„motion“homepages.laas.fr/nic/movie/workshop/slides/lothar.teske.pdflothar teske / toulouse /...

„MOTION“IN VIRTUAL DEVELOPMENT

PROCESS

Lothar TeskeToulouse / 07.01.2005

Lothar Teske / Toulouse / 07.01.2005 / 2

Product Development ProcessContents

1 Milestones

2 Development Partner

3 Network

4 Data Management

5 Synchronization Process

6 Development Tools

7 Summary


Future Targets in theVehicle Development Process

Mule Alpha Beta 1 Gamma Pilot

Simulation

Beta 2HW Phases

Virtual Phases

PastPast

EngineeringEngineeringStartStart

StylStyl. / Pack.. / Pack.FreezeFreeze

ReleaseRelease Start ofStart ofProductionProduction

ValidationValidationMuleMule

Integrated Virtual EngineeringStyl., Design, DMU, CAE, ME, Plants, ...Validation


StylStyl. / Pack.. / Pack.FreezeFreeze

ReleaseRelease Start ofStart ofProductionProduction

Mission

Mission

HW PhasesStructure Integration Validation PilotMule

Initial ConceptStructure Integration ValidationTodayToday StylStyl. / Pack.. / Pack.

FreezeFreezeReleaseRelease Start ofStart of

ProductionProductionEngineeringEngineering

StartStart

44Fast to MarketFast to Market44Workload ReductionWorkload Reduction44Prototype ReductionPrototype Reduction


Milestones in the Development Process


Styling / PackageStyling / PackageFreezeFreeze ReleaseRelease StartStart

ProductionProduction

ArchitectureIntegration

Design, Test

Validation

Initial Concept ValidationIntegrationConceptdet.ArchitectureV i r t u a l V e h i c l e A s s e s s m e n t sV i r t u a l V e h i c l e A s s e s s m e n t s

Initial

IntegrationConceptdet.

Validation

VirtualVehicle

Styling

ArchitectureConcept


Role of Design in theDevelopment Process

2

5

4 6

1 9

2 8

3 7Math

SurfaceRelease

12

3

Competition

of up to

3 Teams

Kickoff

AlternativeDevelopment Styling ConceptStyling Theme

Alternatives

VR supports Development in Clay


Architecture

ConceptInitial


Validation

VirtualVehicle

IntegrationDesign, Test

Validation

Architecture

4 Determination of Hardpointsfor Architecture including- Underbody, Seat Concept- Axles- Powertrain

4 Up-date of PredecessorSimulation Models

4 First Target Balancing

4 Determination of Hardpointsfor Architecture including- Underbody, Seat Concept- Axles- Powertrain

4 Up-date of PredecessorSimulation Models

4 First Target Balancing

Initial Concept ValidationIntegrationConceptdet.Architecture




V i r t u a l V e h i c l e A s s e s s m e n t sV i r t u a l V e h i c l e A s s e s s m e n t s


ArchitekturBOM


Concept

Initial


Validierung

VirtualVehicleArchitecture








Design, Test

Validation

4 Architecture Development4 Design and Release

of Mule Cars4 First Determination of

Hardpoints in Styling Studio

4 Architecture Development4 Design and Release

of Mule Cars4 First Determination of

Hardpoints in Styling Studio


InitialArchitecture


Validation

VirtualVehicleConcept








Design, Test

Validation

4 Pre-Release of Styling4 Integration of Requirements from

Styling,Performance,Package,Manufacturing etc.

4 Pre-Release of Styling4 Integration of Requirements from

Styling,Performance,Package,Manufacturing etc.


Concept

InitialArchitecture

IntegrationValidation

VirtualVehicleConceptdetail








Design, Test

Validation

4 Conceptdetail4 Detailed Manufacturing

Assessment (i.e. Material Flow)4 Virtual Reviews with all Partner

- Plants- Service- etc.

4 Conceptdetail4 Detailed Manufacturing

Assessment (i.e. Material Flow)4 Virtual Reviews with all Partner

- Plants- Service- etc.


Concept

InitialArchitecture

Conceptdet.

Validation

VirtualVehicle

Integration








Design, Test

Validation

4 Development of Design4 Release (agreed through

virtual Development)4 Continued Support

through Simulation

4 Development of Design4 Release (agreed through

virtual Development)4 Continued Support

through Simulation


Architektur

Konzept

InitialArchitektur

IntegrationKonzeptdet.

VirtualVehicle

IntegrationKonstruktion, Test

Validation

Validation






4 Validation of Simulation Models4 Support for necessary late

Product-/Part Changes4 Virtual Plant

4 Validation of Simulation Models4 Support for necessary late

Product-/Part Changes4 Virtual Plant



PlatformPE Body

PE Chassis

PE Thermal

Electric/Electronic

VehicleIntegration

VehicleSimulation

Noise &Vibration

SafetySupplier Eng.

Supplier

Test &Validation

ServiceEngineering

VehicleDevelopment

& Trim

MEAC

MEP

MEB

Plants

GM/ FIATPowertrain

Development Partner


Architecture CAD CAMStyling Dimensions DieVirtualFactoryCAE/CAT

Common Visualization Tool

ParasolidData Management (Product & Process)Data Management (Product & Process)

Service andProcess

Documentation

DesignReviews

ME Process-Simulation

SuppliersPurchasing

Finance

Visual ConceptReviews

GlobalDatabaseSystem

Data ManagementIntegrated Systems & Data Formats


Synchronization Process

Engineering Milestone:i.e. Build Release

Virtual Assessment

Vehicle-Synchronization

Test








Virtual Assessment


Hardware & Test Hardware & Test










Virtual Assessment

CAE-Transfer Point

Hardware & Test




Receipt of all Data tobuild a complete

Vehicle

Build Virtual Vehicle

Data from allDevelopment Partner

Final Date forData AvailabilitySynchro-Point

DMUDigitaler Mock Up



Vehicle Synchronization



CAE-Transfer Point

Exchange FiniteModels withSupplier



CAE-Transfer Punkt

Å Modeling GuidelinesÅÅ Modeling GuidelinesModeling Guidelines É Virtual Vehicle ReportÉÉ Virtual VehicleVirtual Vehicle ReportReport

0 1 2 3

XYZ

Ç Standardized S/W PortfolioÇÇ StandardizedStandardized S/W PortfolioS/W Portfolio



CAE-Transfer Point

SimulationMilestones

ModelingGuidelines

SimulationTasks

SimulationSoftware

Inputfor

Supplier

Outputfrom

Supplier

SimulationModel

ModelValidation

Results /Reports /

Animations

SupplierSupplier

IntegrationintoFull

Vehicle

OverallOverallAssessmentAssessment



CAE-Transfer Point



Virtual Assessment

Timing

VIniVAVirtual Initial Vehicle AssessmentVAVA Virtual Architecture Vehicle AssessmentVCVA Virtual Concept Vehicle AssessmentVSVA Virtual Structure Vehicle AssessmentVIVA Virtual Integration Vehicle AssessmentVPVA Virtual Product/Process Validation Vehicle Assessment Synchronization

Program SOP 1. Quarter 2002 2. Quarter 2002 3. Quarter 2002 4. Quarter 2002 1. Quarter 2003 2. Quarter 2003

Proj 1 03VPVA

7.8.18.7.

Proj 2 04VPVA

6.12.8.11.

Proj 3 04VCVA 2

22.2.

VIVA

9.8.

VSVA

26.4.18.1. 12.7. 20.6.22.2.

Proj 4 05VCVA

16.8.

VIVA

7.2.

VSVA

15.11.12.7. 13.12.27.9.

Proj 5 05VCVA

19.7.

VIVA

14.3.

VSVA

18.12.17.5. 8.11. 14.2.23.8.21.6.

Proj 6 06VIniVA

31.1.

VAVA

18.7.13.6.

Proj 7 07

t.b.d.

t.b.d.

decision



Virtual Assessment

Data Maturity

Maturaty Definition

A Surface, Volume, Weight,Inertia,

4 Typical section, Layout

3 Surface model, Solid model(without or some radius,partwise based, Conceptcompletely clear, not 100%matched)

2 Solid models, Surface models(completely matched, withradius)

1 Solid model (high degree ofintegration, e.g. tooling data)

Maturaty Definition

A Surface, Volume, Weight,Inertia,

4 Typical section, Layout

3 Surface model, Solid model(without or some radius,partwise based, Conceptcompletely clear, not 100%matched)

2 Solid models, Surface models(completely matched, withradius)

1 Solid model (high degree ofintegration, e.g. tooling data)



Virtual Assessment

DevelomentStatus

DevelomentStatus BenchmarkBenchmark

Load CaseLoad Case

SimulationResult

SimulationResult

AnalyzeType

AnalyzeType

NameSim. / Meas.

NameSim. / Meas.

SubsystemSubsystem TargetTargetPredecessorPredecessor

VILV VCV VSV VIV VVV

Status virtual Prototype Vectra MY 2002RohkarosserieGesamtsteifigkeit

Hersteller OPEL OPEL OPEL OPEL OPEL OPEL A BTyp J2900 J3200 NB J3200 NB J3200 NB J3200 NB J3200 NBModelljahr 1996 2004 2004 2004 2004 2004 1998 1997Entwicklungsphase 1996 FORDERUNG VlnlV VCV VSV VIV VVV PROD. PROD.Messung/Berechnung (S/V) 1996 IO SSTS§ S S S V S V VTORSION (mit Hilfsrahmen)

Steifigkeit mit Scheibe (kNm/deg) 11,0 16,0 (SSTS) 15,7 16,8 13,3 14,9 20,5 14,7Stei figkei t ohne Scheibe (kNm/deg) 6,1 11,0 DEV 9,9 8,9 8,9 9,2 11,3 10,7

Diagonale Maßänderungen (ohne Scheibe) 1,18

Frontscheibenöffnung (mm) 1,37 1,00 DEV 0,19 1,03 1,10 1,07 1,07 1,14Heckklappenöffnung (mm) 1,28 0,75 DEV 0,17 0,73 0,85 0,72 0,82 0,51Heckscheibenöffnung (mm) 2,09 1,00 DEV 0,03 1,88 1,00 1,25 1,03 0,93

Diagonale Maßänderungen (mit Scheibe) 121,4

Frontscheibenöffnung (mm) 0,07 0,15 DEV 0,18 0,18 0,19 0,20 0,12 0,28Vordertüröffnung (mm) 0,26 0,25 3.2.1.6.1.1.2 0,19 0,19 0,24 0,22 0,13 0,30Hintertüröffnung (A) (mm) 0,35 0,25 3.2.1.6.1.1.2 0,24 0,24 0,26 0,24 0,21 0,36Heckklappenöffnung (mm) 0,64 0,30 DEV 0,26 0,26 0,44 0,30 0,33 0,17Heckscheibenöffnung (mm) 0,08 0,20 DEV 0,24 0,24 0,23 0,38 0,21 0,27

BIEGUNG ( mit Scheibe, mit Hilfsrahmen )Steifigkeit Schweller (kN/mm) 12,0 16,0 3.2.1.6.1.1.1 19,0 20,2 18,9 21,3 21,5 18,5Stei figkei t 1. Querträger (kN/mm) 5,8 6,0 3.2.1.6.1.1.1 9,3 9,3 8,6 7,3 8,7 6,1Stei figkei t 2. Querträger (kN/mm) 4,8 5,0 3.2.1.6.1.1.1 8,0 8,0 6,8 6,8 8,2 4,1Steifigkeit Vorderrahmen (kN/mm) 11,2 10,0 3.2.1.6.1.1.1 10,6 10,6 8,6 11,4 14,7 6,2Steifigkeit Heck (kN/mm) 3,0 3,0 3.2.1.6.1.1.1 3,5 3,5 3,1 2,5 2,1 2,4Querverformung Seitenwand ( Heckab. ) (mm) 0,68 0,80 3.2.1.6.1.1.1 0,5 1,54 0,48Diagonalen - mit ScheibeVordertür Öffnung ( A ) (mm) 0,12 0,10 3.2.1.6.1.1.1 0,10 0,10 0,18 0,18 0,09 0,05Vordertür Öffnung ( B ) (mm) 0,57 0,40 3.2.1.6.1.1.1 0,25 0,25 0,34 0,32 0,32 0,44Hintertür Öffnung (A) (mm) 0,41 0,40 3.2.1.6.1.1.1 0,17 0,17 0,11 0,16 0,16 0,35Hintertür Öffnung (B) (mm) 0,03 0,10 3.2.1.6.1.1.1 0,03 0,03 0,03 0,07 0,01 0,06

MASSPDT 4.1 Unterboden (kg) 104,5 116,7 3.2.2.2 124,2 124,2 112,3 NA NAPDT 4.2 Aufbau (kg) 133,8 153,2 3.2.2.2 175,6 175,6 151,0 NA NABIW total 1) (IO-MASSE) (kg) 255,5 289,9 3.2.2.2 320,9 320,9 291,4 281,9 299,8 270,8

BENDING (with Glas)

(kN/mm)Stiffness Rocker -- > 12,0 16,0 3.2.1.6.1.1.1 20,219,0 18,9 21,3 21,5 18,5

Standardized Load Cases



Virtual Assessment

Flowchart

Action ItemsAction ItemsVIVA

Acti on Item Res pons ible Assessme nt12. 12.2001

Due Da te

Virtual Integration V ehicle Assessm ent, 12.12.2001Body Data Sta tus, changes

S.Rosenplä nterM. Geyrhofer

Rear Door, Tailga te A. Nauerz

Body-In-White Structure Performan ce B. Justen

Fatigue U. Jung

NVH D. Jennewein

Crash Performanc e B. Justen

Danner Front 17.01.2002

Danner Rear 17.01.2002

Side 17.01.2002

Front 17.01.2002

Rear 17.01.2002

InvitationInvitationDELTA 3301 Virtual Integration Vehicle Assessment (VIVA)

Friday, August 9 th, 2002N55I Room 112

09:00- 11:30AGENDA:

09:00 Introduction K. Hieronimus

09:05 Master Model 008 Cont ent M. Siegel / T. Pohl

09:20 DMU P. Bernhard

09:35 Door Rear, Tailgate O. Czech

09:45 Crash Perform ance J. Perez -Freije- High-speed rear, AZT rear- Side ECE, Side Pole

- Front OD B - Belt Anchora ge, Shift ing Load

10:3 0 Body-in-whit e Structure Performan ce D. Warrington - Global static / dynamics / mass

10:50 Body Fatigue T. Tra n-Quoc / A. Nauerz

11:10 MEP Assessment Rear End A. Wild

11:15 MEB Assessment Rear End M. Gasper

11:20 Wrap Up, Action Items K.-H. Lepper

11:30 Adjourn

DataDataBaseBase

Virtual VehicleVirtual VehicleTimingTiming

VSVA

.

Design, Test

VIVA

19.12.

16.11. MEPPEMEAC VIVeh.Sim.

Virtual Vehicle AssessmentVirtual Vehicle Assessment

Supplier

MEBService

Transp.



§Virtual Styling Studio

§Stamping Simulation

§Crash Simulation

§Manufacturing Simulation

§Thermal Simulation

§Chassis Simulation

§DMU / Dynamic DMU

Product Development ProcessDevelopment ToolsExamples


Development ToolsVirtual Styling Studio


Development StatusDevelopment Status Release StatusRelease Status

WrinklesWrinkles

ThinningThinning

Development ToolsStamping Simulation


Development ToolsCrash Simulation

NEW ASTRA

´98 ASTRA

Number of Elements in Crash Model

Component ´98 ASTRA new ASTRABody-In-White 76.972 744.366Hang-On Parts 10.733 213.243Chassis 20.090 108.739Misc.* 6.619 332.087

Total 114.414 1.398.435* Trim, IP, Pedals, Dummies, Spotwelds, ...


´98 ASTRA

Component ´98 ASTRA new ASTRABody-In-White 76.972 744.366Hang-On Parts 10.733 213.243Chassis 20.090 108.739Misc.* 6.619 332.087

Total 114.414 1.398.435* Trim, IP, Pedals, Dummies, Spotwelds, ...

• Detailed Model of Interior Trim(IP, Seats, Steeringsystem,Pedals, Door Trim, …)

• Prediction of Crash Behavior ofComponents

NEW ASTRA


Number of Elements in Crash Model


Supplier: Component Simulation ModelOpel: Total Vehicle Integration



Development ToolsManufacturing Simulation

• Material Flow

Layout

Ergonomics


Thermal-Simulation

Virtual ThermalAnalysis Vehicle

Development Tools


Development ToolsThermal Simulation


Development ToolsChassis Simulation


Development ToolsDynamic DMU

Static

DM

U

Dyna

mischer

DM

U

VisM

ockup

dyn. Clearance-Analyse

ClearanceProtocol

SweptVolume

dyn. Envelope -Geometry

Motion &Movie

Animation

MovementSimulation

GeometryPoints

MovementData

GeometryCondensation

3-DGeometry

EnvelopeGeometry


Development ToolsDMU


Development ToolsDynamic DMU i.e. Chassis


Development ToolsDynamic DMU i.e. Engine Movement


§ Short product cycles and fast trend changes in the markets will forcethe automotive industry to realize shorter development time frames.

§ The shorter timescales and resulting higher development work loading willlead to a further push towards the utilization of virtual methods in order tomeet increased pressure on costs and timing.

§ In this shortened process simultaneous, handling of latest, synchronizeddata releases by all development partners involved must be ensured.

§ The vehicle manufacturers will concentrate to a much greater degree oncoordination and integration within the vehicle development process.

§The development of integrated modules will become more and more theresponsibility of specialist suppliers.

Product Development ProcessSummary

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