Virtual Product Development using advanced CAE and Design Exploration

Transcription

1 Daniel Scuzzarello, M.Sc. Virtual Product Development using advanced CAE and Design Exploration siemens.com/mdx

2 Agenda Challenges for Product Development Product Development with CAE Virtual Product Development with Advance CAE and Design Exploration Teamcenter for Simulation Design Exploration Page 2

3 Challenges for Product Development Increasing product complexity and requirements More product variants and configurations Greater collaboration needs for multiple location dispersed teams Increasing CAE simulation usage Greater variety and complexity of simulations Vastly greater amounts of simulation data Lack of resources can not be solved with more resources, but with strategy!!! Page 3

4 Product Development with CAE In a Nutshell Typical Unmanaged Analyst Environment Typical CAE Analyst Environment Requests Validate Troubleshoot Predict PDM Program Managers Product Data Configuration Analyst Simulation Applications Requirements Data Storage (Models & Results) Analysts Page 4

5 Product Development with CAE Typical Unmanaged Analyst Environment Inefficiencies in Product Development Analysts are spending significant amount of time on searching for data and providing data to others. Lack of traceability & pedigree. Huge volumes of data Page 5

6 Product Development with CAE Typical Unmanaged Analyst Environment Poor Collaboration and IP Protection Multiple engineering teams Collaboration is manual Simulation tasks are outsourced to external suppliers Protecting IP is a big issue Page 6

7 Product Development with CAE Typical Unmanaged Analyst Environment Do More Simulations (With Less) Start from scratch every time Redo analysis, Redo geometry simplification, Redo meshing, Redo load case definition etc Don t know, don t trust Page 7

8 Product Development with CAE Typical Unmanaged Analyst Environment Different processes, different types of analysis, and different applications Integrating & capturing data seamlessly without adding much overhead Repeatability issues Lost know-how Disparate Processes and Tools Lost process knowledge Page 8

9 Product Development with CAE Typical CAE Analyst Environment Import Geometry Mesh Select Physics Solve and Post-Process Design #N+1 Design #N Change Design (geometry and physics) Page 9 Manual and Laborious Process

10 Virtual Product Development with Advanced CAE and Design Exploration Typical Unmanaged Analyst Environment Managed & Streamlined Analyst Environment Requests Requests PDM Product Data Program Managers Teamcenter Product Data Program Managers Configuration Analyst Simulation Applications Configuration Simulation Data Requirements Simulation Tools Simulation Workflows Analysts Data Storage Requirements Simulation Applications (Models & Results) Analysts Schedules Page 10

11 Objective 2 Virtual Product Development with Advanced CAE and Design Exploration Typical CAE Analyst Environment Virtual Product Development Validate Troubleshoot Predict Explore Optimize = Feasible = Infeasible Page 11 Objective 1 Discover Better Designs Faster

12 VALUE Redefining Simulation Strategy for Innovation Our customers operate here to design better products Most companies operate here to reduce time and cost Validate Troubleshoot Predict Automate Explore SIMULATION PURPOSE REACTIVE PROACTIVE Discover Better Designs, Faster! EXPLORE DIGITALLY, CONFIRM PHYSICALLY Page 12

13 Virtual Product Development with Advanced CAE and Design Exploration Managed & Streamlined Analyst Environment Virtual Product Development Teamcenter Simulation Page 13

14 Teamcenter Simulation Simulation Data Management Simulation Lifecycle Management Closed Loop Product Validation Simulation Structure Management Design and Simulation Process Simulation Structure Automation Simulation Process Management Page 14 Simulation Visualization

15 Teamcenter Simulation: Simulation Data Management CAEGeometry CAD Item CAEResult CAEModel Binary output file Named Reference CAEAnalysis Page Bulk data deck Named Reference Solver (number cruncher)

16 Teamcenter Simulation: Simulation Data Management Simulation Pedigree Illustration Teamcenter provides complete traceability between product and all the simulation data (simplified geometry, models, load cases, results, reports etc.) in both directions. CAD Structure Multiple Analysis run by different attributes Multiple Model Structures built Page 16

17 Teamcenter Simulation: Simulation Lifecycle Management Simulation Lifecycle Management Illustration Capture & Manage Lifecycle of Simulation Data Perform lifecycle operations on the simulation data (Create, Revise, Update, Delete, Release, Archive etc.) Manage simulation lifecycle independent from the product lifecycle, while maintaining the relationship Revise the geometry, models, analysis and results independent from each other (for example multiple meshes on the same geometry, multiple analysis with different load cases using the same mesh etc.) Move data into cheaper storage mechanisms for long-term archival while maintaining associativity and access (using Hierarchical Storage Management capabilities). Analysis Evolution Product Evolution Page 17

18 Teamcenter Simulation: Closed Loop Product Validation Product Revision External Simulation Applications Design Engineer Define Contract Simulation Tool Launch Framework Analyst Create Validation Contract Product Revision Configuration (variants) Requirements Workflow Retrieve Validation Data Create / Reuse Mesh Models Apply connections, Load cases etc. Execute CAE Packages (optional) Validation Contract in the context of 3D simulation Simulation Reports Create Reports Post-Process Run the solver TEAMCENTER Page 18

19 Teamcenter Simulation: Closed Loop Product Validation Link with Requirements Illustration Capture and manage all the product performance requirements, product validation requirements, validation procedures etc. related to simulation. These requirements are associated to the simulation data for complete traceability. Analysts can validate requirements against simulation results to close the loop. Requirements Traceability Report Simulation Results Page 19

20 Teamcenter Simulation: Simulation Process Management Process Automation Illustration Business Process Automation Formalize communication of requirements, design data, results etc. between various disciplines (systems engineers, design team, CAE attributes etc.). Capture and document simulation process steps, resulting in repeatable and standardized processes, which provide guidance to the users. Capture and execute workflows at user level, group level or across disciplines. Establish traceability between processes and the data captured. Example customer simulation business process captured as a workflow Page 20

21 Teamcenter Simulation: Simulation Process Management Initiate Page 21

22 Teamcenter Simulation: Dashboard and Signoff Dashboards Illustration Teamcenter provides different types of dashboards to Analysts, Program Managers, IT Managers etc. for different purposes. These dashboards are supported through powerful data mining techniques. These include: Simulation Data Monitor BOM Reporting Analysis Reporting Reporting & Analytics Page 22

23 Teamcenter Simulation: Systems Driven Product Development (SDPD) Domain Architect Monitor Results 20% 8% Domain Architect Study Alternate Approaches Approve Proposed Solution Simulation Engineer Initiate and Run Simulation Perform Analysis / Report Results Engineer Incorporate Proposed Solution Create Validation Package Page 23

24 Teamcenter Simulation Benefits Speed-up simulations and deliver results faster Remove clerical tasks Eliminate rework Improve collaboration Capture knowledge Process Automation Make better product decisions Deliver simulation results on time Improved confidence in simulation results Minimize implementation costs and risk Configure applications and capture data Leverage out-of-the-box capabilities with configuration Page 24

25 Virtual Product Development with Advanced CAE and Design Exploration Managed & Streamlined Analyst Environment Virtual Product Development Teamcenter Simulation Page 25

26 VALUE Redefining Simulation Strategy for Innovation Validate Troubleshoot Predict Automate Explore SIMULATION PURPOSE REACTIVE PROACTIVE Discover Better Designs, Faster! EXPLORE DIGITALLY, CONFIRM PHYSICALLY Page 26

27 Airbus Static Air Mixer Use STAR-CCM+ to gain insight into pre-conditioned air supply for climate control and de-icing equipment Quickly and simply generate and test a design variant Automate this change to intelligently search the design space Page 27

28 Pratt & Miller - Military Vehicle Design Challenge: Find vehicle ride elements that: Satisfy 40 constraints Improve 44 ride factor variables Subject to 7 vehicle maneuvers Minimize sum of absorbed power and max vertical acceleration Previously, after 12 man weeks of manual effort using DOEs, no feasible designs were found Results: After 200 evaluations, HEEDS discovered 61 feasible designs Identified design with best performance after 123 evals Stellar vehicle performance! Page 28 Best run Factors Simulation Constraint # Dual rate spring 5 Baseline Designed 10" half-round GCWwith Vertical accel HEEDS! 4 Position sensitive damper 12 Front 10" half-round CVW Vertical accel 4 Anti-roll bar 3 Ride frequencies 4 Geometry 3 Drop-off GVW Ride damping 4 Dual rate spring 5 Ride frequencies 4 Position sensitive damper 12 Drop-off CVW Rear Ride damping 4 Anti-roll bar 3 Offroad CVW Absorbed power 4 Geometry 1 Offroad GVW Absorbed power 4 Total 44 Yaw overshoot 1 Step steer Constant radius HEEDS is superior to anything else on the market today. - Jesper Slattengren, Pratt & Miller That s the best vehicle I ve ever ridden in. - Frank Sturek, Infantry Battalion Commander Roll overshoot 1 Yaw damping 1 Roll damping 1 Understeer gradient 2 Max lateral accel 1 Roll gradient 1 Total 40

29 Concepts Explored Customer Example: Concrete Plant Exhaust Treatment Challenge: Improve plant exhaust filtering Maximize velocity uniformity through filter Constraints Largely frozen plant design Design variables Geometry of limited region with or w/o deflectors Results: Increased flow uniformity from 75% to 91% Gas inflow Gas outflow filter Plant design is frozen, can only modify parts in red Current 60 runs, 10 minutes ExtrudeDistance2 85 % 80 % 91 % Ideal TranslationVector ExtrudeDistance1 Page % 76 % 96 % UNIFORM Uniformity ACHIEVED: improved from 75% to 91% %

30 EDAG - Full Vehicle Weight Reduction Challenge: Minimize Body-In-White weight Maintain manufacturability Obtain the same or better performance System-level requirements Full vehicle requirements Constrain increases in cost Previous complex optimizations (with 484 variables) were not possible Results: After 250 evaluations, found 49 feasible designs BODY NVH FRONT CRASH (all load cases) OCCUPANT RESTRAINTS (all load cases) TARGET WEIGHT (20% saving) TARGET COST (10% up) MDO PERFORMANCE ASSESSMENT BASELINE BODY STIFFNESS (global and local) DURABILITY ROOF CRUSH (all load cases) Identified the best design with an 18% reduction in weight and less than 5% increase in cost SIDE CRASH (all load cases) REAR CRASH (all load cases) Page 30 HEEDS allowed us to meet DFSS requirements in record time. Javier Rodriguez, EDAG

31 EDAG - Full Vehicle Design Page 31

32 Virtual Product Development using Advanced CAE and Design Exploration Lack of resources can not be solved with more resources, but with strategy!!! Project 7 Project 6 Project 5 Project 4 TODAY Project 1 Quick Start Baseline Design Space Better Designs Project 3 Project 2 Your Innovation Goal SELECT GET STARTED EXPLORE 1ST SUCCESS EXTEND INNOVATE Teamcenter Simulation Page 32

33 Daniel Scuzzarello Sales Director Phone: +55 (11) Mobile: +55 (11) daniel.scuzzarello@siemens.com siemens.com/mdx Page 33