ISO/TR 24463:2021

TECHNICAL ISO/TR
REPORT 24463
First edition
2021-10
Digital validation by effective use of
simulation
Validation numérique par utilisation efficace de la simulation
Reference number
© ISO 2021
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on
the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address below
or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: +41 22 749 01 11
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
ii
Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms, definitions, and abbreviated terms . 1
3.1 Terms and definitions . 1
3.2 Abbreviated terms . 2
3.3 Trademarks. 2
4 Business case for computer simulation in early design stage . 3
5 Major challenges in simulation . 3
6 Digital validation technology . 5
6.1 State of the art . 5
6.2 1D CAE modelling of digitally integrated products. 6
6.2.1 Introduction to example . 6
6.2.2 Belt conveyor mechanism . 6
6.2.3 Heat roll mechanism . 9
6.3 Interface between simulations in different technical domains .12
6.3.1 Introduction to example .12
6.3.2 FMI/FMU-based co-simulations .12
6.3.3 Control of simulation time . 15
6.4 Interface between 1D CAE and 3D CAD/CAE . 16
6.4.1 Introduction to example . 16
6.4.2 Realisation of 3D CAD models based on 1D CAE results . 17
6.4.3 Modification of 1D CAE model based on 3D CAE results . 18
6.5 Interface between original equipment manufacturer (OEM) and supplier .20
6.5.1 Introduction to example . 20
6.5.2 Multi-enterprise modelling . 20
6.5.3 Results .22
7 Summary and potential use of this document in the existing standards in the
digital validation domain .23
7.1 Summary . 23
7.2 Potential use of this document in the existing standards in digital validation
domain . 24
Bibliography .25
iii
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www.iso.org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to
the World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see
www.iso.org/iso/foreword.html.
This document was prepared by Technical Committee ISO/TC 184, Automation systems and integration,
Subcommittee SC 4, Industrial data.
Any feedback or questions on this document should be directed to the user’s national standard body. A
complete listing of these bodies can be found at www.iso.org/members.html.
iv
Introduction
Precision and high-performance electrical products can be defined as products that integrate
mechanical, electrical/electronic, and software technologies. These digitally integrated products are
expected to simultaneously achieve high functionality and low cost. In order to meet these needs,
computer technology, which enables designing of highly functional products in a limited period of time,
is necessary. Effective measures to realise such design can include active use of computer simulations
from the functional design stage upstream of a design process, evaluating aspects of the feasibility of
the expected function, and narrowing the appropriate design solutions at an early stage.
This document examines the business requirements for using simulation in the functional design
process and identifies the key technical capabilities needed to satisfy those requirements. Based on a
comparison with the capabilities of current technologies validated through research and experimental
examples, this document identifies a number of digital validation technologies which need to be
developed in order to meet future business needs, and the associated standardization requirements.
v
TECHNICAL REPORT ISO/TR 24463:2021(E)
Digital validation by effective use of simulation
1 Scope
This document examines the standardization requirements for the necessary digital validation
technology for improving design efficiency by effectively utilizing simulation data at the functional
design stage of digitally integrated products.
2 Normative references
There are no normative references in this document.
3 Terms, definitions, and abbreviated terms
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at https:// www .electropedia .org/
3.1 Terms and definitions
3.1.1
digitally integrated product
precision and high-performance product that integrates mechanical, electrical/electronic, and software
technologies
3.1.2
model-based development
MBD
mathematical and visual method of addressing problems associated with designing complex control-,
signal-processing and communication systems
3.1.3
functional mock-up interface
FMI
standardized interface used in computer simulations to develop complex cyber-physical systems
Note 1 to entry: See FMI version in Reference [3].
3.1.4
functional mock-up unit
FMU
component that implements the functional mock-up interface (3.1.3)
3.1.5
co-simulation
two or more simulation functions interacting to simulate different aspects of a digitally integrated
product
3.1.6
simulation time interval
Δt
simulation time step size in a dynamic simulation
3.1.7
supplier
manufacturer that supplies parts to original equipment manufacturers (3.1.8)
3.1.8
original equipment manufacturer
OEM
company that manufactures finished or semi-finished products to be sold by another manufacturer
3.1.9
machine-readable data
data in a format that can be automatically read and processed by a computer
Note 1 to entry: Machine-readable data shall be structured data.
3.1.10
human-readable data
encoding of data or information that can be naturally read by humans
Note 1 to entry: In computing, human-readable data is often encoded as ASCII or Unicode text, rather than as
binary data.
3.1.11
reduced order model
ROM
mathematical model with reduced complexity for use in digital simulations
3.1.12
finite element analysis
method for solving problems of engineering and mathematical models
3.1.13
1D CAE
multi-domain systems simulation combined with controls
3.2 Abbreviated terms
For the purposes of this document, the following abbreviated terms apply:
CAD computer aided design
CAE computer aided engineering
3.3 Trademarks
For the purposes of this document, the following trademarks are used. The reason that these trademarks
have been used in this document is given in the footnotes.
1)
Modelica® : An object-oriented, declarative, multi-domain modelling language for component-oriented
modelling of complex systems, e.g. systems containing mechanical, electrical, electronic, hydraulic,
thermal, control, electric power or process-oriented subcomponents.
1) This trademark is provided for reasons of public interest or public safety. This information is given for the
convenience of users of this document and does not constitute an endorsement by ISO or IEC. Modelica® is a
registered trademark of the Modelica Association.
2)
MATLAB® : A proprietary multi-paradigm programming language and numerical computing
environment.
3)
Simulink® : A MATLAB-based graphical programming environment for modelling, simulating and
analysing multi-domain dynamical systems.
TM4)
SystemC : A type of hardware description language (HDL) intended for use in functional design of
electronic circuit equipment.
5)
ANSYS® Maxwell® : A type of industry electromagnetic field simulation software for the design
and analysis of electric motors, actuators, sensors, transformers and other electromagnetic and
electromechanical devices.
TM6)
ANSYS® RMxprt : A template-based design tool that designers of electrical machines and generators
can use to enhance ANSYS Maxwell.
TM7)
ANSYS® Twin Builder : An open solution that allows engineers to create simulation-based digital
twins–digital representations of assets with real-world or virtual sensor inputs.
4 Business case for computer simulation in early design stage
Precision and high-performance electrical products, e.g. multifunctional copiers, printers, digital
cameras, and automated teller machines (ATMs) can be recognized as examples of products that
integrate mechanical, electrical/electronic, and software technologies. These digitally integrated
products have to achieve high functionality, rapid development and low costs simultaneously, therefore,
computer technology which enables designing of such highly functional products in a limited period of
time is a key business demand. Effective measures to realise such designs can include actively utilizing
computer simulations from the functional design stage upstream of a design process, evaluating the
feasibility of the expected function, and narrowing the appropriate design solutions at an early stage
[1,2]
.
These measures are common in a broad range of the manufacturing industry.
5 Major challenges in simulation
Figure 1 shows a typical design process of a digitally integrated product. The blue arrow in the figure
indicates the software development process; the yellow and green arrows indicate the mechanical and
electrical development processes, respectively. The arrow in the top section of the figure indicates
the process where a part of the design work may be contracted to external collaborating companies.
2) This trademark is provided for reasons of public interest or public safety. This information is given for the
convenience of users of this document and does not constitute an endorsement by ISO or IEC. MATLAB® is a
registered trademark of The MathWorks®, Inc.
3) This trademark is provided for reasons of public interest or public safety. This information is given for the
convenience of users of this document and does not constitute an endorsement by ISO or IEC. Simulink® is a
registered trademark of The MathWorks®, Inc.
4) This trademark is provided for reasons of public interest or public safety. This information is given for the
TM
convenience of users of this document and does not constitute an endorsement by ISO or IEC. SystemC is a
trademark of Accellera Systems Initiative Inc.
5) ANSYS® Maxwell® is the of a product supplied by ANSYS. This information is given for the convenience of users
of this document and does not constitute an endorsement by ISO or IEC of the product named. Equivalent products
may be used if they can be shown to lead to the same results.
TM
6) ANSYS® RMxprt is the trademark of a product supplied by ANSYS. This information is given for the
convenience of users of this document and does not constitute an endorsement by ISO or IEC of the product named.
Equivalent products may be used if they can be shown to lead to the same results.
TM
7) ANSYS® Twin Builder is the trademark of a product supplied by ANSYS. This information is given for the
convenience of users of this document and does not constitute an endorsement by ISO or IEC of the product named.
Equivalent products may be used if they can be shown to lead to the same results.
The product specification is determined first, followed by the definition of the basic product system
and architecture. Subsequently, the design process is classified into software, mechanical design, and
electrical design workstreams. Further, functional design, detailed design, and performance design are
conducted in that order in each workstream. Though the work is generally conducted independently in
each workstream, information exchange is often carried out across the boundary of the workstreams
and enterprises as necessary.
Various tests and trials are conducted, and the product functionality is confirmed during the
performance evaluation stage. If problems are identified in this stage, information regarding the
problems is fed back to the detailed design stage and design changes are executed to resolve the
problems. In cases with serious problems, it can be necessary to return to the functional design stage
and restart the work, which can result in large losses in cost and time. Prototyping and testing are
conducted once performance evaluation is successfully completed and production is initiated after
manufacturing preparation.
The EN/NAS 9300 series and sub referenced ISO 10303 series can be useful for manipulating design
feedback.
Figure 1 — Typical design process of the digitally integrated product
To achieve high functionality and low cost simultaneously, it is important to thoroughly conduct
parallel computer simulations at the functional design stage upstream of the design process, to verify
the design and reduce functional uncertainty as much as possible, and to reduce the possibility of cases
where problems are detected downstream of the design process which would require rework of the
product design.
Most geometric information related to the product is not determined at the initial functional design
stage. Since many existing computer simulation or computer aided engineering (CAE) technologies are
based on the shape information of the product, they are difficult to use in the verification work in such
an early stage of the design. Some advanced companies have coped with these types of problems in
their CAE software by developing their own simulation tools, but often their own design knowledge is
embedded in proprietary software. This precludes independence from a specific toolset and constrains
long-term maintenance and development.
Decisions in the upstream design are generally transmitted in the form of documents to the downstream
processes. Therefore, the mechanism to reflect functional design results in the detailed design often
depends on the interpretation of an individual designer, so neither uncertainty nor ambiguity can be
removed. Currently, information exchange between different workstreams and enterprises is usually
carried out through documents, and similar problems are unavoidable.
Based on these issues, the following requirements have been identified for digital validation
technologies ensuring the effective application of simulations at the functional design stage.
a) Simulations without geometric information
Simulations that do not require geometric information of the product are required to support
functional design. These 1D CAE technologies, which are widely used in automobile and aircraft
production, are considered a prime candidate for this type of simulation.
b) Co-simulation of different technical domains
Functional verification of digitally integrated products requires technology that can evaluate
phenomena in different technological domains, e.g. mechanical, electrical/electronic, and software,
simultaneously and in parallel, i.e. technologies that can handle multiple simulations in different
technical domains while considering interaction between them.
c) Simulations connected to 3D CAD/CAE
There are 3D CAD models that have been developed based on functional design and detailed
functional analyses have been conducted using 3D CAE. Currently, designers manually convert
functional design results into 3D models. According to analysis results of 3D CAE, rework of
functional design may be required. At present, the work which reflects the result of this 3D CAE
back to the functional design is also carried out manually.
d) Simulations for collaborative design with multiple companies
Many digitally integrated products are developed by the collaborative work of multiple
workstreams within companies. Recently, the number of joint product developments by multiple
companies is increasing. It is necessary to have a mechanism for sharing not only the relevant
model data used in the simulation but also various technical information on the model beyond the
boundary of the workstreams and enterprises.
This document describes the various components of digital validation technology that extend existing
1D CAE capabilities to satisfy these four requirements.
6 Digital validation technology
6.1 State of the art
Effective measures for increased performance, realisation of required complexity and reduced
cost are common requirements in all manufacturing industries, and various solutions have been
implemented to satisfy the requirements. Model-based development (MBD) has shown some success
in the fields of automobile and aircraft production. MBD describes product function and design
requirements as numerical models (often as ordinary differential equations) and conducts functional
analysis/verification by solving the resulting numerical models. Functional analysis is possible even
with incomplete geometric information of the product if differential equations are defined using this
method; therefore, this method is suitable for use in the upstream design process. The use of MBD in the
functional design process is often referred to as 1D CAE. Modelica and MATLAB/Simulink, which are
examples of 1D CAE tools, have already been developed and applied in automobile design and aircraft
design.
Multiple functionally common components are used for representing mechanical or electrical products.
For example, many mechanical products use coupling, power transmission, power control, fluid
transmission, and lubrication elements. Numerical models that correspond to two or more of these
functional elements are packaged together and supplied as a library in the 1D CAE tool environment.
A designer can select functional elements from a library and model product functions by connecting
elements on a screen with a graphical editor, in order to simulate its behaviour. Common approaches
include creating more complex elements by combining basic functional elements or distributing them
as libraries by packaging these elements.
The use of 1D CAE is believed to be effective in the functional design support of digitally integrated
products, if the following three digital validation technology functions can be provided.
a) In mechanical, electrical/electronic, and software domains, 1D CAE technologies suited for each
domain are already widespread. Thus, it is important to create an interface function for activating
multiple 1D CAE tools in parallel to achieve coupled simulations for different technical domains. It
is believed that a functional mock-up interface/unit (FMI/FMU) is effective to achieve this type of
interface.
b) The 1D CAE models obtained from the functional design results are refined into a 3D CAD model
and used in high-accuracy functional analysis with 3D CAE. The functional design may need to be
reworked based on the 3D CAE analysis results, and therefore, the ability to update the 1D CAE
model based on the 3D CAD/CAE results is also important. An interface for this type of model
conversion between 1D CAE and 3D CAD/CAE is necessary.
c) An interface which enables exchange of 1D CAE models and accompanying technical information
between different workstreams and companies is required. Information exchange between
different workstreams and companies are repeated as the design progresses, and the information
is continuously revised along this process. A function that can suitably record this type of process
and consistently manage the technical information accompanying the models is also required.
The next subclauses explore the state of the art in these technologies, using existing tools, and use
examples to illustrate the new capabilities that are required.
6.2 1D CAE modelling of digitally integrated products
6.2.1 Introduction to example
1D CAE technology enables evaluation of design ideas at a stage where geometric information of the
product is not yet determined. This satisfies the first requirement of the use of simulations in the
functional design process of digitally integrated products. The effectiveness of 1D CAE in the functional
design process can be demonstrated by an example of modelling and analysis of the behaviours of belt
conveyor and heat roll mechanisms that simulate the paper conveyor mechanism and image fixing unit
of a plain paper copying machine (copier), which is a typical digitally integrated product. The former is
referred to as "mechanism analysis", the latter, as "thermal system analysis". These examples show that
two completely different physical phenomena can be modelled using the same 1D CAE technology.
1D CAE is not yet supported by the ISO 10303 series. Such support would require a thorough integration
with existing ISO 10303 parts to make it part of the comprehensive product lifecycle model of STEP. In
order to support exchange, sharing and archival of 1D CAE data and their validation, the integrated
resources of the ISO 10303 series need to be extended. This needs to be carried out in a consistent
manner by following the current methodology and by extending existing and/or developing new
8)
documents. ISO 10303-209, ISO 10303-210, ISO 10303-235, ISO 10303-242 and ISO 10303-243 include
the new capabilities to offer them in an integrated manner to the industrial user.
6.2.2 Belt conveyor mechanism
Figure 2 shows the mechanism that conveys media such as paper using a belt. This mechanism is
comprised of a belt transfer mechanism, a motor driving mechanism that applies a driving force to
the belt, and a mechanism for controlling the motor by detecting the position of the medium by a light-
blocking sensor. The belt conveyor mechanism can be viewed as a mechanical system; the motor driving
mechanism, an electric system; and the motor control system, a software system. In the functional
design of this belt conveyor mechanism, it is necessary to determine the sensor position to satisfy the
8) Under preparation. Stage at the time of publication: ISO/DIS 10303-243:2021.
specifications of the motor control mechanism (see Figure 3). A simulation model was developed with
the following control conditions:
a) When the power is turned on, the drive motor rotates at a speed of M0.
b) The drive motor speed switches from M0 to M1 when the medium is conveyed on the belt from its
initial position and passes the light-blocking sensor S1.
c) The drive motor speed switches from M1 to M2 when the medium is further conveyed and passes
sensor S2.
d) The drive motor speed switches from M2 to M0 when the medium is further conveyed and passes
sensor S3.
Figure 2 — Specification of a belt conveyor mechanism
Figure 3 shows the analysis model of the belt conveyor system created using OpenModelica. This model
was designed by combining components provided in the Modelica Standard Library (MSL). For example,
the belt conveyor mechanism was designed by combining the “Mass” and “SpringDumper” components.
The motor drive mechanism was similarly realised by combining other components provided by the
MSL. The motor control system comprises the light-blocking sensor and feedback control unit; however,
components that correspond to these are not included in the MSL. Therefore, a model with equivalent
functions needs to be created by combining simple components provided by the MSL. Figure 4 shows
the analysis results obtained by using this model. The graph in Figure 4 shows the changes in the
rotation speed and position of the objects on the belt. It also shows the changes in the torques of the
drive and driven rollers. The roller and sensor positions can be determined to satisfy the specifications
of the motor control system by referencing these results.
Figure 3 — Belt conveyor analysis model
Figure 4 — Belt conveyor analysis results
6.2.3 Heat roll mechanism
The image fixing unit of a copier melts the toner by applying heat and pressure so that the toner is
fixed onto the paper surface (Figure 5). An electric heater is included inside the image fixing roller,
which transfers heat to the paper through this roller when heated. The temperature is controlled with
a thermistor and electric circuit to maintain constant temperature on the fixing roller surface. Figure 6
shows a functional block of the image fixing unit. The model comprises a heat roller, pressure roller,
paper, thermistor circuit, temperature controller, and a heat exhaust fan for cooling the housing. Heat is
generated by the heat roller and transmitted to the heat roller surface, paper nip (section in contact with
the roller), and the pressure roller. The heat and fixing rollers rotate to move the paper, and therefore,
rotation and heat transfer must be modelled simultaneously. As in Figure 6, each roller is divided into
four parts; the effect of the roller rotation was evaluated by changing the combination of these sections
in contact over time. Figure 7 shows the 1D CAE model of the image fixing unit achieved by combining
components provided by the MSL.
Heat roll structure Heat roll temperature control
Figure 5 — Specification of heat roll
Figure 6 — Function block of heat roll
------------------
...