Empowering Gearbox Product Development with Simulation Apps March 22, 2016 Starts at 12:00pm ET

Transcription

1 Empowering Gearbox Product Development with Simulation Apps March 22, 2016 Starts at 12:00pm ET

2 Housekeeping Items All attendees are muted The event is being recorded A recording of the event and presentation will be made available to attendees following the conclusion of the event If you have a question during the presentation, you can ask it using the Questions panel on the GoToWebinar Control Panel to the right of your screen. Questions will be answered on a one-onone basis after the conclusion of the event.

3 Agenda Introduction Gearbox System Product Development Where is it today? Brian Wilson, CEO of Advanced Drivetrain Engineering & Technology (ADET) Gearbox Product Design Automation - Integrating common Gearbox tools with Comet Solutions Malcolm Panthaki, Founder & CTO of Comet Solutions, Inc. Comet Demonstration Tim Keer, VP Technical Services Conclusion

4 Virtual Development in Gearbox Industry

5 Issues with Current Product Dev Process Tool Silos Everywhere

6 American Axle NVH Whitepaper Glen Steyer, American Axle s Executive Director of Product Engineering, reports major benefits from the new tool: Average 75% time reduction for each analysis iteration. Approximately $130,000 in annual cost savings at a single engineering site. Improved quality through globally enforced modeling and NVH standards/practices which minimizes opportunity for human error. Ability to run many more NVH analysis iterations, leading to more design decisions, earlier. Ability to redeploy resources as less experienced engineers are now able to safely run simulations.

7 Comet Solutions: Our Mission Comet Solutions helps product development organizations automate design engineering process rapidly, using a software platform that allows easy integration of many popular Math, CAD and CAE tools. Make CAE activities more efficient Automation that works Elimination of rework & repetition Make CAE more impactful to business Useful to more people Results obtained in time to support decisions Simplify the complex process of engineering product systems Build system dependencies into models Create transparency across disciplines

8 Conclusion Next Steps More Detailed Discussions Technology Validation Pilot

9 The Drivetrain CAE Engineer s Dilemma March 2016

10 Principal Brian K. Wilson, Founder, President, & CEO of ADET, has 25+ years of experience in the design, test and analysis of rotating machinery. His experience includes Romax Technology, Inc. where he served as Chief Technology Officer, Ford Motor Company where he held the position of NVH Technical Specialist and work as a consultant for SDRC (Now Siemens PLM). Wilson s expertise is in rotating machinery dynamics, helping major OEMs worldwide to solve an assortment of drivetrain dynamics problems over the years. He currently serves as Vice-Chair on the AGMA Sound & Vibration Committee and sits on ASME s Power and Transmission Gearing Committee. Wilson holds a BSME from Michigan State University.

11 What We Do Drivetrain consulting CAE and custom software Test systems Training and seminars R&D Other advanced technology

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13 Model T Differential

14 Experience based Drivetrain Design PRESENT STATE Definition of Basic Requirements: Speed, Torque, Ratios CONCEPT DESIGN: gear sizing, bearing sizing, bearing forces for housing design CAE DETAILED DESIGN: gears, bearings, shafts, housings CAE REFINEMENT: troubleshooting gears, bearings, shaft, housings, lubrication, cooling! Order Tooling Protos and Production Proto-1 Proto-2 Production Product Development Timeline: months CONCEPT DESIGN: only slight deviations from known successful designs Scramble to support production and launch

15 Drivetrain CAE Engineer s Dilemma Global CAE methods and processes not aligned CAD models are difficult and time consuming to mesh Hardware development is faster than CAE analysis resources don t align Too few CAE resources Optimization? I stop when I have a right answer (not the right answer) due to time constraints Too few experts Experts spend time checking others work, not doing the difficult tasks We need more qualified engineers. The level of inexperience is causing delays Compromise on model quality to save time Monte Carlo? Variation? I can barely complete nominal analyses I need multiple software tools to do my analysis I pass data manually between them. Prone to errors and slow results

16 Drivetrain Design IDEAL STATE (FUTURE?) CFD, lube, thermal Basic Req s (speed, tq, ratio) Real Estate Powerflow (Advanced) Assembly & Variation Proto-1: Additive Manufacturing direct from design quick, inexpensive functional verification no tooling Overall cost 0D/1D/2D/3D 0D/1D/2D/3D CAE tools, New Optimization, Automation, Design Automation, Standardization Standardization Fuel Economy & Controls Lighter, Cheaper, Faster-to-Market, Higher performance Manuf process and tooling defined by design process direct order production tooling Weight Efficiency NVH Durability Manuf Production runs using production tooling only; minor refinement to process not design

17 Thank you for your attention

18 Contact Brian K. Wilson ADET Cell

19 Gearbox Product Design Automation Integrating common Gearbox tools using Comet s Intelligent Templates Malcolm Panthaki, Founder & CTO

20 Comet Solutions Company Overview Pioneer in Simulation Automation for Model-Based Engineering using unique Abstract Modeling Technology Formed in 2001 in Albuquerque, New Mexico, with technology developed at UNM man-years development of proprietary Abstract Engineering Model (AEM) Initial commercial product release in 2008 in the Satellite Optical Systems market Experienced leadership team: >100 years combined PLM industry One of the fastest growing companies in the PLM industry 2

21 Gearbox Product Design: Common Silos & Tools CAD FE Meshing GD&T Tolerance Stack-Up Analysis Gear/Bearing/Shaft System Simulation Acoustics Solvers FE Structural Solvers 3

22 Status Quo: Simulation only for Experts Product Development Team Simulation Data: in silos, inconsistent, non-integrated Product Managers Product Development Engineers Systems Engineers Test Engineers Salespeople everyone needs simulation! Simulation Processes: manual, error-prone, highly inefficient inconsistent Multiple Global Engineering Centers CAE Code 32 CAE Code 40 CAE Code 25 CAE Code 13 CAE Code 38 CAE Code 35 CAE Code 2 Matlab Simulation Team Excel CAE Code 1 Optimization Simulation Experts: become the bottleneck 5 days to clean up geometry and create a perfect mesh?? 4-6 weeks to complete a single analysis? How can simulation be a driving force in design? Simulation has been in the hands of too few, for too long How can we get complex simulation safely and effectively to Everyone Who Needs It? 4

23 The Problem With Engineering Models Product Descriptions Are Functional and Descriptive Common language understood by all your designers, engineers, customers, and suppliers Clutch Bearing But, Engineering Models Are Tool-Specific And Unique C-Bush, P-Bush, Spider Joint, MNF, M-File, Modal Model, FRF, Beam with rotational DOF Every tool has its own language Each Product Variation Drives Many Model Changes FEA, CAD, MBD, Excel, In-House Tools, and more Shaft Every Model Change introduces rework, translation errors, cost, and huge amounts of time for re-analysis Gear 5

24 What Engineers Really Need Functional representation of product systems System & product Intent Functional requirements Design variables System constraints Operating conditions Performance metrics Comet Template Tool-agnostic engineering automation CAD, FEA, MBD, Gearbox, math tools Automation that is robust across design changes and Product Families Automated mixed-fidelity modeling Clutch Bearing CAD In-house tools Acoustics Analysis Gear/Bearing System Analysis Structural FEA & Life FE Mesher Shaft Gear 6

25 Comet s Intelligent Templates Product Evaluation Using Simple Engineering Calculators (SimApps) Embed expert knowledge In robust, reliable, easy-to-create templates Minimal or no scripting Experts Tools Your CAD, Your CAE Automate repetitive modeling & analysis work Using Abstract Modeling, they work across the entire Family of Products that share a basic architecture Deploy Anywhere! Web-based, cloud-enabled Run by Anyone! Easily, Rapidly & Automatically analyze and optimize design variants Within a discipline or across multiple disciplines True Virtual Test Rigs Template Report out CAD in 7

26 Automating Product Development Processes Integrating Tools & Data Across All Design Phases CAD Models Mesh Models Systems Models CODE V Optics Product Representations Analysis Models (Auto-Generated) Comet Workspace Parametric, Multi-Fidelity, Multi-Source, Multi-Discipline Abstract Engineering Model Adaptors to External Tools ANSA Mesher MBD Tools FEA Tools Systems Tools Optimization Tools Isight 8

27 Simulation Apps: Simulation for Everyone Product Development & Sales Teams Product Managers Systems Engineers Designers Salespeople (use the Sim Apps) Simulation Apps (SimApps ) Simulation Team Simulation Experts (author the Apps + use the apps) PLM CAD Tool Math Tool Systems Tool CAE Code 2 CAE Code 1 Optimization Targeted Applications: answer particular questions, on a particular product family, at a particular level of fidelity Simple GUI s that drive Templates that capture/enforce expertise Must work across significant design changes and across a Product Family Must speak the language of the user, not Simulation Expert Certified! Safe and robust for all users Robust across a Product Family Optionally, Web-deployed on Intranets & The Cloud Provide all the computing required for rapid throughput 9

28 Target End Users of Comet SimApps Simulation Experts: Multi-Disciplinary Processes Create and validate best-practice analysis processes Run the most complex simulations Design Engineers: Standard, Repetitive Processes Run well-defined standard analyses safely & consistently Use web-deployable, role-based Vertical Applications that drive Comet Templates (built and updated by the experts) Chief Engineers/Program Managers/Systems Engineers Run multi-fidelity systems analyses from the dashboard Conduct design reviews effectively, without needing presentations 750K engineers worldwide of this type today already using CAE 8M engineers who aren t benefiting from the use of simulation tools today Ultimately, Anyone asking Performance Questions Run actual simulations through a simple web interface to quickly ascertain the performance and cost of customized engineered products 10

29 Wide Scope of SimApps Automotive Spring Design Plastic Bottle Design Aircraft Metallic Seal Design Automotive Driveline Design Heavy Equipment Design Vehicle Suspension Design Automotive subsystems Off-Road vehicles Plastics & containers Consumer appliances Aerospace subsystems Optical Imaging systems Laser systems Electronics PCBs Automotive Bumper Design Engine Connecting Rod Design Washing Machine Design Space-Borne Optical Systems with Thermal Controls Laser Systems Design Electronics Board Reliability 11

30 Business Benefits of Comet Automation Enable Engineers and Teams of Engineers to perform Rapid & Robust Design Space Exploration early & often Significantly reduce the cycle time of each design iteration (>80-90%) Explore the design space more accurately and automatically Evaluate more concepts Better utilize limited resources: human experts & non-experts, time/schedule, program cost Capture knowledge of scarce and dwindling number of experts in an executable/reusable form using Comet s Templates Facilitate the spread of Systems Thinking across the multidisciplinary team of product development engineers Significantly increase the ROI of your simulation investments over the entire product development lifecycle 12

31 Planetary Gearbox Template: Summary Full automation: Rebuilt the CAD with new CAD Parameters Created a Finite Element Mesh Ran an ANSYS Modal Analysis Ran a RomaxDESIGNER static analysis Post-processed in 10 minutes Comet template includes the embedded experience of various experts Not restricted to a single topology this template will accept any combination of CAD / RomaxDesigner models which are consistent and tagged appropriately Can be used for design space exploration Design of Experiments Parameter Study Optimization

32 Conclusion Key Take Aways Comet Automation Templates Capture CAD/CAE expertise & company best Practice/IP for safe reuse Are intelligent and work across a wide range of design changes and product families Are easy to use and enterprise accessible allowing the safe creation of complex designs by experts and non-experts Benefits Increased efficiency (>80%) Increased product design quality Global process consistency and repeatability Enterprise wide impact of your best engineering expertise

33 Thank You Contact: Steve Brown Phone: