innovation and technology in the automotive · 2011. 11. 21. · innovation and technology in the...

INNOVATION AND TECHNOLOGY IN THE AUTOMOTIVE INDUSTRY: CHALLENGES AND OPPORTUNITIES

17.11.2011

Mathematical Challenges within the Automotive Industry

INDEX

21/11/11 2

• OVERVIEW OF THE AUTOMOTIVE INDUSTRY

• MAIN AREAS OF INNOVATION WITHIN THE SECTOR

• CONTRIBUTION OF APPLIED MATHEMATICS

INDEX

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The automotive industry at a

glance…

It is a sector in crisis…

And will hit the 100 million mark in 2020

Global production established a

new record in 2010 with a 67

million vehicle output

Low impact on today’s

economic scene…

3% Europe’s GDP

6 million direct jobs y

12 million indirect jobs

Scarce research efforts…

Leading industry, just

ahead of

pharmaceutics

20 billion annually in

Europe

Will dissapear as we know

it with the electric vehicle…

In 2020 only 1,2 % of the

vehicles will be fully electric

But it faces new

challenges…

…which need to be understood

and tackled

Como la globalización…

Nuestro mercado ya es el

mundo, con todo lo que conlleva

Such as globalization…

Our market is the world, with

all the associated implications

The entrance of new

competitors in our clients…

Most of whom are unknown to

us

Growth in emerging

markets…

Such as China, India, Brazil

o Russia

Alejamiento mercados

emergentes…

A China, India, Brasil o Rusia

Technological changes in

the vehicles…

New materials, integration of

electronics…


emergentes…


Aumento del papel de los

proveedores…

En diseñar, en desarrollar, en

producir,…

Resposibility transfer down

from the OEMs…

In design, development and

production stages…


emergentes…


Con reducción continua de

costes…

Una de las industrias más

exigentes y eficientes

Continuous cost reduction

Among the most demanding and

efficient industries


emergentes…


Con incremento de

materias primas…

No pudiendo siempre

repercutirlo a los clientes

Increase in raw

materiales…

May not always be passed on

to customers


emergentes…


Higher safety and

environmental standards…

Lead to new mobility solutions

and new business models

INDEX

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Energy & Environment

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• Efficiency increase in gasoline engines • Efficiency increase in diesel engines • Specific engines for hybrid applications • Improvement in the engine’s tribological systems.

Efficiency increase in internal combustion engines

• Second generation of biofuels • Specification set up for alternative fuels

Development of alternative fuels

• Fuel cell technology development • Hydrogen production from renewable sources • Hydrogen storage and distribution systems

New propulsion strategies

• Designed for life cycle • Noise and emission reduction

Environmental efficiency increase of other products and processes

19

Electric vehicle

ImprovedVehicle Fuel Economy &Emissions

DisplacePetroleum

EnergyDiversity

Hybrid ElectricVehicles (including

Plug-In HEV)IC Engine andTransmissionImprovements

Hydrogen Fuel Cell

Petroleum (Conventional & Alternative Sources)

Bio Fuels (Ethanol E85, Bio-diesel)

Hydrogen

Electricity (Conventional & Alternative Sources)

Battery ElectricVehicles (E-Flex)

Time

Full and plug-in hybrids incl. range extender concepts

High reliability, best availability

Powertrains suitable for bio-mass based fuels

Fuel efficiency and low cost powertrains

Efficient powertrain systems – downsizing and mild hybridization (incl. Diesel)

Powertrains based on alternative fuels (incl. E-drive)

Full hybrids based on efficient SI engines (niche fleets with FC)

Regional diversification of requirements leads to diversification of powertrain technologies

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Customer requirements and trends Prospects of new technologies

Transport & Mobility

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• Driver information assistance systems about road conditions • Urban traffic management efficient systems • Efficient use of differente transport systems by means of improved multimodal interfaces • Development of an open source Intelligent Transport Systems for the improvement of multimodal logistic transport

Advanced, efficient, cooperative traffic management systems

• Complementary modularization principles and architechture development for vehicles and transport of goods • New design and concepts of commercial vehicles

New vehicle concepts

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Safety and Security

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• Advaced driver assistance systems • Driver monitoring systems • Driver-vehicle interface

On-boardriver assistance systems for accident avoidance or impact minimization

• Low cost pre-crahs system • Low cost and high reliability sensor and actuator network development • Reliability of software systems • Integrated vehicle safety • Driver autonomous assistance on specific situations • Vehicle stability systems (Anti-lock Braking System, Electronic Stability Control, Electronic Brake Assist System)

Increase in passive and active safety

• Accident prevention or consequence minimization in cooperative safety systems • Data merging and processing gathered from a network of sensors in a cooperative environment • Post-accident communications

Vehicle-infrastructure data exchange cooperative systems

• Security increase in road freight transport • Monitorization and tracking of special or dangerous goods’ transport

Freight transport security

• Human body modelization for virtual simulation of advanced protection systems • Driver behaviour analysis

Virtual systems and studies for the development of new safety systems

Efficiency & Competitiveness

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• Efficient use of raw materials and end of life reuse • Research and use of sustainable alternative materials • Development and integration of adaptative material systems in vehicle structures • Component and system performance improvement from intelligent materials focusing on the integration of nanostructures and nanotechnologies in macrosystems (reduced weight and energy consumption. Higher

efficiency)

Technological development of advanced and sustainable materials

• Vehicle and subsystem sustainable manufacturing • Manufacturing flexible processes • Advanced and adaptative manufacturing strategies and processes

Flexible, efficient and sustainable manufacturing

• Virtual tools for energy consumption optimization • Digital manufacturing • Virtual engineering for product and process performance management along the entire life cycle.

Virtual tools for design, development and manufacturing

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Comfort & Customization

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• Variety of options • Reconfiguration • Innovation in interior parts’ functional integration • Lighter and more compact seat systems • Desiging towards elderly people needs

Customization and perceived quality development

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INDEX

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New materials and

advanced

components

Embedded systems

Power electronics Vehicle

electrification

Advanced automation and control

Integrated

communication systems

Modeling, simulation, forecasting

and optimization

Sensing and measurement

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New materials

and advanced

components

Embedded systems

Power electronics Vehicle

electrification

Advanced automation and control

Integrated

communication systems

Modeling, simulation,

forecasting and optimization

Sensing and measurement

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Comfort Handling

Reliability

Energy Efficiency

28 Safety

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Assymetric

collision test

analysis

through finite

element

analysis

method

Energy Efficiency / Performance

Real-time engine optimization

Efficient in-vehicle energy management

Lightweight technologies implementation

Powertrain electrification

Battery management optimization

Comfort

Continuous road surface monitoring

Cockpit ergonomics optimization

Cabin temperature and humidity control

Driver recognition based configuration

Handling

Real-time vehicle dynamics control

Reliability

Component and subass evaluation

New material introduction evaluation

Virtual prototyping

Safety

Advanced driver assistance systems

Comprehensive passive safety systems

Ultra high strength steel and composite usage

Hybrid Propulsion System Modeling Levels and Simulation Framework

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• Challenges: interdisciplinarity of software, electrical and mechanical engineering • Electronics: sensors/actuators, ECUs and power electronics • ECU proliferation: mechanical parts + information/entertainment • Vehicle electrification • Advanced materials • New joining technologies • …

• “do things as early as possible”

• Model-based Testing of Automotive Systems • Consistency of tools and model throughout the environments:

MiL

SiL

HiL

Test Bed

Road

• Plant model: ENGINE+DRIVETRAIN+TIRE+SUSPENSION+BRAKE+ROAD TRAFFIX+DRIVER • Real time behavior, robustness to signals, etc. • Novel methods and tools for system-level analysis and modeling are for predictability,

composability and providing guidance and support to the designer

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Sustainability High-productivity

ICT-enabled intelligence Materials efficiency and processing

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Sustainable manufacturing

Human-robot collaboration (voice recognition, natural

language and gesture comprehension)

Machinery customisation

Optimisation of working architectures, methods

Virtual ergonomics

Environmental impact assesment

High productivity manufacturing

Adaptive production equipment

Rapid micro-manufacturing

Integrated compact system design

Proactive control

Advanced decision-making tools

Defect-tolerant configurations

ICT-enabled intelligent manufacturing

Life-cycle management

Multivariable control

Digital manufacturing

Supply chain real-time monitoring

Advanced maintenance

Materials in manufacturing

Additive production or “net-shape” methods

Material consumption parameters integration

High-performance material manufacturing

Advanced

human motion

capture

technology in

combination

with human

modeling

software to

improve

workstation

ergonomics

Digital manufacturing allows for a flexible

and more responsive process

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• Multivariable, multiprocess and multilocation manufacturing • Flexible manufacturing and agile manufacturing techniques to address a multiple

location supplier strategy.

• Digital modeling of factories to reduce the need for physical prototyping and construction of pilot plants.

• Virtual factories to support the management of ever more complex supply chains between manufacturing plants around the world.

• New monitoring and control techniques of multiple variable processes to manufacture more sophisticated products in shorter cycle times (stochastic control).

• Increased interaction between machines and people, enhancement of human-robot collaboration (human centered production environments).

• Manufacturing processes for new high-performing materials • Effective systems to implement addition of new features to materials during the

manufacturing processes so as to increase the value of the final product.

• Integration of material consumption parameters in modelling algorithms to analyze and optimize manufacturing chain in terms of resource efficiency.

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Integration of

vehicle in

transport

infrastructure

Optimal use of road, traffic and travel data

Road safety and security

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Optimal use of road, traffic and travel data

Real time traffic and travel information

Optimized collection and provision of road,

traffic and travel data

Availability of accurate public data for digital maps

Traffic safety information services

Promotion of multimodal journey planners

Road safety and security

Promotion of advanced driver assistance

systems and safety-related ITS

eCall

Safe onboard human-machine interfaces

Vulnerable road users

Integration of the vehicle into the transport

infrastructure

Cooperative systems

I2I, V2I, V2V communication

Standardisation Development

of a common

ITS

framework

architecture

Macroscopic, microscopic and mesoscopic model networks

serve as a basis for a travel demand forecasting model

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• Consistency and robustness of integrated communication systems. • Advanced in-vehicle monitoring techniques to gather reliable traffic information. • Flexible communication arquitectures to incorporate ever more complex data

systems.

• Development of simpler, more intuitive human interfaces that gather a wider array of data and deliver it in the appropiate timing and fashion.

• Modeling and simulation of future driving scenarios • Mathematical generation of random velocity profiles representative of diverse

scenarios (e.g. Markov chain models).

• Montecarlo studies of PHEV, BEV energy analysis • Need of risk analysis, likehood than an event will occur • New agents participating in the supply chai

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Main areas of innovation focused on energy & environment, transport & mobility, safety & security,

efficiency & competitiveness, confort and customization

Mathematicals models involve development in three main areas: vehicles systems, manufacturing and ITS

Technological changes and new business models require efficient tools for decisions makers (strategic and

technical)

MBT: Consistency of tools and model throughout the environments: MiL/SiL, HiL, Test Bed, Chassis Dyno,

Road

Embedded Systems: Novel methods and tools for system-level analysis and modeling are for predictability,

composability and providing guidance

Consistent models to respond to multivariable, multiprocess and multilocation manufacturing

ITS: Consistency and robustness of integrated communication systems; modeling and simulation of future

driving scenarios

Thank you Gracias Eskerrik asko Parque Empresarial Boroa, P2A-4 || 48340 Amorebieta-Etxano || tel.: +34 94 656 9400 || [email protected]

innovation and technology in the automotive · 2011. 11. 21. · innovation and technology in the...

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