exploring design-to-cost in vehicle engineering using altair’s enterprise solution - hiqube

Exploring Design-To-Cost in Vehicle Engineering using Altair’s Enterprise Solution:

Bonn, 8 - 9 November 2011 Dr.-Ing. Hans Sippel CAEvolution GmbH, Carlo Serio Altair Engineering GmbH

CAEvolution

Agenda • Challenges in Vehicle Engineering

• Business Intelligence Software

• Altair‘s Enterprise Solution: – HiQube at a glance

– Advanced Data Engine

– The Dashboard Concept (Data Analytics)

– Multi - Objective Simulation & Optimization

– Reporting & Publishing

• Case Study Engineering

• Summary

Dr.-Ing. Hans Sippel 2

CAEvolution

Challenges in Vehicle Engineering

Dr.-Ing. Hans Sippel

New drive line concepts Climate Changes CO2 Emission Reduction Innovative vehicle concepts Advanced material concepts 3

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Challenges in Vehicle Engineering

4

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Shared Data Bus

SimulationModule 1

SimulationModule 2

SimulationModule xyz …..


Crash & Occupant Safety

NVH

…..

Mechatronics

Business Intelligence Software

5

CAEvolution

What is the

objective of the

simulation?

Status, milestone,

or study?

HiQube at a glance

Decision and Analytic Layer Allowing users to freely move & explore the design & information space

How is the performance evolving during

the project?

Which load

case or car has

no status

simulation? What are

cost

drivers?

Number of

simulation per car,

variant, milestone,

discipline, load

cases, …?

Comparison of

simulation and test


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HiQube at a glance


Source Systems (PDM, SDM, ERP, …)

Data Mart

Relational

Database

Multi-Dimensional

Database

Flat

File

Spreadsheet

File

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HiQube at a glance


Different people have different ways of looking at and interpreting data, like: Analysts Car Line Managers Controllers Executives Investigation of multi-dimensional Qubes

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Cars

Car Class

Car Type

Car Model

Products Dimension

Hierarchy

Simulation Load Case

Crash

NVH

Durability

CFD

Hierarchy

Measures/facts/metrics

Product Performance

Dimension Attributes/Keys/members

Saturn

X320

X330

Focus


Advanced Data Engine


CAEvolution

Cars

Car Class

Car Type

Car Model

Products Dimension

Hierarchy


Crash

NVH

Durability

CFD

Hierarchy


Performance metrics

Saturn

X320

X330

Focus


Crash Performance of Version xyz in Phase 1

+ + +




CAEvolution

Cars

Car Class

Car Type

Car Model

Products Dimension

Hierarchy


Crash

NVH

Durability

CFD

Hierarchy


Performance metrics

Saturn

X320

X330

Focus


Progress of Version xyz

from Phase 1 to Phase 3

Performance Metrics Reports DATA




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The Dashboard Concept (Data Analytics)

Dashboard philosophy: „Green light says go, red light says no“

For „decision support“ data review from the requirements´perspective across • disciplines • load cases …


Function BL Alt A Alt B Iter 3

Discipline A 50% 70% 69% 73%

Loadcase 1 50% 70% 60% 71%

Loadcase 2 40% 80% 69% 73%

Requirement a ++ + + +

Requirement b -- + - +

Loadcase 3 10% 30% 48% 88%

Discipline B 40% 45% 76% 94%

Loadcase X 30% 40% 56% 86%

Loadcase Y 50% 50% 100% 100%

Requirement Y.a pass failed pass pass

Requirement Y.b failed pass pass pass

+

+

+

-

-

--

failed

failed

Key Performance Indicators

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Reporting & Publishing


More than 25 original and refined chart types all

provided with a multidimensional navigator.

Intuitive dashboard design.

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Visual Analytics.

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Multi-Objective Simulation & Optimization

Be aware of local minima & spikey behaviour!

Considering contradicting objectives

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Which one is „best“? What is „best“?

Uncertainty: How „noisy“ is the system?

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Case Study Engineering The ULSAB-AVC Project (www.ulsab-avc.org)


Automotive (R)Evolution in Steel using: High-Strength Steel Tailored Blanks Welded & Tailored Tubes …

which help to ensure

Safety

affordability

fuel Efficiency

environmental Responsibility

Performed by Porsche Engineering Services & Suppliers

http://www.ulsab-avc.org/



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Cost analysis per vehicleMaterial - Total Type

Cost Scenario 1

181,60

Cost Scenario 2

175,77

Delta

-5,83

-3.2%

Ordinary Stampings

+6,73

Bulkhead Crash Box Dash R&L: 0,78Body Side Inner Rear LH: 0,65Body Side Inner Rear RH: 0,52

Reinforcement Waist B-Pillar R&L: 0,48Crossmember Kick-up: 0,46

Dash: 0,40Reinforcement Tunnel: 0,39

Support Back Panel: 0,36Gutter C-Pillar R&L: 0,33

Closeout Inner Crash Box Dash R&L: 0,32Back Panel: 0,31

A-Post Inner R&L: 0,30Reinf Rail Rear Suspension Crossmember R: 0,30

Wheelhouse Outer R&L: 0,26Bracket Support Front Seat Rear (x2): 0,21

A-Brace Cowl Front: 0,17Reinforcement Rail Rear Spring Attachmen: 0,14

Crossmember Roof: 0,13A-Brace Cowl Rear: 0,10

Crossmember Tunnel: 0,09Reinforcement B-Pillar Lower R&L: 0,02

Bracket C-Member Instrument Panel Attach: 0,01Rail Rear Outer Floor Extension R&L: -0,03Crossmember Back Panel: -0,06Plate Crash Box Rail Front Attachment (x: -0,07Header Front: -0,07Crossmember Support Front Seat Front R&L: -0,10Reinforcement Waist B-Pillar Outer R&L: -0,11Closeout Outer Crash Box Dash R&L: -0,15Bracket Member Body Side Inner Attach Re: -0,20Header Rear: -0,22Assembly Reinf Rail Rear Suspension Atta: -0,23Support Header Front R&L: -0,24Closeout Lower Crash Box Dash R&L: -0,41Crossmember Rear Suspension: -0,75C-Pillar Inner RH: -0,88Cowl Front: -0,90B-Pillar Inner R&L: -0,96Reinf Crash Box Dash R&L: -0,97Roof: -1,58Floor Front R&L: -2,23Tunnel: -2,40

-12,56


Case Study Engineering

16

„Drill-Down“

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Cost Scenario 1

181,60

Cost Scenario 2

175,77

Delta

-5,83

-3.2%

Ordinary Stampings

Tunnel 19.1%

Floor Front R&L 17.7%

Roof 12.6%

Reinf Crash Box Dash R&L 7.7%

B-Pillar Inner R&L 7.7%

Cowl Front 7.2%

C-Pillar Inner RH 7.0%

Crossmember Rear Suspension 6.0%

Bulkhead Crash Box Dash R&L 11.7%

Body Side Inner Rear LH 9.7%Body Side Inner Rear RH 7.7%Reinforcement Waist B-Pillar R&L 7.1%Crossmember Kick-up 6.8%

+6,73

-12,56

Further Options …

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Cost Scenario 1

146,87Cost Scenario 2

141,52

Delta

-5,35

-3.6%

Tailored Blanked Stampings

+4,95

Rocker Inner R&L (unattached): 2,95

Floor Rear: 1,99

Wheelhouse Inner R&L: -0,46

Rear Rail R&L (unattached): -1,39

Reinforcement B-Pillar Rocker Rear R&L (: -2,19

Body Side Outer RH: -6,25

-10,30

„Slice“ for Tailored Blanked Stampings

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Cost Scenario 1

58,01Cost Scenario 2

55,82

Delta

-2,19

-3.8%

Tubular Hydroformed Parts

+2,04

Member Body Side Inner LH: 2,04

Member Body Side Inner RH: -0,40

Member Rail Front RH: -0,57

Member Rail Front LH: -3,25

-4,22

„Slice“ for Tubular Hydroformed Parts

CAEvolution

„Human Being“ is centric

Engineering tasks are changing CAE Technology is indispensible:

High Prognosis Quality Ease of Use Predictive

Summary


Business Intelligence Software is considered critical to ensure a reliable decision making going forward.