Challenges and requirements for automated processes in Commercial Vehicle Development

Challenges and Requirements for an Automated

Process in Commercial Vehicle Development

2014 European Altair Technology Conference

Munich, 26th June 2014

Mustafa Gök

Sebastian Straube

Dr. Andreas Kruppa

MAN Truck & Bus AG

2 < > Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014 M. Gök / S. Straube / Dr. A. Kruppa MAN Truck & Bus AG

Power Engineering Business

areas

Divisions

Commercial Vehicles

MAN

Truck & Bus

MAN

Latin America

MAN SE

The MAN Group in 2013: €15.7 billion revenue, 53,509 employees

Investments Sinotruk, Scania

MAN

Diesel & Turbo Renk

Company Structure


Long-haul transport

Traction

Short-haul transport

Long-haul transport

Traction

Short-haul transport

Traction

Short-haul transport Short-haul transport

18 t – 41 t 18 t – 41 t 18 t – 41 t 12 t – 26 t 8 t – 12 t

TGX TGS TGS WW TGM TGL

Truck product portfolio


4x2

4x4

6x2-

6x2/

6x4

6x4-

8x2-

TGX TGS TGS WW TGM TGL

4x2

4x4

6x2-

6x2/

6x4

6x4-

6x6

6x6

8x2-

8x4

8x4

8x4/

8x4-

8x6

8x8

Type list


Type list

Different load distribution

Different strength level

Driving dynamics loads from the road

to the structure


Why a lot of types? Body types and customer usage


Modular Kit Truck Product structure in development and BoM

Building blocks

Suspension

Cabin type

Transmission

Frame length

Axles

Engine power

Max. weight

7-12t 13-26t 18-41t

Product Decomposition

Model / type

TGL TGM TGS TGX TGS WW

Simplified visualization

Suspension front

Engine

Side member

Front axle 1

Gearbox

Cabin

Cross member

Rear axle 1

Suspension rear

Options / Properties


Modular Kit Truck Product structure in development and BoM

Suspension

Cabin type

Transmission

Frame length

Axles

Engine power

Options / Properties

Max. weight

7-12t 13-26t 18-41t

Product Decomposition

Model / type

TGL TGM TGS TGX TGS WW

Building blocks

Suspension front

Engine

Side member

Front axle 1

Gearbox

Cabin

Cross member

Rear axle 1

Suspension rear

Simplified visualization


Disadvantages of the current course of action:

high manual effort in meshing and generation of connections

long training period for new employees (complexity of the process)

compliance with standards depend on the person in charge

Process for the analyzing of entire frame models General approach

25 % 50 % 5 % 5 % 15 %

Preparation of input data Generating of FE-model Preparation of Analysis Simulation Evaluation

of results


Process for the analyzing of entire frame models Reduction of efforts

Preparation of input data Generating of FE-model Preparation of analysis Simulation Evaluating of

results

25 % 50 % 5 % 5 % 15 % Manual

FTB current

CAD new

25 % 15 %

100 %

65 %

FTB current

CAD in DB

10 % 5 % 5 % 15 %

50 %

15 %

15 %

Potential entire

process

5 % 2,5

%

2,5

% 5 %

25%

10 %

5 % 5 %


Process for the analyzing of entire frame models Process overview

Result documentation

Solve

Define & apply load case data

Prepare solver input

Define properties

Create connections

Assembling

Meshing

Prepare input data

Parameter

file

CAD-Data provision

„Frame Tool Box“

PDM

Vehicle

data

sheet

Part list

Connector

position

file

model.cdb

-APDL

FE-DB

model.rst

Report

automated task manual task

Color legend automation degree:



CAD-Data provision

CAD – Model of complete vehicle

Provided by package department via

PDM-System

PDM



FE-DB

…

Prepare input data

Parts already in FE-DB?

Prepare new parts

Create list of parts to be used

Create connector position file

Create Vehicle data sheet

CAD-Data provision

Vehicle

data

sheet

Part list

Connector

position

file

FE-Database:

„Prepare once and use it again“.

Prepare new parts:

Mostly Catia (mid) surface

and solid models

partly automated with Catia macro

Meshes also possible

for more complex parts



FE-DB FE-DB

Meshing

Fully automated in BatchMesher and

Simlab

Manual checking and correction

Prepare input data

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file

Part list



Assembling

Fully automated in HyperMesh

Part position from part list

Meshing

Prepare input data

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file FE-DB Part list



Create connections

Fully automated with tcl-script

Location from connector position file

Manual checking and correction

Assembling

Meshing

Prepare input data

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file FE-DB

Connector

position

file

Connection type 1:

Shell / Shell

Connection type 2:

Solid / Shell



Define properties

Fully automated with tcl-script

Thickness information from partname

Material information from part list

Create connections

Assembling

Meshing

Prepare input data

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file FE-DB Part list



Vehicle

data

sheet


Mass balancing

Overall quality check

Write ANSYS parameter file

Write model file

Define properties

Create connections

Assembling

Meshing

Prepare input data

Parameter

file

CAD-Data provision PDM

Vehicle

data

sheet

Part list

Connector

position

file

model.cdb

FE-DB





Read model and parameter file

Define loads according to weight

distribution

Set air spring stiffness

Fully automated in APDL


Define properties

Create connections

Assembling

Meshing

Prepare input data

Parameter

file

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file

model.cdb

-APDL

FE-DB

Parameter

file model.cdb


Solve Start ANSYS job

Output: ANSYS result file



Define properties

Create connections

Assembling

Meshing

Prepare input data

Parameter

file

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file

model.cdb

-APDL

FE-DB

model.rst





Read result file and write report (h3d format)

Fully automated in HyperView

Solve



Define properties

Create connections

Assembling

Meshing

Prepare input data

Parameter

file

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file

model.cdb

-APDL

FE-DB

model.rst

Report

model.rst




Solve



Define properties

Create connections

Assembling

Meshing

Prepare input data

Parameter

file

CAD-Data provision


PDM

Vehicle

data

sheet

Part list

Connector

position

file

model.cdb

-APDL

FE-DB

model.rst

Report

automated task manual task

Color legend automation grade:


•Concept analysis

•Tooling release for

Prototypes

•Detailed analysis

for series

•Tests -

Optimization

•Tooling release

series

•Final virtual

clearance

Simulation in Development Process

Product

definition

Concept

development

Series

development

Pre

development

•Concept analysis

Type

evaluation

Selection of the

vehicle types for FEA

Selection of the

vehicle types for tests

(measurements, rough

road)


Advantages

Reproduction of the whole process in Software „Frame Tool Box“

Modular kit, in this way it is possible to reuse the components

Significant time savings through automation of process steps (i.e. meshing

and generation of the connections)

Standards are anchored in the software, thereby ensuring the model quality

and comparability

User guide and shortening the training time

Risks

A high degree of automation leads to late identification of bad design

CAD audit

Advantages & Risks


Outlook

Define properties

Assembling


Solve

Define & apply loadcase data


Meshing


Integrate FE-Database into PDM/PLM system for

better change tracking

Further automation of input data preparation Prepare input data

CAD-Data provision PDM

FE-DB

Create connections

Introduce new connection types to increase

results quality

Integrate further user requirements

MBS intersection

…


• Increasing requirements and more flexible use of the

commercial vehicles lead to complex challenges in

engineering.

• Variant range, the number of FE models and the need for

parallel product development are a great challenge in CAE.

• It‘s necessary to use the advantages of the modular principle

in the virtual development

• Frame tool box was developed with ALTAIR

• It includes the entire process from building the FE model to

the evaluation of results in automated and standardized

process.

• CAD audit is necessary

• This meets the requirements with shorter time, higher

density of coverage and improved result quality.

• Reduction and specification of the test vehicles for validation

Simulation makes a great contribution in the development

Conclusion


Mustafa Gök

+49(0)89/1580-4405

[email protected]

Sebastian Straube

+49(0)89/1580-4878

[email protected]

Dr. Andreas Kruppa

+49(0)89/1580-1760

[email protected]

Thank you for your attention!

Challenges and requirements for automated processes in Commercial Vehicle Development

Engineering

Transcript of Challenges and requirements for automated processes in Commercial Vehicle Development