MOTION IN VIRTUAL DEVELOPMENT PROCESS Lothar Teske Toulouse / - - PowerPoint PPT Presentation

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MOTION IN VIRTUAL DEVELOPMENT PROCESS Lothar Teske Toulouse / - - PowerPoint PPT Presentation

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MOTION IN VIRTUAL DEVELOPMENT PROCESS Lothar Teske Toulouse / 07.01.2005 Product Development Process Contents 1 Milestones 2 Development Partner 3 Network 4 Data Management 5 Synchronization Process 6 Development Tools 7 S ummary

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SLIDE 1

„MOTION“

IN VIRTUAL DEVELOPMENT PROCESS

Lothar Teske Toulouse / 07.01.2005

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Lothar Teske / Toulouse / 07.01.2005 / 2

Product Development Process

Contents

1 Milestones 2 Development Partner 3 Network 4 Data Management 5 Synchronization Process 6 Development Tools 7 S ummary

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Future Targets in the Vehicle Development Process

Mule Alpha Beta 1 Gamma Pilot

Simulation

Beta 2 HW Phases Virtual Phases

Past Past

EngineeringEngineering Start Start Styl

  • Styl. / Pack.. / Pack.

Freeze Freeze Release Release Start of Start of Production Production

Validation Validation Mule Mule Integrated Virtual Engineering

Styl., Design, DMU, CAE, ME, Plants, ...Validation

EngineeringEngineering Start Start Styl

  • Styl. / Pack.. / Pack.

Freeze Freeze Release Release Start of Start of Production Production

M i s s i

  • n

M i s s i

  • n

HW Phases Structure Integration Validation Pilot Mule Initial ConceptStructure Integration Validation

T

  • d

a y T

  • d

a y

Styl

  • Styl. / Pack.. / Pack.

Freeze Freeze Release Release Start of Start of Production Production EngineeringEngineering Start Start

4 4 Fast to Market Fast to Market 4 4 Workload Reduction Workload Reduction 4 4 Prototype Reduction Prototype Reduction

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Milestones in the Development Process

Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

Architecture Integration

Design, Test

Validation

Initial Concept Validation Integration Conceptdet. 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 s V 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 Integration Conceptdet. Validation

Virtual Vehicle

Styling Architecture Concept

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Role of Design in the Development Process

2

5 4 6 1 9 2 8 3 7

Math Surface Release

1 2 3

Competition

  • f up to

3 Teams Kickoff

Alternative Development Styling Concept Styling Theme Alternatives

VR supports Development in Clay

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Architecture Concept

Initial

Integration Conceptdet. Validation

Virtual Vehicle

Integration

Design, Test

Validation Architecture

4 Determination of Hardpoints for Architecture including

  • Underbody, Seat Concept
  • Axles
  • Powertrain

4 Up-date of Predecessor Simulation Models 4 First Target Balancing 4 Determination of Hardpoints for Architecture including

  • Underbody, Seat Concept
  • Axles
  • Powertrain

4 Up-date of Predecessor Simulation Models 4 First Target Balancing

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

Milestones in the Development Process

Architektur BOM

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Concept Initial Integration Conceptdet. Validierung

Virtual Vehicle

Architecture

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

Milestones in the Development Process

Architecture Integration

Design, Test

Validation

4 Architecture Development 4 Design and Release

  • f Mule Cars

4 First Determination of Hardpoints in Styling Studio 4 Architecture Development 4 Design and Release

  • f Mule Cars

4 First Determination of Hardpoints in Styling Studio

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Initial Architecture Integration Conceptdet. Validation

Virtual Vehicle

Concept

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

Milestones in the Development Process

Architecture Integration

Design, Test

Validation

4 Pre-Release of Styling 4 Integration of Requirements from Styling, Performance, Package, Manufacturing etc. 4 Pre-Release of Styling 4 Integration of Requirements from Styling, Performance, Package, Manufacturing etc.

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Concept Initial Architecture Integration Validation

Virtual Vehicle

Conceptdetail

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

Milestones in the Development Process

Architecture Integration

Design, Test

Validation

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

  • Plants
  • Service
  • etc.

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

  • Plants
  • Service
  • etc.
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Concept Initial Architecture Conceptdet. Validation

Virtual Vehicle

Integration

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

Milestones in the Development Process

Architecture Integration

Design, Test

Validation

4 Development of Design 4 Release (agreed through virtual Development) 4 Continued Support through Simulation 4 Development of Design 4 Release (agreed through virtual Development) 4 Continued Support through Simulation

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Architektur Konzept Initial Architektur Integration Konzeptdet.

Virtual Vehicle

Integration

Konstruktion, Test

Validation

Validation

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

4 Validation of Simulation Models 4 Support for necessary late Product-/Part Changes 4 Virtual Plant 4 Validation of Simulation Models 4 Support for necessary late Product-/Part Changes 4 Virtual Plant

Milestones in the Development Process

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Platform PE Body PE Chassis PE Thermal Electric/ Electronic Vehicle Integration Vehicle Simulation Noise & Vibration Safety Supplier Eng. Supplier Test & Validation Service Engineering Vehicle Development & Trim MEAC MEP MEB Plants GM/ FIAT Powertrain

Development Partner

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Architecture CAD CAM Styling Dimensions Die Virtual Factory

CAE/CAT

Common Visualization Tool Parasolid Data Management (Product & Process) Data Management (Product & Process)

Service and Process Documentation Design Reviews ME Process- Simulation Suppliers Purchasing Finance Visual Concept Reviews

Global Database System

Data Management Integrated Systems & Data Formats

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Synchronization Process

Engineering Milestone: i.e. Build Release Virtual Assessment Vehicle-Synchronization Test

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

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Engineering Milestone: i.e. Build Release Virtual Assessment Vehicle- Synchronization Hardware & Test Hardware & Test

Synchronization Process

Initial Concept Validation Integration Conceptdet. Architecture Engineering Engineering Start Start Styling / Package Styling / Package Freeze Freeze Release Release Start Start Production Production

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

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Engineering Milestone: i.e. Build Release Vehicle-Synchronization Virtual Assessment CAE-Transfer Point Hardware & Test

Synchronization Process

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Vehicle-Synchronization Receipt of all Data to build a complete Vehicle

Build Virtual Vehicle

Data from all Development Partner Final Date for Data Availability Synchro-Point

DMU Digitaler Mock Up

Synchronization Process

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Vehicle Synchronization

Synchronization Process

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CAE-Transfer Point

Exchange Finite Models with Supplier

Synchronization Process

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CAE-Transfer Punkt

  • Modeling Guidelines
  • Modeling Guidelines

Modeling Guidelines

  • Virtual Vehicle Report
  • Virtual Vehicle

Virtual Vehicle Report Report

1 2 3 XYZ

  • Standardized S/W Portfolio
  • Standardized

Standardized S/W Portfolio S/W Portfolio

Synchronization Process

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CAE-Transfer Point

Simulation Milestones Modeling Guidelines Simulation Tasks Simulation Software

Input for Supplier Output from Supplier

Simulation Model Model Validation Results / Reports / Animations

Supplier Supplier Integration into Full Vehicle Overall Overall Assessment Assessment

Synchronization Process

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CAE-Transfer Point

Synchronization Process

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Virtual Assessment Timing

VIniVAVirtual Initial Vehicle Assessment VAVA Virtual Architecture Vehicle Assessment VCVA Virtual Concept Vehicle Assessment VSVA Virtual Structure Vehicle Assessment VIVA Virtual Integration Vehicle Assessment VPVA 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 03

VPVA 7.8. 18.7.

Proj 2 04

VPVA 6.12. 8.11.

Proj 3 04

VCVA 2 22.2. VIVA 9.8. VSVA 26.4. 18.1. 12.7. 20.6. 22.2.

Proj 4 05

VCVA 16.8. VIVA 7.2. VSVA 15.11.

12.7. 13.12. 27.9.

Proj 5 05

VCVA 19.7. VIVA 14.3. VSVA 18.12. 17.5. 8.11. 14.2. 23.8. 21.6.

Proj 6

06

VIniVA 31.1. VAVA 18.7. 13.6.

Proj 7

07 t.b.d. t.b.d. decision

Synchronization Process

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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, Concept completely clear, not 100% matched) 2 Solid models, Surface models (completely matched, with radius) 1 Solid model (high degree of integration, 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, Concept completely clear, not 100% matched) 2 Solid models, Surface models (completely matched, with radius) 1 Solid model (high degree of integration, e.g. tooling data)

Synchronization Process

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Virtual Assessment Develoment Status Develoment Status Benchmark Benchmark Load Case Load Case Simulation Result Simulation Result Analyze Type Analyze Type Name

  • Sim. / Meas.

Name

  • Sim. / Meas.

Subsystem Subsystem Target Target Predecessor Predecessor

VILV VCV VSV VIV VVV

Status virtual Prototype Vectra MY 2002

Rohkarosserie Gesamtsteifigkeit

Hersteller OPEL OPEL OPEL OPEL OPEL OPEL A B Typ J2900 J3200 NB J3200 NB J3200 NB J3200 NB J3200 NB Modelljahr 1996 2004 2004 2004 2004 2004 1998 1997 Entwicklungsphase 1996 FORDERUNG VlnlV VCV VSV VIV VVV PROD. PROD. Messung/Berechnung (S/V) 1996 IO SSTS§ S S S V S V V TORSION (mit Hilfsrahmen) Steifigkeit mit Scheibe (kNm/deg) 11,0 16,0 (SSTS) 15,7 16,8 13,3 14,9 20,5 14,7 Steifigkeit 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 1,14 Heckklappenöffnung (mm) 1,28 0,75 DEV 0,17 0,73 0,85 0,72 0,82 0,51 Heckscheibenöffnung (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 0,28 Vordertüröffnung (mm) 0,26 0,25 3.2.1.6.1.1.2 0,19 0,19 0,24 0,22 0,13 0,30 Hintertüröffnung (A) (mm) 0,35 0,25 3.2.1.6.1.1.2 0,24 0,24 0,26 0,24 0,21 0,36 Heckklappenöffnung (mm) 0,64 0,30 DEV 0,26 0,26 0,44 0,30 0,33 0,17 Heckscheibenöffnung (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 18,5 Steifigkeit 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 6,1 Steifigkeit 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 4,1 Steifigkeit Vorderrahmen (kN/mm) 11,2 10,0 3.2.1.6.1.1.1 10,6 10,6 8,6 11,4 14,7 6,2 Steifigkeit Heck (kN/mm) 3,0 3,0 3.2.1.6.1.1.1 3,5 3,5 3,1 2,5 2,1 2,4 Querverformung Seitenwand ( Heckab. ) (mm) 0,68 0,80 3.2.1.6.1.1.1 0,5 1,54 0,48 Diagonalen - mit Scheibe Vordertür Öffnung ( A ) (mm) 0,12 0,10 3.2.1.6.1.1.1 0,10 0,10 0,18 0,18 0,09 0,05 Vordertür Öffnung ( B ) (mm) 0,57 0,40 3.2.1.6.1.1.1 0,25 0,25 0,34 0,32 0,32 0,44 Hintertür Öffnung (A) (mm) 0,41 0,40 3.2.1.6.1.1.1 0,17 0,17 0,11 0,16 0,16 0,35 Hintertür 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 MASS PDT 4.1 Unterboden (kg) 104,5 116,7 3.2.2.2 124,2 124,2 112,3 NA NA PDT 4.2 Aufbau (kg) 133,8 153,2 3.2.2.2 175,6 175,6 151,0 NA NA BIW 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 20,2 19,0 18,9 21,3 21,5 18,5

Standardized Load Cases

Synchronization Process

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Virtual Assessment Flowchart

Action Items Action Items

VIVA Acti on Item Res pons ib le Assessme nt 12.12.2001 Due Da te Virtual Integration V ehicle Assessm ent, 12.12.2001 Body Data Sta tus, changes S. Rosenplä nter
  • M. Geyrhofer
Rear Door, Tailga te
  • A. Nauerz
Body-In-White Structure Performan ce
  • B. J
usten Fatigue
  • U. Jung
NVH
  • D. Jennewein
Crash Performance
  • B. J
usten Danner Fr
  • nt
17.01.2002 Danner R ear 17.01.2002 Side 17.01.2002 Front 17.01.2002 Rear 17.01.2002

Invitation Invitation

DELTA 3301 Virtual Integratio n Vehicle Assessment (VIVA) Friday, August 9th , 2002 N55I R
  • om 112
09:00
  • 11:30
AGENDA: 09:00 Introduction
  • K. Hieronimus
09:05 Master Model 0 08 Cont ent
  • M. Siegel / T. Pohl
09:20 DMU
  • P. Bernhard
09:35 Door Rear, Tailgate
  • O. Czech
09:45 Crash Perform anc e
  • J. Perez-Freije
  • High-speed rear, AZT rear
  • Side E
CE, Side Pole
  • Front ODB
  • Belt Anchorage, Shift ing Load
10:30 Body-in-whit e Structure Performan ce
  • D. Warrington
  • Glo
bal static / dynamics / mass 10:50 Bod y Fatigue
  • T. Tra n-Quoc / A. Nauerz
11:10 MEP As sessment Rear E nd
  • A. W
ild 11:15 MEB As sessment Rear E nd
  • M. Gasper
11:20 Wrap U p, A ction It ems K.-H. Lepper 11:30 Adjou rn

Data Data Base Base Virtual Vehicle Virtual Vehicle Timing Timing

VSVA . Design, Test

VIVA 19.12. 16.11.

MEP PE MEAC VI Veh.Sim.

Virtual Vehicle Assessment Virtual Vehicle Assessment

Supplier MEB Service Transp.

Synchronization Process

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§Virtual Styling Studio §Stamping Simulation §Crash Simulation §Manufacturing Simulation §Thermal Simulation §Chassis Simulation §DMU / Dynamic DMU

Product Development Process

Development Tools Examples

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Development Tools Virtual Styling Studio

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Development Tools Virtual Styling Studio

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Development Tools Virtual Styling Studio

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Development Status Development Status Release Status Release Status Wrinkles Wrinkles Thinning Thinning

Development Tools Stamping Simulation

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Development Tools Crash S imulation

NEW ASTRA ´98 ASTRA Number of Elements in Crash Model

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

Total 114.414 1.398.435

* Trim, IP, Pedals, Dummies, Spotwelds, ...

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´98 ASTRA

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

Components

NEW ASTRA

Development Tools Crash S imulation

Number of Elements in Crash Model

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Supplier: Component S imulation Model Opel: Total Vehicle Integration

Development Tools Crash S imulation

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Development Tools Manufacturing Simulation

  • Material Flow

Layout Ergonomics

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Thermal-Simulation

Virtual Thermal Analysis Vehicle

Development Tools

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Development Tools Thermal Simulation

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Development Tools Chassis Simulation

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Development Tools Chassis Simulation

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Development Tools

Dynamic DMU

Static DMU Dynamischer DMU

Vis Mockup

  • dyn. Clearance-

Analyse Clearance Protocol Swept Volume

  • dyn. Envelope -

Geometry Motion & Movie Animation Movement Simulation Geometry Points Movement Data Geometry Condensation 3-D Geometry Envelope Geometry

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Development Tools

DMU

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Development Tools

Dynamic DMU i.e. Chassis

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Development Tools

Dynamic DMU i.e. Engine Movement

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§ Short product cycles and fast trend changes in the markets will force the automotive industry to realize shorter development time frames. § The shorter timescales and resulting higher development work loading will lead to a further push towards the utilization of virtual methods in order to meet increased pressure on costs and timing. § In this shortened process simultaneous, handling of latest, synchronized data releases by all development partners involved must be ensured. § The vehicle manufacturers will concentrate to a much greater degree on coordination and integration within the vehicle development process. §The development of integrated modules will become more and more the responsibility of specialist suppliers.

Product Development Process

Summary

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