Innovation and productivity in test-based engineering Bruno Massa Vice President Testing solutions Siemens PLM Software

Transcription

1 Innovation and productivity in test-based engineering Bruno Massa Vice President Testing solutions Unrestricted. Realize innovation.

2 Key trends that drive innovation in vehicle development and engineering Emissions Reduction New Mobility Market Globalization Electrification Hybridization Autonomous Drive Customization Downsizing Mobility as a Service Local market requirements Lightweight Connectivity Guaranteed Lifetime Page 2

3 Innovation creates new challenges in test-based engineering Enable product innovation and deliver process efficiency Enable product innovation Handle the uncertainty of innovative designs Engineer designs to deliver the expected brand values Balance between key performance attributes Support process efficiency Speed up time to market at reduced cost and risk Gain more insight from less prototypes and testing Enable globalization of product engineering Page 3

4 New challenges in test-based engineering Enable product innovation Downsized engines and driveline integration Vehicle Electrification Lightweight structures and body optimization Auxiliary integration Page 5

5 New challenges in test-based engineering Enable product innovation Downsized engines and driveline integration Vehicle Electrification Lightweight structures and body optimization Auxiliary integration Page 6

6 Vehicle NVH & Acoustic Innovation Area Downsized combustion engines Challenges Torque irregularities Caused by boosting performance and efficiency Driveline integration Low-frequency torsional vibrations are amplified in the driveline Balancing performances Conflicting performance characteristics (NVH, fuel economy, drivability) Page 7

7 Assessing the impact of control strategies on powertrain NVH Balance engine NVH, fuel efficiency and performance LMS Test.Lab allows combining 4 historically separate measurements systems into one integrated system. The big strength is that we are now capable to view NVH versus other attributes! Thanks to this, we can provide valuable information to the engine calibration group to optimize the NVH performance Balance NVH, torsional vibrations, combustion efficiency, engine controls to design an optimal engine Page 8

8 Engine downsizing calls for new approaches in separating combustion from mechanical noise sources Combustion/mechanical noise breakdown Technical metrics for specific engine noises 600 OASPL A-weigthed - total noise 115 Combining advanced array techniques with angle domain sound source localization Torque Torque OASPL A-weigthed - mechanical noise mechanical RPM Torque OASPL A-weigthed - combustion noise combustion Turbocharger noise SSL example ( khz) Ferrari V8 engine (2w testing) RPM RPM Combustion/mechanical breakdown Page 9

9 Punch Powertrain Reduce booming noise when integrating transmissions in full vehicle Analyze transmission torsional vibration induced by torque fluctuations Simulation Test bench evaluation Avoid risks of a redesign after design freeze by frontloading potential booming noise assessment Ensure smooth integration of the transmission in the full vehicle Assess booming noise using a single transmission/driveline configuration model Set up a structured process combining simulation and testing Thanks to the Simcenter engineering expertise, we encounter no more issues with booming noise when integrating our continuously variable transmissions with customer vehicles. Diederik Brems, Mechanical Engineer Page 10

10 New challenges in test-based engineering Enable product innovation Downsized engines and driveline integration Vehicle Electrification Lightweight structures and body optimization Auxiliary integration Page 11

11 New challenges in test-based engineering Electric and hybrid electric vehicles 200+ (H)EV New NVH Balancing models issues performances 220 Increased engineering complexity High-frequency noise in EV and transient noise in HEV impact the driver comfort Conflicting performance characteristics (NVH, fuel economy, drivability) Page 12

12 New noise sources call for new testing and analysis techniques Support to handle new sound signature Full support of Sound Quality process Support of new sensors e.g. ability to derive rotational speed from available resolver Handling new important noise sources Ability to support high-frequent offzero orders that come from power electronics Support to swtich RPM axis between different shafts (important for hybrids) Sound quality Acquisition, incl 3D binaural headset for recording at ear position Fully realistic replay Sound quality analysis and Processing Reuse resolver that is already present at electric motor Derive rotational speed and shaft position from electric motor without any additional sensors Gear whine analysis Battery cooling system noise Electric Motor TPA analysis Page 13

13 Investigation of electrical motor noise Source-Transfer-Receiver methodology Applying TPA and ASQ methodologies on an electric vehicle Traditional TPA technology applied to electric vehicles Identification of major noise contributors up to high frequency (up to 100 th engine order) Electro-magnetic forces, gear whine and PWM switching as noise generating mechanisms Structure borne TPA Airborne TPA Investigation of airborne and structure borne source contributions from the powertrain to the interior by applying common TPA technologies. Traditional TPA methodologies prove well capable of investigating high frequency noise content as seen in electric vehicles if measurements and analysis are done with appropriate care. Page 14

14 Daimler Wind Tunnel Acoustic Properties and Measurement System Wind tunnel acoustic testing and simulation Highly automated & extremely fast acoustic measurements and analysis of 100 s of microphone locations Linked interior and exterior measurements to correlate interior noise to outside sources Wind tunnel testing (LMS Test.Lab) Acoustic testing and analysis in dramatically reduced time Highly accurate full vehicle CFD/Acoustics simulation Simulation (STAR-CCM+) Test Correlation The New Daimler Automotive Wind Tunnel Acoustic Properties and Measurement System Published at 10 th FKFS Conference Page 15

15 New challenges in test-based engineering Enable product innovation Downsized engines and driveline integration Vehicle Electrification Lightweight structures and body optimization Auxiliary integration Page 16

16 New challenges in test-based engineering Lightweight structures Identify potential Find out which components have best weight-saving potential New materials Understand the NVH behavior of lightweight materials Performance balancing Keep well-balanced vehicle for crash, durability and NVH Page 17 Source: McKinsey

17 Volvo New body concept development for NVH and vehicle dynamics Multi-attribute analysis Analysed body flexibility for vehicle dynamics to understand how the vehicle body deforms during handling maneuvers Defined links between BiG performance and full vehicle using multi-attribute beam concept optimization NVH optimization beam / joints concept model Vehicle dynamic step steer trajectory Use multi-attribute analysis methods for better optimization of vehicle performances Improve front end lateral bending stiffness as well as shear mode frequencies as highly sensitive parameters so to improve both handling and acoustic comfort New xc90 body concept development for NVH and vehicle dynamics, Magnus Olsson, Volvo 2015 LMS European Vehicle Performance Engineering Conference Page 18

18 Fiat Group Automobiles S.P.A. Using Simcenter solutions to verify and validate durability virtually Conducting complete fatigue analysis Reduced margin of error in real loads between 8 and 15 percent Reduced overdesign by performing simulation prior to building a prototype Diminished costs by developing equivalency between two proving grounds Proving grounds in Turin, Italy Virtual prediction and use experimental data for model validation Long-term partnership between Fiat and The ability of to deliver customized solutions Although we can t measure the improvement because we previously didn t use virtual data, the results that we have received by using both LMS products are absolutely excellent. Marco Spinelli, Head of the Chassis CAE Department Page 19

19 New challenges in test-based engineering Enable product innovation Downsized engines and driveline integration Vehicle Electrification Lightweight structures and body optimization Auxiliary integration Page 20

20 New challenges in test-based engineering Auxiliary integration New NVH issues No masking noise in hybrid and electric vehicles Sub-systems interaction Study and analyze interactions with other sub-systems Vehicle integration Keep performance targets when integrating into the vehicle Page 21

21 Denso Releasing products 3 times faster by using LMS Engineering services Quantify noise transfer paths in a shorter time Speeding the release of products Close cooperation enhances results Released products 3 times faster than previously possible Reduced time it took to measure TPA by 70 percent Enhanced collaboration with OEMs Develop new approach in close cooperation with LMS Engineering services Deploy LMS testing methods & tools into Denso s HVAC system development process OEMs are really satisfied with the input that we deliver using LMS tools. Thanks to LMS solutions, we are able to release our new products three times faster than was previously the case. Tomohiro Sudo, Assistant Project Manager NVH Page 22

22 ZF TRW Positioning steering systems NVH at the front of the development cycle Development of the world s first NVH steering system bench Reduced overall resources to solve NVH-related issues Accurately estimated resources for NVH resolution upfront Received positive feedback from customers, who appreciate the output data as well as the approach used to gather it Developing a powerful partnership Translate NVH recommendations into real and objective requirements and targets Integrate test and simulation to determine and resolve the root causes of problems We can establish exactly how much force we are allowed to introduce to a particular car to stay below a given NVH target, and we find that our customers appreciate this approach a lot. Christian Landsberg, Global Chief Engineer NVH Restricted Siemens AG 2017 Page

23 Innovation creates new challenges in test-based engineering Enable product innovation and deliver process efficiency Enable product innovation Handle the uncertainty of innovative designs Engineer designs to deliver the expected brand values Balance between key performance attributes Support process efficiency Speed up time to market at reduced cost and risk Gain more insight from less prototypes and testing Enable globalization of product engineering Page 24

24 Supporting testing process efficiency Accelerate design verification and enable benchmarking efficiency Automated data acquisition, analysis and reporting Automated Test project preparation Unified testing instrumentation / data acquisition Multiple consecutive tests reduced to single integrated campaign Automated processing in function of systems / NVH attributes Deployment of an automated data acquisition, analysis and reporting process for the Design Validation of NVH and related attributes on key sub-systems and full vehicle. Our design verification process is now 5 times shorter and the processing of data has gone from 2 weeks to 3 hours. Page 25

25 Supporting testing process efficiency Component-based TPA for full-vehicle NVH what-if analysis Objective Compare Contribution Analysis Characterize noise contribution of source components in a vehicle early in the design Target users Component development teams Vehicle integration departments AOEM s, Tier 1 Suppliers Pa db(a) Sound Synthesis Result F F B B Left Side Left Side Virtual Right Side Right Side Virtual m Pass-by Noise Synthesis db(a) Pa Basic principles weak & strong coupling models Invariant component loads (blocked forces & acoustic loads) Linking component loads to FRF of receiver structure Page 26

26 INTERFACE INTERFACE Supporting testing process efficiency Creating a unified testing framework from virtual testing to field testing Virtual testing Conventional bench testing Virtual testing Model-based System Testing Enable component Testing in the lab in near real-life conditions, by means of realtime simulations Conventional bench testing Field testing Model Based System Testing same metrics and postprocessing tools from 100% simulated to 100% real model-in-the-loop enables system-level testing for real components/subsystems common toolset and same user interface Page 27

27 Model-based System Testing Testing frontloading using simulation models Host PC SUT Page 28

28 Innovation creates new challenges in test-based engineering Enable product innovation and deliver process efficiency Enable product innovation Engineer designs to deliver the expected brand values Handle the uncertainty of innovative designs Balance between key performance attributes Support process efficiency Speed up time to market at reduced cost and risk Gain more insight from less prototypes and testing Enable globalization of product engineering Page 29

29 Simcenter Testing Solutions The integrated platform for Test-based engineering > Data Acquisition > Data Analytics > Reporting > Data Management LMS Test.Lab Structural Dynamics Acoustics Transfer Path Analysis Rotating Machinery Durability Vibration Control Dynamic Environmental LMS SCADAS > Lab > Mobile > Handheld > Rugged > Standalone Testing departments around the world count on Simcenter Testing Solutions to increase test productivity, maintain the utmost quality and ultimately achieve a higher return from existing testing facilities. Page 30

30 Simcenter Testing Solutions Part of the Simcenter portfolio, uniquely combining Test & Simulation LMS Test.Lab LMS SCADAS LMS Engineering LMS Imagine.Lab Amesim Simcenter 3D, NX Nastran & STAR-CCM+ Page 31

31 Thank you! Siemens AG 2017