Implementation and application of Simpackmulti-attribute vehicle models at Toyota Motor Europe Ernesto Mottola, PhD. Takao Sugai Vehicle Performance Engineering Toyota Motor Europe NV/SA Technical Center Simulia European MBS User Group Meeting Nov 7, 2017 Copyright Toyota Motor Europe 2017 Do not reproduce
Agenda 1. Background 2. MBS related technical development at TME 3. Model based development application samples 4. Summary 2 SimuliaEU MBS UGM 2017 -Nov 7, 2017
1. Background
About us TMNA (USA) TME (Belgium) TMC (Japan) TMEC (China) TDEM (Thailand) TMC : Toyota Motor Corporation (Head Office Technical Center) TMNA : Toyota Motor North America, Inc. TME : Toyota Motor Europe NV/SA TDEM : Toyota Daihatsu Engineering and Manufacturing Co., Ltd. TMEC : Toyota Motor Engineering & Manufacturing (China) Co., Ltd. Toyota Motor Europe Technical Center is one of Toyota R&D Centers worldwide 4
Mission of Toyota Motor Europe R&D Vehicle development Research and technical development Perf. / Style concept Engineering Production We continuously develop new technologies to innovate vehicle development 5
Model Based Development Concept Power Train Performance study by Common Model / parameter set (as much as possible) Customer Engine Virtual Environment Ride Handling Durability Real Test Drivetrain Control Target Body Chassis Control NV Drivability Fuel Econ. Source: Google Maps Chassis Source: FraunhoferITWM Body Vehicle performance evaluation replaced where possible by in the loop simulation. 6 TME establishes, utilizes and improves simulation methods for concurrent performance development in European projects SimuliaEU MBS UGM 2017 -Nov 7, 2017
Model Based Development Key enablers: 1. Concurrent performance development 2. Performance improvement with less prototype vehicle 7
Motivation for Simpack introduction in TME for vehicle dynamic performance development All the expected features from a high-end MBS software Rich library of modeling elements Automotive templates + easy components replacing for specific model application Flexible scripting and post-processing for effective load case library development A unique feature set to expand model application scope With Automotive DB Source: DassaultSystemes Can reproduce load cases according to Toyota in-house testing standards Source: DassaultSystemes Easy to use interface Adv. Bushing model Co-simulation RT Solver & HiLS Simpack delivers the features needed to enable Model Based Development Source: TMG 8
2. MBS related technical development at TME
Multi-attribute vehicle models at TME Modeling features driven by required performance physics Physical shock absorber model Guidelines / checklists for model data & setup Advanced tire models Automated process for bushing param. identif. Powertrain SiLS Source: FraunhoferITWM Challenges: Efficient & standardised co-simulation architecture Collaboration with suppliers for data & model exchange Source: DassaultSystemes Multi-attribute capability is realized by appropriate model features and process 10
Model validation: K&C, handling Subsystem validation Test Simulation θ Full Vehicle validation θ t Slow input (100kph) Yaw rate gain Test Simulation Steering wheel angle θ θ t Step input (100kph) Yaw rate gain Test Simulation 11 Achieved accuracy is suitable for vehicle development Frequency
Model validation: ride comfort, drivability A Unsprungmass Ride track, 80 kph B Test Simulation Suspension top mount Tip-in accel., coasting, 30kph Vehicle longitudinal acceleration B Test Simulation A C C Seat rail Current limitations: Rigid body Low fidelity of digital road profile Achieved accuracy is suitable for vehicle development 12
3. Model based development application samples Key MBD enablers: 1. Concurrent performance development 2. Performance improvement with less prototype vehicle
MBD enabler #1: Concurrent performance development Model setup Parameterisation Scenario simulation Postprocessing Easy to use Wizard interface Mass adjustment, Posture setup (incl. KnCadjustment), etc. Simulation specialists Componen tdatabase Variant A Variant B Variant X Load case library Test case 1 Test case 2 Test case 3 Standardised workflow Quality & model accuracy guaranteed by specialists KPI Extraction Import Data scientist Export Workflow deployment Performance specialists Common model base Evaluation by virtual prototype Same vehicle model can be used in various performance areas with limited effort 14
MBD enabler #1: Concurrent performance development Simulation scenarios can be coupled to a 3rd party DoE / Optimisation tool Setup & Param. Scenario simulation Postproc. & KPI Input Param. DoE Scatter plots / sensitivity maps Parameters performance trends Performance trade-offs Output KPIs Multi-objective optimisation Optimal design selection Conflicting performance balancing Baseline design Optimal design 1Optimal design 2 Same vehicle model can be used to develop multiple and conflicting performances 15
MBD enabler #2: Development with less prototype vehicle 4 Agile performance development by simulation 1 Vehicle Virtual test driving Drive Simulators Vehicle 3 Leverage use of subsystem test Multi-attribute model Subsystem SiLS Subsystem Eng bench HiLS 2 Component Virtual validation Component Increase simulation confidence by validation Physical validation RT capable model can be used for virtual and part of physical performance validation 16 Simulia EU MBS UGM 2017 - Nov 7, 2017
Application: drivability evaluation by HiLS HV Vehicle D Mode Powertrain (REAL) Test vehicle HiLS Simulation Veh. Gx Source: TMG Vehicle (Virtual) Torque Gx Torque is provided by RT co-simulation with powertrain bench Vehicle model predicts Gx HV Vehicle EV Mode Veh. Gx Driveshaft Torque Driveshaft Torque HiLSprediction accuracy is suitable for vehicle development Vehicle model + HiLS can replace some vehicle tests for calibration of powertrain ECU 17
Application: steering feel evaluation by DiLS Simpack vehicle model Parts stiffness & friction (Virtual) Proving Ground Power steer logic Source: rfpro Objective evaluation Virtual Subjective evaluation Real time simulation Source: Google Maps Subjective eval. Visuals & controls Performance KPIs Performance sensitivity Desktop tuning of power steer logic Source: Concurrent RT Systems Virtual test drive Test drive Driving simulation can bridge some gap between objective and subjective evaluation 18 Simulia EU MBS UGM 2017 - Nov 7, 2017
Summary TME recognises Simpackas a suitable vehicle simulation platform to enable Model Based Development 1. Concurrent performance development Multi-attribute vehicle models multi-objective DoE / Optimisation Standardised and quality controlled workflow for performance prediction Easy to use interface for deployment to non-specialists in simulation 2. Performance improvement with less prototype vehicle RT capable models Same model for offline and XiLsimulation Example applications: Virtual calibration, virtual test driving 19