challenge of dealing with complexity

Transcription

1 Digital Automotive Development - challenge of dealing with complexity Armin Müller, Director Innovations, Concepts; Dr. Ing. h. c. F. Porsche AG Electronic systems as significant contributers and Seite 1

2 From boundary conditions to an engineering tool environment Initial Situation situation The development of a vehicle is influenced by competition, differentiation, legal requirements and trends in a global society as well as by customers. These complex and partly contradictory requirements have to be balanced for an exeptional product and have to be integrated in the vehicle. This results in a high complexity in the car developing process. The process of managing the complexity is organized by a systematic model. The application of this model foucusses on the organizational and technical aspects. One of the main focus concerns the application of digital prototypes. Vehicle engineering needs further development and extension of current tools. Seite 2

3 The automotive market demands attractive products and leads to a permanently rising variety of model versions. Seite 3

4 Beyond the variety of model versions, each vehicle has to meet additional requirements. The automotive overall system has to meet all legal demands, requirements of consumer protection and inhouse demands. The automotive overall system has to meet trends of interest in a global society for at least the product life cycle. The automotive overall system gets its distinguishing by the styling of the overall system and the integrated innovations. The value of the the overall system thereby is higher than the value of the addition of its subsystems. The automotive overall system accomplishes the economical competitiveness. Seite 4

5 The amount of safety requirements to be fullfilled has tenfold since Inhouse Consumer U.S. laws RoW laws Amount of crash configurations Seite 5

6 The characteristics of a brand are also designed by inhouse demands. Performance oriented towards uncompromising, purposeful sport Safety minimisation of risks by applying latest technology Costumers Feel Porsche sport-tuned, performance-oriented as well as efficient and comfortable, quality, reliabilty emotions, wellbeing, precious moments, fun by driving, relaxtion, pleasure Performance oriented costumers Porsche Engineering new technologies and innovations sport-tuned, performance-oriented, fun by driving, individualisation, motorsport up to professional racing Harmony with environment consumer electronics, information technology Social responsibilty and acceptance responsible consumption Women as customers sport-tuned, performance-oriented, fun by driving, ergonomics, aesthetics, operations Seite 6

7 Essential global trends drive the change and generate additional requirements for the vehicle. Environment Information Society Traffic & Mobility need for resources CO2 emissions petroleum dependancy/ market-price assistance systems & integrated safety tracking systems tele service customers in best age cultural differences overcrowded areas infrastructure Seite 7

8 The start-stop-system is an innovation to reduce fuel consumption with high requirements for implementation. Partitioning of the Start-Stop -function Gateway Battery sensor Gear box Sensor cluster PSM Power Lift Gate Trailer Assistance systems 1 Dash board Engine Level Seat Bodycontroller (front) Assistance systems 2 Air-condition control unit Chassis Axle-differentiallock Steering-columnswitch Bodycontroller (back) Parking assistance Airbag All-wheel-drive Back side door (2x) Rear view camera Independant car heating Occupant classification Wheel angle sensor Front side door (2x) RDK Infotainment Cooled generator Reinforced starter DC/DC transmitter AGM battery RPM transmitter Seite 8

9 The partially contradictory requirements result in a high complexity for the automotive development. Seite 9

10 Integrating the requirements in the overall vehicle requires the content related synchronisation of the development s core processes. operative core processes Definition Overall vehicle Chassis Engine/transmission Electric/electronics Concept production-vehicle development Body Seite 10

11 An early project evaluation minimizes project risks and increases the scope of action. Degree of freedom for change Definition Decision stage and basic concept Concept Production-vehicle development Production low degree of specification high degree of variety forecast as good as possible short response time Product optimisation, problem analysis and trouble shooting high degree of specification several small modifications high forecast precision short/medium response time Seite 11

12 The process of managing complexity follows the V-model used in electronics development. Executable specification Support processes Change management Configuration management Quality management Evolution and assembly Status of requirements met Evaluation and interpretation Parts, modules & systems testing The model is valid for both real vehicles and digital vehicles. Seite 12

13 Main processes are model build up, assembly and operation of digital prototypes and support processes. s Model build up Anforderungen Executable specification Support processes Change management Configuration management Quality management Evolution and assembly Digital prototype Status Anforderung of requirements Erfüllungsstatus met Evaluation and interpretation Parts, modules, systems testing Seite 13

14 The requirements are realized by executable specifications. Project specifications Product and project descriptions Executable specifications design models geometry data design surface models geometry data styling functional models technology data Seite 14

15 Data of model set up and digital prototypes are organized in the data management. Task/ Requirement Geometry data DPT data Working process Documentation Technology data Data management Results Material list Support - Processes Digital Prototypes Seite 15

16 Depending on the use of digital prototypes, the results are presented in different ways. Topside Frequenz [Hz] haptics 3D stereo interactive 3D stereo 3D mono animation 3D mono 2D animation x/y plots number sequence TOTAL MASS OF MODEL LOCATION OF THE CENTER OF MASS OF THE MODEL MOMENTS OF INERTIA ABOUT THE ORIGIN I(XX) I(YY) I(ZZ) PRODUCTS OF INERTIA ABOUT THE ORIGIN I(XY) I(XZ) I(YZ) MOMENTS OF INERTIA ABOUT THE CENTER OF MASS I(XX) I(YY) I(ZZ) PRODUCTS OF INERTIA ABOUT THE CENTER OF MASS I(XY) I(XZ) I(YZ) Seite 16

17 In order to develop a product by using analogy models, significant aspects have to be considered. Model build up towards executable specification with different data models from different domains like CAD and electronics Suitable representation of results - e. g. visualization Data management for models, digital prototypes, support processes and supplier integration for digital prototypes Build up and operation of digital prototypes Seite 17

18 Steps for experimental validation are mostly transferable to the virtual world. Digital Prototype Protoype real virtual Preparation Build up Execution Evaluation Seite 18

19 MATLAB and Simulink can be used to run digital prototypes on complete vehicle level. Digital Prototype Protoype Function 1 Input Output Module Digital Prototype Results/Test-Suite With an organized process and modularised structure the digital prototype is easy to handle and use. Seite 19

20 For electronic systems a full test environment exists including a digital prototype. Digital Prototype Protoype overall vehicle test/digital prototype vehicle integration and vehicle test complete network integration and complete network testing system/bus segment integration and part network test software-/hardware integration and control unit test software module integration and software component test real environment sensor Sensorik technology part system Overall vehicle/digital prototype close to customer use real vehicle... vehicle control unit network real regular track... ECU network real driving condition actuator actuator technology bus segment bus segment... part system system and bus management control unit control unit control unit... ECU control unit CPU software component software component... I/O software component foo.c foo.mdl foo.c... foo.c Porsche software module test software module foo.c Supplier Seite 20

21 Non-electronic based systems are used in a individual test environment. They are based on mechanics and hydraulics. Digital Prototype Protoype Seite 21

22 Traction switch Wheel speed sensor Info lamp Brake light switch BLS ABS LSD unit The influence of electronic functions on full vehicle level has to be organized by co-simulation. Digital Prototype Protoype Trimmed-body Function 1 Function 2 Stiffness Input Output Input Output Fatigue strength (BIW) Interdisciplinary Crash Digital Prototypes Input Output Input Output Pedestrian protect. Function 3 Function x Restraint systems FMH/Greenhouse Control unit Control unit Hydraulic LSD: Limited slip device al-aq Acceleration sensors slip LSD: Limited NVH/Acoustic elastic MKS MKS CFD Thermal model Performance/ fuel consumption Control & regulation system Seite 22

23 Interactions of digital prototypes causes a lot of time to build up the digital prototype. Digital Prototype Protoype Supplier model Digital cpl-vehicle prototype 3D 1,5 D MKS CAD 10 SFE concept Control & regulation system models Cpl.-car response models 1 D to 3 D Geometry CFD Geometry 14 MKS-body MKS power train MKS chassis Actuators 11 FEM Flow aerodynanics Virtual flow body Functions of cpl. car with -regulation systems Brake loads Cooling requirements MKS cpl.-car model Trimmed-Body Stiffness model Stiffnesses/frequences Crash model 1 4 Test data 2 Resistance, lift, air forces Flow about components heat dissipation Thermal models brake, cooling circuit Collective loads excitation functions NVH legislation model Treasuri emks-gsfz.-modell Fatigue strength Pedestrian protection 12 FMH/Greenhouse NVH > 50 Hz Air-borne noise NVH < 50 Hz Damages Pedestrian protectsion FMH Occupant loads vehicle deformation intrusions, sensors Madymo model Occupant loads 6 Performance & consumption model 13 Driving performances consumption, lap times Temperatures, fluids, components, brakes Seite 23

24 The integration environment should support the set up, configuration and operation of the digital prototypes. Digital Prototype Protoype test cases, driving cycle integration environment digital prototype, set up results, visualisation environment, test track profile data management, support processes Central goals for the digital prototype are short build up time and easy to use. Seite 24

25 In the next step the integration environment offers a complete integration platform for the build up of the digital prototypes. Definition Concept Production-vehicle development Production Integration environment digital prototypes 4 Crash 2 Stiffness The digital prototype has to be build up in an autonomized work flow. Additionally a digital concept prototype will be integrated. Seite 25

26 Based on the integration environment the validation of the digital prototypes will be managed. Digital Prototype Protoype Definition Concept Production-vehicle development Production 4 Crash Digital Prototype Integration environment easy to use on full vehicle level The validation will be automated by a workflow and dedicated user interfaces. The complexity in this stage increases especially by the execution and test data management. The test cases will be key for product quality in the future. Seite 26

27 Digital Automotive Development - requirements to an engineering tool Increasing complex requirements and legal regulations evolve extensive demands on theoverallvehiclesystem. In addition to the complexity management tools, models and methods to develop an overall vehicle can be used in analogy to the electric/electronic process. Improvement potentials for faster processes can be seen in the data management, support process, in new problem solving methods of co-simulation of digital prototypes and in the improvement of calculation speed. Long term goal is an integration environment on complete vehicle level that allows to build up and work on a digital prototype with various technologies in early stage and seamless structure. Additionally the environment has to be automated and easy to use. Seite 27

28 Thank you very much for your attention Seite 28