Enhancement of Virtual Development in FGA Harald J. Wester Chief Technical Officer Fiat Group 1
Virtual Development OBJECTIVES 1. 1. Reduce the the TTM TTM 2. 2. Improve Product Performances & Quality APPROACH 1. 1. Standardization of of Technical Solutions and and Components 2. 2. Widespread use use of of Virtual Analyses in in all all Development Phases 2
FIAT: Pioneer in Virtual Reality Dante Giacosa, the the father of of 500 and and 600, :: electronic brains will will become fundamental to to the the creation of of better automobiles in in the the future 3
What we achieved Concept definition Technical concept definition Technical / technological Development & Tooling Product / process validation Preseries Ramp-up Kick off Briefing Approval of the initiative Technical release Job 1 Launch 0 2001-26 -16,5-4 -18 2006-9 -2.5-16 2008-8.5-2.5 4
Key Drivers of Virtual Development Enhancement Concept definition Technical concept definition Technical / technological Development & tooling Product / process validation Preseries Ramp-up Kick off Briefing Approval of the initiative Technical release Job 1 Launch Frontload V.D. V.D. in in Technical Concept Definition Phase Enhance multifunction integration and and optimization in in Technical / Technological Development Develop integration with with Manufacturing V.D., involving also also Logistics & Quality 5
Virtual Coverage in Technical Release Concept definition Technical concept definition Technical / technological Development & Tooling Product / process validation Preseries Ramp-up Kick off Briefing Approval of the initiative Technical release Job 1 Launch Ergonomics & Driver Interface Climate Fuel Economy and Driveability Vehicle Dynamics Aerodynamics Passive Safety NVH Operational Strength Electric / Electronic Compliance Environmental Compliance 80 % of the targets are now evaluated in virtual Physical verification is done with Process Verification Vehicles In few cases physical evaluation is not needed 6
The Growth in Virtual Coverage of Targets Technical concept definition Technical / technological Development & tooling Approval of the initiative Technical release Technical Targets Covered in Virtual 2001 20-30% 40-50% 2007/8 40-50% 80% 2010 80% 85% With reference to the set of targets relevant in each phase 7
From physical to virtual: no prototypes Virtual engineering has has enabled the the initial less less significant test test cycles to to be be eliminated and and the the number of of prototype vehicles to to be be reduced or or even cancelled. 8
From physical to virtual: infinite number of tests Computer simulations enable a limitless number of of virtual prototype configurations to to be be realised and and subjected to to practically infinite number of of tests, far far greater than than ones feasible with with physical prototypes. 9
From physical to virtual: deeper insight Mathematical models to to perform highly complex analyses enables our our engineers and and designers to to gain gain an an understanding of of the the vehicle which is is significantly deeper and and more detailed than than was was possible in in the the past. 10
From physical to virtual: paperless Traditional drawing: 3D Annotated CAD model: 3D View: Section 3D View: Section A company-wide evolution now now involving Engineering & Development, Manufacturing, Parts Parts & Services, and and others 3D View: Mid-plane 3D View: composite view 11
From physical to virtual: product / process integration Product optimization and and robustness are are achieved assuming the the real real properties given by by the the process. 12
From physical to virtual: product / process Integration Each assembly step step has has manufacturing virtual validation in in parallel with with each step step of of product development Stamping Body in white Painting Final assembly First process verification vehicle is virtual 13
From physical to virtual: the Digital Mock-Up The The Digital Mock-Up enables all all aspects of of layout, assembly and and accessibility to to be be evaluated with with the the option of of using a total immersion approach employing state-of-the-art virtual reality equipment. 13 14
Functional virtual prototypes: Aeroacoustics Today we we can can carry out out virtual checks before prototypes are are made, even for for performances involving complex phenomena 15
Functional virtual prototypes: Handling and Ride-Comfort Simulation models also also embrace the the wide range of of active systems such as as ABS, Stability Control, Damping Control which may may be be incorporated into into the the vehicle. 14 16
Index of Virtual Development Computation Power Computation Power Index 2000 1800 1600 1400 1200 1000 800 600 400 200 0 1509 880 429 100 206 2004 2005 2006 2007 2008 17
Achieved performances The The investment in in virtual techniques pays those companies trusting them through the the full full exploitation in in Product Development. 16 18
Our Vision for the Future Achieving the fully virtual Product-Process Development Optimization of of Product performances through a rigorous multi-objective approach Improved quality Reduced time-to-market, constrained only only by by tooling time time to gain excellence in customer perception THIS IS THE NEW FIAT 19