Empowering Gearbox Product Development with Simulation...
33
Empowering Gearbox Product Development with Simulation Apps March 22, 2016 Starts at 12:00pm ET
Transcript of Empowering Gearbox Product Development with Simulation...
Empowering Gearbox Product Development with Simulation Apps
March 22, 2016 Starts at 12:00pm ET
• All attendees are muted
• The event is being recorded
• A recording of the event and presentation will be made available to attendees following the conclusion of the event
• If you have a question during the presentation, you can ask it using the Questions panel on the GoToWebinar Control Panel to the right of your screen. Questions will be answered on a one-on-one basis after the conclusion of the event.
Housekeeping Items
• Introduction
• Gearbox System Product Development – Where is it today?
– Brian Wilson, CEO of Advanced Drivetrain Engineering & Technology (ADET)
• Gearbox Product Design Automation - Integrating common Gearbox tools with Comet Solutions
– Malcolm Panthaki, Founder & CTO of Comet Solutions, Inc.
• Comet Demonstration
– Tim Keer, VP Technical Services
• Conclusion
Agenda
Virtual Development in Gearbox Industry
Issues with Current Product Dev Process Tool Silos Everywhere
American Axle NVH Whitepaper
Glen Steyer, American Axle’s Executive Director of Product Engineering, reports major benefits from the new tool:
• Average 75% time reduction for each analysis iteration. • Approximately $130,000 in annual cost savings at a single engineering site. • Improved quality through globally enforced modeling and NVH standards/practices which minimizes opportunity
for human error. • Ability to run many more NVH analysis iterations, leading to more design decisions, earlier. • Ability to redeploy resources as less experienced engineers are now able to safely run simulations.
Comet Solutions: Our Mission
Comet Solutions helps product development organizations automate design engineering process rapidly, using a software platform that allows easy integration of many popular Math, CAD and CAE tools.
• Make CAE activities more efficient
– Automation that works
– Elimination of rework & repetition
• Make CAE more impactful to business
– Useful to more people
– Results obtained in time to support decisions
• Simplify the complex process of engineering product “systems”
– Build system dependencies into models
– Create transparency across disciplines
• More Detailed Discussions
• Technology Validation Pilot
Conclusion – Next Steps
The Drivetrain CAE Engineer’s Dilemma
March 2016
Principal
Brian K. Wilson, Founder, President, & CEO of ADET, has 25+ years of experience in the design, test and analysis of rotating machinery. His experience includes Romax Technology, Inc. where he served as Chief Technology Officer, Ford Motor Company where he held the position of NVH Technical Specialist and work as a consultant for SDRC (Now Siemens PLM). Wilson’s expertise is in rotating machinery dynamics, helping major OEMs worldwide to solve an assortment of drivetrain dynamics problems over the years. He currently serves as Vice-Chair on the AGMA Sound & Vibration Committee and sits on ASME’s Power and Transmission Gearing Committee. Wilson holds a BSME from Michigan State University.
What We Do
• Drivetrain consulting
• CAE and custom software
• Test systems
• Training and seminars
• R&D
• Other advanced technology
Model T Differential
Drivetrain Design – PRESENT STATE
Product Development Timeline: 24-36 months
Definition of Basic Requirements: Speed, Torque, Ratios
CONCEPT DESIGN: gear sizing, bearing sizing, bearing forces for housing design
CAE DETAILED DESIGN: gears, bearings, shafts, housings
Order Tooling – Protos and Production
Proto-1 Proto-2 Production
CAE REFINEMENT: troubleshooting gears, bearings, shaft, housings, lubrication, cooling
CONCEPT DESIGN: only
slight deviations from known
successful designs
Scramble to support
production and launch
!
Exp
erie
nce
b
ase
d
Hardware development is faster than CAE analysis – resources don’t align
Too few CAE resources
Too few experts
Experts spend time checking others work, not doing the difficult tasks
Compromise on model quality to save time
I need multiple software tools to do my analysis – I pass data manually between them. Prone to errors and slow results
CAD models are difficult and time consuming to mesh
Global CAE methods and processes not aligned
Optimization? I stop when I have a right answer (not the right answer) due to time constraints
We need more qualified engineers. The level of inexperience is causing delays
Monte Carlo? Variation? I can barely complete nominal analyses
Drivetrain CAE Engineer’s Dilemma
0D/1D/2D/3D
CAE tools,
Optimization,
Automation,
Standardization
Real Estate
Powerflow (Advanced)
Assembly&
Variation
Fuel Economy
& Controls
Efficiency
Manuf
Durability
NVH
Weight
Overall cost
CFD, lube, thermal
Basic Req’s (speed, tq,
ratio)
Drivetrain Design – IDEAL STATE (FUTURE?)
Proto-1: Additive Manufacturing direct from design – quick, inexpensive functional verification – no “tooling”
Manuf process and tooling defined by design process – direct order production tooling
Production runs using production tooling only; minor refinement to process – not design
Lighter, Cheaper, Faster-to-Market, Higher performance
New Design
0D/1D/2D/3D CAE tools,
Optimization, Automation,
Standardization
Thank you for your attention
Gearbox Product Design Automation Integrating common Gearbox tools using Comet’s Intelligent Templates
Malcolm Panthaki, Founder & CTO
Comet Solutions Company Overview
Pioneer in Simulation Automation for Model-Based Engineering using unique Abstract Modeling Technology
• Formed in 2001 in Albuquerque, New Mexico, with technology developed at UNM
• 100-150 man-years development of proprietary Abstract Engineering Model® (AEM)
• Initial commercial product release in 2008 in the Satellite Optical Systems market
• Experienced leadership team: >100 years combined PLM industry
• One of the fastest growing companies in the PLM industry
2
FE Structural Solvers
Acoustics Solvers
GD&T Tolerance Stack-Up Analysis
CAD
Gearbox Product Design: Common Silos & Tools
3
FE Meshing
Gear/Bearing/Shaft System Simulation
Simulation Team
Status Quo: Simulation only for Experts
Simulation has been in the hands of too few, for too long How can we get complex simulation safely and effectively to “Everyone Who Needs It”?
CAECode 1
CAECode 2
CAECode 25
CAECode 13
CAECode 32
CAECode 35
CAECode 40
CAECode 38
Excel
Matlab
Optimization
Product Managers Product Development Engineers Systems Engineers Test Engineers Salespeople …everyone needs simulation!
Product Development Team Simulation Data: in silos, inconsistent, non-integrated Simulation Processes: manual, error-prone, highly inefficient inconsistent
Multiple Global Engineering Centers
5 days to “clean up” geometry and create a “perfect” mesh?? 4-6 weeks to complete a single analysis?
How can simulation be a driving force in design?
Simulation Experts: become the bottleneck
4
Gear
Clutch
Bearing
Shaft
The Problem With Engineering Models
• Product Descriptions Are Functional and Descriptive
– Common language understood by all your designers, engineers, customers, and suppliers
• But, Engineering Models Are Tool-Specific And Unique
– C-Bush, P-Bush, Spider Joint, MNF, M-File, Modal Model, FRF, Beam with rotational DOF
– Every tool has its own language
• Each Product Variation Drives Many Model Changes – FEA, CAD, MBD, Excel, In-House Tools, and more…
• Every Model Change introduces rework, translation errors, cost, and huge amounts of time for re-analysis
5
What Engineers Really Need
Gear
Clutch
Bearing
Shaft
Structural FEA & Life In-house
tools
FE Mesher CAD
Gear/Bearing System Analysis
Acoustics Analysis
• Functional representation of product systems – System & product Intent
– Functional requirements
– Design variables
– System constraints
– Operating conditions
– Performance metrics
• Tool-agnostic engineering automation – CAD, FEA, MBD, Gearbox, math tools
• Automation that is robust across design changes and Product Families
• Automated mixed-fidelity modeling
6
Comet Template
Comet’s Intelligent Templates Product Evaluation Using Simple “Engineering Calculators” (SimApps)
• Embed expert knowledge – In robust, reliable, easy-to-create templates – Minimal or no scripting – Experts Tools – Your CAD, Your CAE
• Automate repetitive modeling & analysis work – Using Abstract Modeling, they work
across the entire Family of Products that share a basic architecture
• Deploy Anywhere! – Web-based, cloud-enabled
• Run by Anyone! – Easily, Rapidly & Automatically analyze
and optimize design variants – Within a discipline or across multiple
disciplines
CAD in
Report out
7
Template
True Virtual Test Rigs
Comet Workspace Parametric, Multi-Fidelity, Multi-Source, Multi-Discipline
Abstract Engineering Model™
Adaptors to External Tools
Mesh Models
Systems Models
CAD Models
Product Representations
Analysis Models (Auto-Generated)
Isight Optimization Tools
MBD Tools Systems Tools FEA Tools
ANSA Mesher
CODE V Optics
Automating Product Development Processes Integrating Tools & Data Across All Design Phases
8
Simulation Apps: Simulation for Everyone
Product Managers Systems Engineers
Designers Salespeople
… (use the Sim Apps)
Targeted Applications: answer particular questions, on a particular product family, at a particular level of fidelity
Simple GUI’s that drive Templates that capture/enforce expertise Must work across significant design changes and across a Product Family
Must speak the language of the user, not “Simulation”
Optionally, Web-deployed on Intranets & “The Cloud” Provide all the computing required for rapid throughput
Product Development & Sales Teams Simulation Team
Simulation Apps (SimApps™)
(author the Apps
+ use the apps)
CAE Code 1
CAE Code 2
Math Tool Systems Tool
CAD Tool Optimization
Simulation Experts
PLM
Expert Certified! Safe and robust for all users
9
Robust across a Product Family
Target End Users of Comet SimApps
Simulation Experts: Multi-Disciplinary Processes Create and validate best-practice analysis processes Run the most complex simulations
Design Engineers: Standard, Repetitive Processes Run well-defined standard analyses safely & consistently Use web-deployable, role-based Vertical Applications that
drive Comet Templates (built and updated by the experts)
Chief Engineers/Program Managers/Systems Engineers Run multi-fidelity systems analyses from the dashboard Conduct design reviews effectively, without needing
presentations
Ultimately, “Anyone asking Performance Questions” Run actual simulations through a simple web interface to
quickly ascertain the performance and cost of customized engineered products
750K engineers
worldwide of this type today already using
CAE
8M engineers who aren’t benefiting
from the use of simulation tools today
10
Wide Scope of SimApps™
Automotive subsystems Off-Road vehicles
Plastics & containers Consumer appliances
Aerospace subsystems Optical Imaging systems
Laser systems Electronics PCBs
Plastic Bottle Design Automotive Driveline Design
Automotive Spring Design
Vehicle Suspension Design Engine Connecting Rod Design
Electronics Board Reliability Laser Systems Design
Heavy Equipment Design
Washing Machine Design
Automotive Bumper Design
Aircraft Metallic Seal Design
Space-Borne Optical Systems with Thermal Controls
11
Business Benefits of Comet Automation
• Enable Engineers and Teams of Engineers to perform Rapid & Robust Design Space Exploration early & often
• Significantly reduce the cycle time of each design iteration (>80-90%)
• Explore the design space more accurately and automatically
• Evaluate more concepts
• Better utilize limited resources: human experts & non-experts, time/schedule, program cost
• Capture knowledge of scarce and dwindling number of experts in an executable/reusable form using Comet’s Templates
• Facilitate the spread of “Systems Thinking” across the multi-disciplinary team of product development engineers
Significantly increase the ROI of your simulation investments
over the entire product development lifecycle 12
Planetary Gearbox Template: Summary
• Full automation: – Rebuilt the CAD with new CAD Parameters
– Created a Finite Element Mesh
– Ran an ANSYS Modal Analysis
– Ran a RomaxDESIGNER static analysis
– Post-processed
… in 10 minutes
• Comet template includes the embedded experience of various experts
• Not restricted to a single topology – this template will accept any combination of CAD / RomaxDesigner models which are consistent and tagged appropriately
• Can be used for design space exploration – Design of Experiments
– Parameter Study
– Optimization
• Comet Automation Templates – Capture CAD/CAE expertise & company best Practice/IP for
safe reuse
– Are intelligent and work across a wide range of design changes and product families
– Are easy to use and enterprise accessible allowing the safe creation of complex designs by experts and non-experts
• Benefits – Increased efficiency (>80%)
– Increased product design quality
– Global process consistency and repeatability
– Enterprise wide impact of your best engineering expertise
Conclusion – Key Take Aways
