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Modeling and Simulation Overview

Modeling and simulation is a discipline that is used to develop an understanding of the interaction of the parts within a system. This acquired level of understanding leads to a better understanding of the system as a whole. Southwest Research Institute (SwRI) has been using modeling and simulation to solve complex science and engineering problems for more than 50 years.

Because more and more emphasis is being placed on reduction of time and money spent on product development, modeling and simulation continues to be an effective way to verify, validate, calibrate and achieve results without the need for procuring prototype parts, other expensive components. SwRI is prepared to analyze the client's needs, design solutions, and develop strategies, methods, models and media to provide effective and affordable solutions. Some of the areas in which SwRI offers modeling and simulation are discussed below.

Avionics and Support Systems Modeling and Simulation

In today’s world, simulation models are essential in enhancing scientific understanding through the use of system development, management, and planning. The Aerospace Electronics, Systems Engineering & Training Division of SwRI has applied modeling and simulation solutions in support of technologies that include aircraft avionics, ballistics, and unmanned systems.

SwRI’s efforts to develop efficient simulation models are important in reducing non-recurring engineering cost through:

• Evaluation of mechanical designs before prototyping

• Simulation of vehicle electronics to uncover design issues

• Redesigning prototypes in simulation only

• Evaluating novel concepts for feasibility

• Leveraging existing model repositories

• Using simulation playback with actual test range data

	Developed mission reply HIL simulator and verified ballistic algorithms to a Low Drag Bomb
	Commercially available vehicle modeling software is used to analyze the interaction and dynamic response to a simulated real world environment for robust algorithm development.

SwRI engineering staff applies Model Based Design techniques to develop ballistic models, design weapon scoring algorithms, and test real-time software. SwRI staff evaluates fire control avionics with a mission replay tool which includes a hardware-in-the-loop (HIL) simulation. Previous efforts included redesign of avionics hardware.

Modeling and simulation technologies are also applied to evaluate developed algorithms using kinematic and dynamic

models of unmanned systems. This provides the capability to experiment and analyze the real world effects while eliminating physical, environmental, and economic restrictions. The developed environments provide the investigation of manned and unmanned systems interaction ranging from performance-limiting factors to integrated technologies.

The elements of the modeling and simulation capabilities that span many applications across air and land systems include developing:

• Dynamic Systems

• Sensor Systems

• Environment Models

• Autonomous Algorithms

• Pilot Vehicle Interface (PVI) , Maintainer Vehicle Interface (MVI)

• Hardware-In-the-Loop Simulators

• Machine/Computer Vision Systems

• Digital Signal Processing

• Control Systems

• Weapons Scoring

In developing state-of-the-art technology capabilities, lab facilities include:

ISO 9001:2000 Registered and AS9100 Compliant

For more information about aviation and support systems modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Christopher E. Camargo at ccamargo@swri.org or (210) 522-2095, or visit the following:

• The brochure entitled Modeling and Simulation of Aerodynamic and Ballistic Systems contains information about SwRI’s aerodynamics and ballistic systems modeling and simulation activities. 

• SwRI's Avionics and Support Systems Department performs modeling and simulation of aerodynamic and ballistic systems.

Automotive Modeling and Simulation

	The SwRI-developed RPECS, used extensively in test cell developmental applications, is easy to modify and troubleshoot.

The Engine, Emissions and Vehicle Research Division at SwRI routinely evaluate a variety of vehicle components using the modeling and simulation approach. Some of these components include:

• Engines

• Transmissions

• Powertrain controllers

• Axles

• Electric motors

• Motor controllers

• Batteries

• Suspension systems

• Brakes

• Chassis

• Hydraulic systems

• Auxiliary systems

During component and system development, performance predictions are often based on specific physical characteristics and deterministic operating parameters. Engineers at SwRI develop vehicle models in MATLAB^®/Simulink^® to simulate vehicles from automobiles to heavy trucks. The scope of vehicle modeling and simulating activities at SwRI include:

• Optimized component selection

• Vehicle performance

• Vehicle emissions and fuel economy

• Individual component performance

• Parasitic losses

• Powertrain control strategies

• Trade-off studies and what-if simulations

• Effect of driving cycle on vehicle emissions/fuel economy

To analyze components and subsystems, SwRI engineers use a variety of sophisticated modeling and simulation tools, such as the Institute-developed RAPTOR^®, NESSUS^®, APACE^® and others.

SwRI's automotive staff emphasizes the economic benefits of mathematically based and laboratory-based development, while helping customers minimize dependence on road-based testing and save time and money in the area of product development.

SwRI engineers are extensively experienced in the following real-time applications:

• Real-time operating systems using compiled Simulink models (QNX^®, OPAL-RT, dSPACE)

• Digital signal processing to communicate with physical hardware device I/O signal streams

For more information about automotive modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Daniel W. Stewart at dstewart@swri.org or (210) 522-3657, or visit the following:

• SwRI's Advanced Vehicle Technology section performs vehicle modeling and simulation activities.

For more information on the Advanced Vehicle Technology section's capabilities at SwRI or how you can contract with SwRI, please contact Cheuk Ng at cng@swri.org or (210) 522-3311.

• To learn about systems engineering, control algorithm development and software implementation, powertrain control system development, integration, and calibration, hardware development, and rapid prototyping control development, please view the brochure entitled Powertrain Control Technology. 

For more information about modeling and simulation activities related to powertrain control capabilities at SwRI or how you can contract with SwRI, please contact Jayant Sarlashkar at jsarlashkar@swri.org or (210) 522-5506.

Geologic Modeling and Simulation

SwRI's Geosciences and Engineering Division has developed effective approaches to building and analyzing geomechanical models of complex geologic structures, including:

• An extensional fault-tip monocline in west Texas

• A contractional fault-related fold in the North American Cordillera

• A 3D analysis of subsurface stress development following faulting and erosion

	Digital terrain model (oblique view) showing extensional fault system in clay model.

When coupled with realistic rock properties, geomechanical simulation provides a valid forward model that can be used to validate a geometric and kinematic restoration.

SwRI has developed a new technique to produce digital terrain models (DTMs) of the deformed model upper surface using dynamic structured light (DSL). Using this technology, scientists quantify the morphology of deforming models in high resolution and expand the data derived from laboratory simulations of geologic deformation.

Physical analog modeling is a well-established laboratory technique for reproducing the developmental sequence and overall geometry of geologic structures. SwRI's Physical Modeling Laboratory is a state-of-the-art facility designed to emulate a variety of tectonic settings. The modeling apparatus is modular and can be configured to represent most tectonic deformation styles, including:

• Extension

• Shortening

• Strike slip

• Localized uplift and doming

• Normal and reverse faulting

• Tectonism of a brittle layer over a ductile substratum

• Combinations of these styles

For more information about geologic modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Kevin Smart, Ph.D. at ksmart@swri.org or (210) 522-5859 or visit one of the following:

• The Geomechanical Modeling flyer defines SwRI's approaches to building and analyzing geomechanical models of complex geologic structures.

For more information about geomechanical modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Kevin Smart, Ph.D. at ksmart@swri.org or (210) 522-5859.

• The brochure entitled Digital Terrain Modeling of Geologic Structure Physical Models contains information about SwRI’s capabilities and activities in that area.

For more information about the digital terrain modeling of geologic structure physical models capabilities at SwRI or how you can contract with SwRI, please contact Danielle Y. Wyrick at dwyrick@swri.org or (210) 522-6837.

• SwRI's Physical Analog Modeling provides a state-of-the-art facility designed to emulate a variety of tectonic settings. 

For more information about the physical analog modeling capabilities and facilities at SwRI or how you can contract with SwRI, please  contact Danielle Y. Wyrick at dwyrick@swri.org or (210) 522-6837.

Modeling and Simulation of Network and Radio Communications and Security

	Effective modeling and simulation of today’s complex communications systems requires a team of scientists and engineers with experience in a broad range of capabilities.

The Communications and Embedded Systems Department at SwRI is an interdisciplinary department with broad experience in modeling and simulating complex systems. We have applied our expertise in communications modeling and simulation to:

• Model the deployment of wireless sensor networks in hazardous terrain

• Generate network test traffic from stochastic models of user behavior

• Analyze the performance of various ad hoc network protocols

• Simulate the effects of various network security device deployment strategies

• Develop synthesis-capable models of distributed network defense agents

• Simulate telemetry communications among vehicles on a military test range

• Model the mitigation of multi-path effects in a mobile sensor system

• Simulate total network traffic and network performance on a large commercial jet airplane

Effective modeling and simulation of today’s complex communications systems requires a team of scientists and engineers with experience in a broad range of capabilities such as Internet and wireless network protocols and standards, radio frequency (RF) engineering, computer science, hybrid and ad hoc network design, and cyber security. Our staff of engineers and scientists has expertise in:

• Communications system modeling

• Network modeling and analysis

• RF coverage analysis and multi-path modeling

• Antenna performance modeling and characterization

• Hardware-in-the-loop simulation

• Model-integrated computing technology

In addition to a qualified staff, high-end tools and equipment are required that facilitate realistic traffic generation, that are able to operate at the speed of today’s communications backbones, and that enable hybrid simulations which meld simulated communications elements with actual hardware. SwRI’s Network Simulation and Test Laboratory is equipped with state-of-the-art hardware and software such as:

• OPNET^®

• MATLAB

• RadioPlan

• Agilent N2X traffic generator and test environment

• High-Speed Network Analyzers with capability for time-correlated, multi-tap sampling

For more information about network and radio communications modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Ronnie Killough at rkillough@swri.org or (210) 522-3616.

Read about how SwRI is working to improve the security of the global information infrastructure. For more information about cyber security and information assurance modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Sandra G. Dykes, Ph.D. at sdykes@swri.org or (210) 522-3329.

For additional information, visit one of the following:

• The article entitled Automation and Data Systems briefly summarizes the latest developments in hardware and software solutions for some of today's transportation problems.

• SwRI's Electronic Sensors and Systems section has developed broad experience in the modeling, simulation, and analysis of complex systems.

• Modeling, Simulation and Analysis Brochure

Radar and Electronic Warfare Modeling, Simulation, and Analysis

	Phase array radar coverage modeling and orbital object simulation was conducted by SwRI.
	SwRI simulated an integrated air defense system (IADS) communication and engagement model for the Air Force Information Operations Command (AFIOC).

SwRI has broad experience in the modeling, simulation, and analysis of radio frequency (RF) systems, antennas, radars, and electronic warfare systems. In the context of today’s tool-rich environment, we have the experience to integrate these best-of-class tools to leverage the combined core strengths of the tools to meet the objectives of the modeling and analysis effort. SwRI engineers have experience integrating tools such as Satellite Toolkit (STK) and MATLAB^® to combine advanced algorithm development, orbit simulations, and data visualization.

SwRI engineers have evaluated, developed, deployed, and verified computer-based threat analysis systems for more than a

decade. Our staff has extensive experience in the design, development, deployment, testing, and maintenance of systems used by military organizations to evaluate data collected by a number of sources, analyze planned courses of action, and reduce the development time and cost for complex systems.

SwRI has conducted research in the design of novel antenna topologies and simulation of single and multi-antenna systems. In addition to having optimized design parameters for given antenna topologies for specific applications, entire platform simulations have been conducted to determine the optimal placement of a set of antennas with regard to co-site interference and calibration challenges. Simulations can also include monte-carlo and worst-case simulations to extrapolate the effects of changes in element performance to entire phased array systems.

Simulated current distributions in the SwRI TASH antenna		Model of single plus four quarter elements with periodic boundary conditions for large array simulation

For more information about radar and electronic warfare modeling, simulation and analysis capabilities at SwRI or how you can contract with SwRI, please contact Tom Untermeyer at tuntermeyer@swri.org or (210) 522-5040.

Manufacturing Modeling and Simulation

The Manufacturing Systems Department and Information Systems Engineering Department within the Automation and Data Systems Division at SwRI have extensive experience in utilizing modeling and simulation capabilities in increasing and improving the manufacturing throughput of product development environments.

Today’s manufacturing plants utilize plant level control systems, commonly known as Factory Information Systems (FIS), to:

• Control how the raw material is input into the line

• Control the timing of the processes within the line that transform the material into the finished product

• Control the handling of exceptions that have the potential to reduce productivity during the manufacturing process

SwRI has built scale-model representations of plant floors that allow industrial engineers and plant managers to visualize the production capabilities of the manufacturing line and change characteristics to modeling events such as:

• Unexpected equipment failure

• Scheduled down time

• Configuration changes to equipment

• Effects of changing conveyor and equipment speeds

• Efficiency of new plant and automation designs

• Introduction of new processes within an existing process

SwRI uses a wide range of tools and technologies to build simulations and model, such as:

• ProModel

• MATLAB

• C#/.NET Framework

• Java/Java 2 Enterprise Edition

The combination of industrial engineers and software engineers at SwRI provides the subject matter and technological expertise to develop and utilize modeling and simulation solutions that can increase manufacturing capabilities and improve plant processes in a cost effective manner.

SwRI’s Manufacturing Systems Department has broad capability for modeling and simulation of mechanical systems that, when simulated, can decrease development times, reduce cost, increase performance, and improve reliability. Areas of expertise include a wide range of manufacturing equipment such as:

• Robotics

• Packaging systems

• Food processing systems

• Automated assembly machines

SwRI has experience with the following methods:

• Kinematic simulations of custom mechanisms

• Dynamic mechanical simulations of high-speed machinery

• Time studies and optimization of multi-axis machines

• Robotic simulations and animations of work cell operations

• Finite element modeling of static structures

• Optical modeling for computer vision applications

• 3D solid modeling and animation of machines, production lines, and plant layouts

	This large-scale mail-order pharmacy plant has over ¾ of a mile of conveyors connecting 6 different automated filling systems, one autopackaging system, and multiple workstations for manual filling, refrigerated items, labeling, pharmacy check, and packaging.

SwRI engineers design and develop modeling and simulation systems that are used as test environments for factory control systems development. This allows for performance testing of software against a complete scale model of the plant floor without requiring downtime of the systems as is typical in system software testing in manufacturing. SwRI builds test frameworks that model each individual aspect of the manufacturing process, including:

•  Automation equipment

• Conveyor and material transit systems

• Manual processes, such as QA and hand assembly

• Routing options

• Routing optimization

	In this simulation, it can be seen that there are two traffic problems, one at the Optifill2, and the other at Flexpick1. Using this information SwRI engineers can adjust the routing logic to better optimize the order in which items are filled and make better use of under utilized equipment, increasing overall production.

These individual models are combined into a plant model and developed software code is “plugged in.” This realistic modeling allows simulations to be run that show the impact the developed software algorithms will have on the manufacturing process.

SwRI’s ability to validate manufacturing software design and development through simulation provides a low-cost solution to verifying the performance characteristics of the system prior to deployment without the burden of shutting down the manufacturing environment and reconfiguring software systems to allow for software testing.

For more information about manufacturing modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Clay Flannigan, Manufacturing Systems Department, at cflannigan@swri.org or (210) 522-6805, or Sean Mitchem, Information Systems Engineering Department, at smitchem@swri.org or  (210) 522-2698.

SwRI has developed a low-cost Excavator Operator Training Simulator that provides: • The ability to train equipment operator skills ranging from simple tasks to complex procedures • A risk-free environment eliminating potential equipment damage or personal injury • Highly accessible training not restricted by weather and/or equipment availability • Engaging instruction providing immediate and meaningful feedback

Training Modeling and Simulation

SwRI focuses on delivering training solutions and systems that provide interactive, user-centered experiences with real and simulated objects in a realistic, synthetic environment. We have conducted extensive research and development in the use of modeling and simulation techniques and technologies to provide interactive training for an array of applications. These systems range from desktop applications to fully immersive simulations employing real-time visual, haptic, and olfactory feedback. SwRI's experience in interactive simulation covers the evaluation, assessment, and integration of existing technologies as well as the development of new technologies and application methods.

Areas of expertise include:

• Live, virtual and constructive

   simulation

• Discrete event simulation

• Real-time simulation

• Visual analytics

• Physics-based modeling

• Aggregate behavior modeling

• 3D graphics

• Virtual, augmented and mixed reality

	The Virtual Coatings Application System uses computer simulation and virtual reality technologies to provide a highly capable and flexible system to train spray painting techniques. This system allows a user to view and interact with real equipment while simulating the application of a finishing product on a virtual surface.

SwRI has extensive experience and expertise in the use of

modeling and simulation techniques, technologies and tools for development of training and performance support applications in a variety of industries and government sectors including:

• Aviation & aerospace

• Construction

• Law enforcement

• Medical

• Military

• Telecommunications

For more information about training modeling and simulation capabilities at SwRI or how you can contract with SwRI, please contact Susan Porter at sporter@swri.org or (210) 522-2812, or visit the Training, Simulation and Performance Improvement Division.

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Southwest Research Institute^® (SwRI^®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 11 technical divisions.

March 07, 2013