Basics of Product Data Management in Automotive Engineering

Transcription

1 Basics of Product Data Management in Automotive Engineering Name of institute Mario Hirz Institute of Automotive Engineering G r a z U n i v e r s i t y o f T e c h n o l o g y M. Hirz 2009

2 What is PDM? PDM (Product Data Management) includes all organization based tasks for the identification, the supply and the archival storage of product related data during the product development. Nomenclature: EDM Engineering Data Management, former notation of PDM M. Hirz 2

3 Development of PLM-technologies M. Hirz 3

4 Development of PLM-technologies M. Hirz 4

5 Why PDM? Change of products Volkswagen Beetle 1939 Nowadays: VW model range 2009 Big number of car variants Manifold drive train & chassis configurations Manifold supplementary equipment Source: VW M. Hirz 5

6 Why PDM? - Summary PDM helps to organize the data and information flow throughout the development process. The management of the entire flow of data, processes and documents during the development or modification of products across the products lifecycle states the basis for an efficient virtual product generation. Complex product structures or product variations create numerous product parameter and information. A powerful PDM system supports the interaction of the data transfer between different phases of the development. M. Hirz 6

7 Production Project start Project start Production Institute of Automotive Engineering Simultaneous engineering Conventional procedure Definition of requirements Concept phase 3D/2D design Optimization Production planning Procedure with simultaneous engineering Definition of requirements Concept phase 3D/2D design Optimization Production planning Time saving Integrated virtual product model M. Hirz 7

8 Challenges Product development in the automotive industry presents several challenges in the area of PDM, including: Insufficient transmission of knowledge gained in process and knowledge management to product data management Systematic approach to the design and development of PDM processes and systems (functional strategy, roadmap) Few use cases for operative and project-oriented application of PDM The implementation of PLM approaches involves some difficulties, especially in larger companies with complex structures Data management activities can lack a process orientation Excessive orientation towards systems and software in PDM designs M. Hirz 8

9 Process oriented functions Product oriented functions Institute of Automotive Engineering Main functionalities of PDM Product structure management Documentation & scripts Configuration management Product classification File management Data archive Data network Product versions / releases Lifecycle management PDM System Change management Process management Workflow management Project management Status management Process interfaces Release management Rights & communication Lifecycle management M. Hirz 9

10 Main functionalities of PDM Product structure management Workflow management Project management Relations Persons Processes Part Document File Management of documents Classification - Variants Module 1 Part x A1 B1 C1 A2 B2 C2 acording to Müller, N. M. Hirz 10

11 Product Data - Product defining data in view of technical requirements (target specification data) - Product describing data in view of technical product documentation (article code, article attributes, releases BOM) - Geometry data - Process data - Product configuration data - Meta data - Documents - Characteristics of data - Data quality - Data age, maturity - Project progress - Data status - Data format - Utilization and validity, M. Hirz 11

12 Management of documents - Provision of data and documents - Documents - Target requirements, technical product specifications - Standards, job instructions - Drawings - Documentations - Test reports - Offers, contracts - Documents of change management - Manuals, scripts - Data archiving - Document control - Document distribution M. Hirz 12

13 Workflow management - Control of document (modification, verification) - Integration of customer & supplier - Distribution of documents - CAD data management - DMU / CAx workflow - Change management Change management - Problem identification (detection, registration and tracking) - Modification proposal (assessment of adaptation variants, synchronization of involved parties, result definition) - Modification order (start of product correction) - Modification verification (model check) - Release management (update of data management system, customer and supplier) M. Hirz 13

14 Interfaces Institute of Automotive Engineering PDM system architecture Graphical user interface Functional modules Application related functions - Product data management - Document management - Product structure & configuration management - Classification management - Management of product configurations - Workflow management - User management - Project data management Application independent functions - External functions - Collaborative functions - Data base system Administration Configuration Settings M. Hirz 14

15 Relationship between CAD, CAE, CAT and CAM M. Hirz 15

16 Criteria for the integration of CAD-systems M. Hirz 16

17 Examples of application for CAx - process workflows DMU (Digital Mock Up) FEM (Finite Element Method) CFD (Computational Fluid Dynamics) CAD MBS (Multi Body System) VR (Virtual Reality) TPD (Technical Product Documentation) RPT (Rapid Prototyping) NC/RC/MC (Numerical Control / Robot Control / Measure Control) PPC (Production Planning & Control) M. Hirz 17

18 Process workflow: CAD - DMU Digital Mock Ups are digital dummies, which include a simplified representation of a product. DMUs contain information of: - Product geometry (volumes and / or surfaces) - Product structure DMU processes are used for packaging studies, clash detection, mounting & assembling simulations, and others. Basis for the DMU processes are converted (simplified) 3D-CAD data from a virtual product model (master model). Based on the simplification, the accuracy of a DMU model is lower than those of the 3D-CAD master model (DMU tessellated geometry). In the DMU process, a direct modification of geometry data is not possible. M. Hirz 18

19 Process workflow: CAD - DMU Example: Vehicle packaging study M. Hirz 19

20 Process workflow: CAD - DMU Support of frontloading - approaches by: Handling of large data structures through the product development Localizing and elimination of problems in complex assemblies Target oriented and early assembling based optimization Trends: Geometrical freeze in early sections of the development cycle Integration of functional investigations into the DMU process Integration of data from supplier and external engineering partners Integration of DMU software functionalities into 3D-CAD software packages M. Hirz 20

21 DMU - process 3D-CAD design Master model: CAD - native data including history & structure Data transfer Common data formats: CAD native, STEP, IGES, VDA, DMU model Simplified model: Tessellated geometry data & model structure DMU investigations Information back flow - Packaging - Clash detection - Assembling simulation - Kinematics - M. Hirz 21

22 Process workflow: CAD - FEM The Finite Element Method (FEM) is used for the calculation of stress, deformation, thermal load and natural frequency. The FEM calculation process is based on an approximated geometry, witch is derived from the 3D-CAD model. Depending on the type of geometry and on the target of simulation, different types of approximation are used. The data transfer from the 3D-CAD model into the FE program is performed by a discretization process. Boundary conditions of loads (forces, momentums, ), restraints (fixed components, bearings,...), material characteristics, temperatures, etc. are defined in the FE program. After the simulation process, the results have to be evaluated and lead to an optimization of the master geometry in the 3D-CAD program. A direct modification in the FEM software is not possible. M. Hirz 22

23 stress according to Mises Institute of Automotive Engineering Process workflow: CAD - FEM FEM simulation of a 1-cylinder engine crank train conrod M. Hirz 23

24 Example of application: natural frequency Torsional oscillation Bending oscillation f = 226 Hz f = 406 Hz f = 880 Hz f = 413 Hz M. Hirz 24

25 Information back flow Institute of Automotive Engineering FEM - process 3D-CAD design Master model: CAD - native data including history & structure Data transfer Common data formats: CAD native, STEP, IGES, VDA, FEM model Geometry approximated by finite basis elements Analysis & evaluation Stress - Deformation - Natural frequencies - FEM calculation - Boundary conditions - Load definition - Material characteristics - Rules & functions - M. Hirz 25

26 Process workflow: CAD - CFD CFD (Computational Fluid Dynamics) - simulation enable the calculation and optimization of gaseous and liquid flow processes. Similar to the FEM calculation process, the CFD - model is based on a approximated geometry, the CFD - mesh. The data transfer from the 3D-CAD model into the CFD - program is performed by neutral standard data formats (STEP, IGES, ). Boundary conditions of the calculations are defined in the CFD - program directly. After the simulation process, the results have to be evaluated and lead to an optimization of the master geometry in the 3D-CAD program. A direct modification in the CFD - software is not possible. M. Hirz 26

27 Example of application: CFD simulation of a water jacket V, T T DMU including cylinder and cylinder head of a 1-cyl. engine Convection heat transfer coefficiency at the water jacket M. Hirz 27

28 Process workflow: CAD - MBS Multi Body Simulation (MBS) is used for kinematical based calculation and optimization of assembled (movable) products. The MBS - model is based on the CAD - product structure, whereas bodies, links and joints are considered as rigid in principle. Boundary conditions (forces, momentums, masses, degrees of freedom in movement) are defined in the MBS program. The MBS model often consists of simplified geometrical elements, which are equipped with relevant data for the kinematical calculation. After the simulation process, the results have to be evaluated and lead to an optimization of the master geometry in the 3D-CAD program. A direct modification in the MBS - software is not possible. M. Hirz 28

29 Example of application: MBS simulation of an automotive suspension Simulation of suspension characteristics under different road conditions source: ADAMS M. Hirz 29

30 Process workflow: CAD - VR VR (Virtual Reality) describes a computer - generated virtual environment, which works as user interface. VR based studies include the user into the virtual environment. Real time interactions of geometries and / or functionalities support an assessment of the model. An imagination of manipulability objects gives a near to real life feeling of the virtual product. The VRML - data format (Virtual Reality Modeling Language, 1994) was designed to display 3D - models and to integrate user based interactions. VRML - data, which are generated from a 3D-CAD master model, include simplified geometry information without history data. M. Hirz 30

31 Examples of application sources: VRVis, Audi M. Hirz 31

32 Process workflow: CAD - TPD The Technical Product Documentation (TPD) enables a derivation of technical drawings, bill of material, spare part lists, prospects, and others directly from the 3D-CAD model. The CAD master model has to include all the required information (product structure, geometry, tolerances, material, production related data, etc.). TPD formats are: Text based (PDF), 2D - vector & pixel graphics (DXF, TIFF, GIF), hypermedia formats (HTML, XML), or 3D-documentation software based formats (3D-PDF, WRL) TPD processes are always linked to standardization regulations and guidelines (ISO, DIN, company defined standards). M. Hirz 32

33 Examples of application 1 piston 2 piston pin 3 piston pin bearing 4 con rod 5 lower con rod bearing 6 crank pin 7 crank webs D exploded view Part list and 2D workshop drawings M. Hirz 33

34 Process workflow: CAD - RPT Rapid Prototyping (RPT) is used to generate hardware models from virtual geometry data during the product development phase. The early available prototype enables real life studies, test bench optimization or customer discussions. RPT is used for concept models, design- or ergonomic studies or functional tests and optimization. Rapid prototypes are generated from a tessellated geometry, which is derived from a 3D-CAD master model. The most usual file format is STL (Structural Triangle Language). STL geometries are based on triangulated surfaces without any history or product structure information. Productions techniques are Laser Sintering, Stereo Lithographic, 3D- Printing, etc. M. Hirz 34

35 Process workflow: CAD - RPT Virtual product Physical rapid prototype source: Bluming Physical product source: ZCorp source: rapid MFG source: Ducati M. Hirz 35

36 Process workflow: CAD - NC/RC/MC CAD - NC/RC/MC (Numerical Control / Robot Control / Measure Control) processes take over geometry data of a product from a 3D-CAD master model into a manufacturing specific environment (language). Beside the geometry information, the master model includes all production relevant data (tolerances, surface treatment, material characteristics, etc.). A NC - data model contains machine-specific information of applied tools, model fixation, cutting speed, and others. RC - data enclose handling and / or assembling relevant data of the product in the manufacturing process. MC - data define prescribed measurement procedures for the analysis of the manufacturing process, deviation of tolerances or abrasion parameters. M. Hirz 36

37 Example of application: Stamp milling simulation sources: predator CNC M. Hirz 37

38 Process workflow: CAD - PPC PPC (Production Planning & Control) includes the administration and organization of manufacturing relevant data and procedures. Only released product data are transformed into the production planning process. PPS data base on the 3D-CAD geometry, 2D- drawings and additional manufacturing relevant information. M. Hirz 38

39 CAM / CAQ control Production control CAE/CAD/CAP planning Production planning Institute of Automotive Engineering Process workflow: CAD - PPC Bill of Material (BOM), working schedule, manufacturing recourses CAD / CAM: Basically technical functions PPC: Basically economical / operational functions - Product concept - Design / simulation - Process planning - Material logistics - C - programming - Customer order - Project calculation - Requirements planning - Material logistics - Production capacity calculation - Order release - Control of NC - machines - Transportation control - Storage management - Assembling control - Maintenance management - Quality management - Production management & control - Operating data logging - Controlling (time, quantity, costs) - Shipment management according to Scheer M. Hirz 39

40 Abbreviations BOM... Bill of Material CAD... Computer Aided Design CAE.. Computer Aided Engineering CNC.. Computer Numerical Control CFD... Computational Fluid Dynamics DIN Deutsches Institut für Normung (German Institute of Standardization) DMU.. Digital Mock Up DXF... Drawing EXchange Format FEM... Finite Elements Method GIF. Graphics Interchange Format HTML HyperText Markup Language IGES.. Initial Graphics Exchange Specification ISO International Organization for Standardization MC. Measure Control MBS.. Multi Body System MPV.. Multi Purpose Vehicle NC. Numerical Control PDF... Portable Document Format PDM.. Product Data Management PLC Product Lifecycle Collaboration PLM... Product Lifecycle Management RC. Robot Control RPT... Rapid Prototyping STEP. Standard for the Exchange of Product data SUV... Sport Utility Vehicle TIFF... Tagged Image File Format TPD... Technical Product Documentation VDA... Verband Der Automobilindustrie, DIN - standard for data exchange VR.. Virtual Reality WRL.. Web Rule Language XML... Extensible Markup Language M. Hirz 40

41 Further literature: ISBN-13: M. Hirz 41

42 Thanks for your attention M. Hirz 42