Different (Simulink) simulation results when called from App designer than a matlab script (.m)

I have a matlab app which takes in some properties and want to get it to simulate based on these in simulink, then show the results. I have a script which includes some while/if functions, to control the simulation:

%% Sim Setup
close all
load('Battery_2.mat')

%% Operating Conditions
SOC_Initial = 0.95;
SOC_Target = 0.95;
T_Initial = 15;
T_Amb = 15;
Weather = 0;
if(Weather==1)
    Weatherstr = 'Rough';
else
    Weatherstr = 'Calm';
end
s = 112;

%% Day Cycle
Run_Time = 14.5 * (60 * 60); %Day run time in seconds
Wait_Time = 20 * 60; %turnaround time when not charging in seconds
Home = 1; %=1 if hovercraft is at day start point
Charge_Threshold = 0.25; %SOC at which full charge is initiated
Charge_at_home = 1;
Charge_at_dest = 0;

%% Drive Cycle
%Acceleration profile
HAH = 0.1; %Home acceleration from dock to harbour speed in m/s/s
HVH = 10 / 1.944; %Home max velocity in harbour in m/s
HXH = 135; %Home distance within harbour in m
HAC = 0.2; %Home acceleration from harbour speed to cruising speed in m/s/s
VC = 30 / 1.944; % Cruising speed in m/s

%Deceleration profile
DAC = 0.2; %Destination deceleration from cruising to harbour speed in m/s/s
DXH = 135; %Destination distance within harbour in m
DVH = 10 / 1.944; %Destination velocity in harbour in m/s
DAH = 0.1; %Destination deceleration from harbour speed to dock in m/s/s
Xtrip = 7250; %Trip distance in m

HX = HXH + ((VC^2 - HVH^2)/(2*HAC)); %Distance travelled to cruising speed in m
DX = DXH + ((VC^2 - DVH^2)/(2*DAC)); %Distance travelled from cruising speed in m
XC = Xtrip - HX - DX; %Cruising distance
TC = XC / VC; %Time at cruising speed
OTimeq = []; OTimeq(1)=0; OTimeq(2)=(OTimeq(1) + HVH/HAH); OTimeq(3)=(OTimeq(2)/2 + HXH/HVH); OTimeq(4)=(OTimeq(3) + (VC-HVH)/HAC); OTimeq(5)=(OTimeq(4) + TC); OTimeq(6)=(OTimeq(5) + (VC-DVH)/DAC); OTimeq(7)=(OTimeq(6) + DXH/DVH - DVH/(2*DAH)); OTimeq(8)=round(OTimeq(7) + DVH/DAH);
OVelocityq = [0 HVH HVH VC VC DVH DVH 0];
ITimeq = []; ITimeq(1)=0; ITimeq(2)=(ITimeq(1) + DVH/DAH); ITimeq(3)=(ITimeq(2) + DXH/DVH - DVH/(2*DAH)); ITimeq(4)=(ITimeq(3) + (VC-DVH)/DAC); ITimeq(5)=(ITimeq(4) + TC); ITimeq(6)=(ITimeq(5) + (VC-HVH)/HAC); ITimeq(7)=(ITimeq(6) + HXH/HVH - HVH/(2*HAH)); ITimeq(8)=round(ITimeq(7) + HVH/HAH);
IVelocityq = flip(OVelocityq);

figure(1)
plot(OTimeq./60,OVelocityq)
hold on
title('Outbound Velocity Profile')
xlabel('Time (min)')
ylabel('Hovercraft Velocity (m/s)')

%% Run Day Simulation
while Time_Total<Run_Time && ans.End==0
    %Run time loop
    while Time_Total<Run_Time && ans.End==0 && SOC_Initial>Charge_Threshold
        %Discharge cycles
        if (Time_Total<Run_Time && Home==1 && ans.End==0 && SOC_Initial>Charge_Threshold)
            % Run Outward Trip
            State = 1;
            Time = linspace(0,OTimeq(end),(OTimeq(end)+1))';
            Duration = Time(end);
            Velocity = interp1(OTimeq,OVelocityq,Time);
            set_param('Sim_Powertrain_1','Solver','VariableStepAuto','MaxStep','1')
            sim('Sim_Powertrain_1.slx');
            Home = 0;
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
            
            if (Time_Total<Run_Time && ans.End==0 && SOC_Initial>Charge_Threshold)
                %Run turnaround cycle
                if ((Home==1 && Charge_at_home==1) || (Home==0 && Charge_at_dest==1))
                    State = -1;
                    SOC_Change = ans.SOC_Cell(end) - SOC_Target;
                    Capacity_Change = SOC_Change * Cell_Capacity;
                    SOC_Range = linspace(ans.SOC_Cell(end),SOC_Target,100)';
                    ITimeT = interp1(T_ILim,ITime',ans.T_Cell(end));
                    Duration = min([60.*60.*Capacity_Change./mean(interp1(SOC_ICharge,ITimeT,SOC_Range)) Wait_Time]);
                    set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
                    sim('Sim_Powertrain_1.slx');
                    SOC = [SOC;ans.SOC_Cell];
                    Temperature = [Temperature;ans.T_Cell];
                    Current = [Current;ans.Pack_Current];
                    Voltage = [Voltage;ans.Pack_Voltage];
                    Power = [Power;ans.Pack_Power];
                    SOC_Initial = ans.SOC_Cell(end);
                    T_Initial = ans.T_Cell(end);
                    Time_Total = Time_Total + ans.tout(end) + 1;
                elseif ((Home==1 && Charge_at_home==0) || (Home==0 && Charge_at_dest==0))
                    State = 1;
                    Time = [0;Wait_Time];
                    Velocity = [0;0];
                    Duration = Time(end);
                    set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
                    sim('Sim_Powertrain_1.slx');
                    SOC = [SOC;ans.SOC_Cell];
                    Temperature = [Temperature;ans.T_Cell];
                    Current = [Current;ans.Pack_Current];
                    Voltage = [Voltage;ans.Pack_Voltage];
                    Power = [Power;ans.Pack_Power];
                    SOC_Initial = ans.SOC_Cell(end);
                    T_Initial = ans.T_Cell(end);
                    Time_Total = Time_Total + ans.tout(end) + 1;
                end
            end
        end
        
        if (Time_Total<Run_Time && Home==0 && ans.End==0 && SOC_Initial>Charge_Threshold)
            % Run Inbound Trip
            State = 1;
            Time = linspace(0,ITimeq(end),(ITimeq(end)+1))';
            Duration = Time(end);
            Velocity = interp1(ITimeq,IVelocityq,Time);
            set_param('Sim_Powertrain_1','Solver','VariableStepAuto','MaxStep','1')
            sim('Sim_Powertrain_1.slx');
            Home = 1;
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
            
            if (Time_Total<Run_Time && ans.End==0 && SOC_Initial>Charge_Threshold)
                %Run turnaround cycle
                if ((Home==1 && Charge_at_home==1) || (Home==0 && Charge_at_dest==1))
                    State = -1;
                    SOC_Change = ans.SOC_Cell(end) - SOC_Target;
                    Capacity_Change = SOC_Change * Cell_Capacity;
                    SOC_Range = linspace(ans.SOC_Cell(end),SOC_Target,100)';
                    ITimeT = interp1(T_ILim,ITime',ans.T_Cell(end));
                    Duration = min([60.*60.*Capacity_Change./mean(interp1(SOC_ICharge,ITimeT,SOC_Range)) Wait_Time]);
                    set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
                    sim('Sim_Powertrain_1.slx');
                    SOC = [SOC;ans.SOC_Cell];
                    Temperature = [Temperature;ans.T_Cell];
                    Current = [Current;ans.Pack_Current];
                    Voltage = [Voltage;ans.Pack_Voltage];
                    Power = [Power;ans.Pack_Power];
                    SOC_Initial = ans.SOC_Cell(end);
                    T_Initial = ans.T_Cell(end);
                    Time_Total = Time_Total + ans.tout(end) + 1;
                elseif ((Home==1 && Charge_at_home==0) || (Home==0 && Charge_at_dest==0))
                    State = 1;
                    Time = [0;Wait_Time];
                    Velocity = [0;0];
                    Duration = Time(end);
                    set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
                    sim('Sim_Powertrain_1.slx');
                    SOC = [SOC;ans.SOC_Cell];
                    Temperature = [Temperature;ans.T_Cell];
                    Current = [Current;ans.Pack_Current];
                    Voltage = [Voltage;ans.Pack_Voltage];
                    Power = [Power;ans.Pack_Power];
                    SOC_Initial = ans.SOC_Cell(end);
                    T_Initial = ans.T_Cell(end);
                    Time_Total = Time_Total + ans.tout(end) + 1;
                end
            end
        end
    end
    
    if (Time_Total<Run_Time && ans.End==0 && SOC_Initial<=Charge_Threshold)
        % Run charge cycle
        if ((Home==1 && Charge_at_home==1) || (Home==0 && Charge_at_dest==1))
            State = -1;
            SOC_Change = ans.SOC_Cell(end) - SOC_Target;
            Capacity_Change = SOC_Change * Cell_Capacity;
            SOC_Range = linspace(ans.SOC_Cell(end),SOC_Target,100)';
            ITimeT = interp1(T_ILim,ITime',ans.T_Cell(end));
            Duration = 60 .* 60 .* Capacity_Change ./ mean(interp1(SOC_ICharge,ITimeT,SOC_Range));
            set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
            sim('Sim_Powertrain_1.slx');
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
        elseif (Home==1 && Charge_at_home==0)
            % Wait then Run Outward Trip
            State = 1;
            Time = [0;Wait_Time];
            Velocity = [0;0];
            Duration = Time(end);
            set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
            sim('Sim_Powertrain_1.slx');
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
            State = 1;
            Time = linspace(0,OTimeq(end),(OTimeq(end)+1))';
            Duration = Time(end);
            Velocity = interp1(OTimeq,OVelocityq,Time);
            set_param('Sim_Powertrain_1','Solver','VariableStepAuto','MaxStep','1')
            sim('Sim_Powertrain_1.slx');
            Home = 0;
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
        elseif (Home==0 && Charge_at_dest==0)
            State = 1;
            Time = [0;Wait_Time];
            Velocity = [0;0];
            Duration = Time(end);
            set_param('Sim_Powertrain_1','Solver','FixedStepAuto','FixedStep','1')
            sim('Sim_Powertrain_1.slx');
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
            State = 1;
            Time = linspace(0,ITimeq(end),(ITimeq(end)+1))';
            Duration = Time(end);
            Velocity = interp1(ITimeq,IVelocityq,Time);
            set_param('Sim_Powertrain_1','Solver','VariableStepAuto','MaxStep','1')
            sim('Sim_Powertrain_1.slx');
            Home = 1;
            SOC = [SOC;ans.SOC_Cell];
            Temperature = [Temperature;ans.T_Cell];
            Current = [Current;ans.Pack_Current];
            Voltage = [Voltage;ans.Pack_Voltage];
            Power = [Power;ans.Pack_Power];
            SOC_Initial = ans.SOC_Cell(end);
            T_Initial = ans.T_Cell(end);
            Time_Total = Time_Total + ans.tout(end) + 1;
        end      
    end
end

%% Plot Results
TIME = linspace(0,(Time_Total-1),(Time_Total))';

figure(2)
plot(TIME./3600,Current)
hold on
title(strcat(Weatherstr,' Weather - Pack Current'))
xlabel('Time (hours)')
ylabel('Current (A)')

figure(3)
plot(TIME./3600,Voltage)
hold on
title(strcat(Weatherstr,' Weather - Pack Voltage'))
xlabel('Time (hours)')
ylabel('Voltage (V)')

figure(4)
plot(TIME./3600,Temperature)
hold on
title(strcat(Weatherstr,' Weather - Cell Temperature'))
xlabel('Time (hours)')
ylabel('Temperature (degC)')

figure(5)
plot(TIME./3600,Power)
hold on
title(strcat(Weatherstr,' Weather - Pack Power'))
xlabel('Time (hours)')
ylabel('Power (W)')

figure(6)
plot(TIME./3600,SOC)
hold on
title(strcat(Weatherstr,' Weather - Pack SOC'))
xlabel('Time (hours)')
ylabel('SOC')

When I run it, it returns graphs as expected. When I copied and pasted the code from the script to the app, the results came out different. I then tried calling the script from app designer, instead of copying and the same issue came up.

Any ideas what could be causing it or potential work arounds?

Answer 1

[Fangjun Jiang]

This happened several times now and it might be related.

Give a return variable when you call sim() such as Result=sim(...). Otherwite, the results from previous simulation run in the workspace is not over-written. Search in the answers. It resolved the problem at least three times.

[Ruta Czaplinska]

I tried that and unfortunately it did not help. Thank you for the suggestion, though!

[Fangjun Jiang]

There is always this "workspace" issue. Running a script, it is using the base workspace. Running in an APP, it is in the APP workspace. You could make this script a fucntion to encapsulate it to see if it helps.

By the way, variable "ans" is used by MATLAB in base workspace as the return varialbe for any command that doesn't specify a return variable. In your code, it seems to be loaded from the .mat file. You might want to check if that could be a factor.

[Ruta Czaplinska]

I am not sure if I understood correctly, but I tried:

simout = Script_Powertrain_4;

(where 'Scrip_Powerstrain_4' is the name of the script file) and I received the following error: Attempt to execute SCRIPT Script_Powertrain_4 as a function

I am investigating the ans issue.

[Fangjun Jiang]

You need to add "function Script_Powertrain_4" as the first line to make it a function.

Once you make it a function and you can make it run properly in MATLAB Command Window, you have better chance to call it in APP to make it run properly.

[Ruta Czaplinska]

I added a function in app designer:

 function Script_Powertrain_4(app)
            Script_Powertrain_4
            
 end
 

and called it, it showed the wrong results again.