Model of scaled test rig for real time applications

The existing mechatronic models of scaled test rigs are usually built in multibody simulation programs or in the interactive simulation tool. In these cases, the simulation processes run so slowly that makes this approach not ideal and not realistic for test rig dynamics, especially when it is necessary to develop electronic controller systems. In the present work, the design approach for the a real-time simulation is proposed and based on a decomposition of the mechatronical system into groups with elements, which are modeled separately, and then all groups are integrated in the full system. The mechanical system can be split into two subsystems. The first subsystem model has been realized in Simpack multibody symbolic code generator and describes the behavior of mechanical components of the test rig. The second one, the wheel-roller contact model, has been developed in C program language and integrated in Simulink as S-function blocks. The controller and the electrical parts have also been simulated in Simulink. The numerical experiment for the mechatronical system was made in Simulink. The obtained data about the behavior of the mechanical model has been used for the verification of the real-time contact model inside of a dSpace Modular System, built on the DS1006 Processor board.