as input to the physical test rig to generate a second test rig response of the test.

12. The method of claim 11, wherein the comparing another portion of the first test rig response with the first model response yields a difference.

13. The method of claim 12, wherein the comparing comprises comparing the difference at intermittent intervals over a period of time to conduct the actual test of the physical component.

14. The method of claim 12, wherein the comparing comprises comparing the difference continuously over a period of time to conduct the actual test of the physical component.

15. The method of claim 12, wherein the generating the new test rig drive signal to use is based on a parameter of the difference reaching a selected threshold.

16. The method of claim 12, wherein the generating the new test rig drive signal to use comprises repeatedly generating a new test rig drive signal when a parameter of the difference reaches a selected threshold.

17. The method of claim 15, wherein the parameter is based on a rate of change of the difference.

18. The method of claim 15, wherein the computer processor is configured to limit an extent of adjustment of the new test rig drive signal with respect to an earlier drive signal.

19. The method of claim 18, wherein the generating the new test drive signal includes using the initial test drive signal input.

20. A method of controlling simulation of a coupled hybrid dynamic system comprising a component under test in a physical test rig and a virtual model less a physical component under test, the method comprising:

prior to conducting a test, driving the physical test rig and using responses from the virtual model and responses from physical test rig to obtain a system dynamic response model and using the system dynamic response model to obtain an initial test drive signal input;

after obtaining the initial test drive signal input;

driving the physical component under test of the system on the physical test rig over a first period of time to conduct a test by applying the initial test drive signal input to the physical test rig to generate a first test rig response;

inputting at least a portion of the first test rig response into the virtual model of the system and obtaining a first model response of the system;

identifying a changed condition of the physical component under test during at least a portion of the first period of time to conduct the test based on comparing another portion of the first test rig response with the first model response due to continued application of the initial test drive signal input to the physical test rig;

generating a new test drive signal from data corresponding to the identified changed condition of the physical component under test during the first period of time and the initial test drive signal;

after obtaining the new test drive signal;

further driving the physical component under test of the system on the physical test rig over a second period of time to conduct a second test by applying the new test drive signal as input to the physical test rig to generate a second test rig response;

inputting at least a portion of the second test rig response into the virtual model of the system and obtaining a second model response of the system;

identifying a changed condition of the physical component under test during at least a portion of the second period of time to conduct the test based on comparing another portion of the second test rig response with the second model response due to continued application of the new test drive signal as input to the physical test rig; and

generating an updated test drive signal from data corresponding to the identified changed condition of the physical component under test during the second period of time.