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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
3 < > 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
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
4 < > 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
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
5 < > 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
Type list
Different load distribution
Different strength level
Driving dynamics loads from the road
to the structure
6 < > 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
Why a lot of types? Body types and customer usage
7 < > 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
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
8 < > 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
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
9 < > 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
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
10 < > 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
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 %
11 < > 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
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:
12 < > 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
Process for the analyzing of entire frame models Process overview
CAD-Data provision
CAD – Model of complete vehicle
Provided by package department via
PDM-System
PDM
13 < > 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
Process for the analyzing of entire frame models Process overview
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
14 < > 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
Process for the analyzing of entire frame models Process overview
FE-DB FE-DB
Meshing
Fully automated in BatchMesher and
Simlab
Manual checking and correction
Prepare input data
CAD-Data provision
„Frame Tool Box“
PDM
Vehicle
data
sheet
Part list
Connector
position
file
Part list
15 < > 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
Process for the analyzing of entire frame models Process overview
Assembling
Fully automated in HyperMesh
Part position from part list
Meshing
Prepare input data
CAD-Data provision
„Frame Tool Box“
PDM
Vehicle
data
sheet
Part list
Connector
position
file FE-DB Part list
16 < > 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
Process for the analyzing of entire frame models Process overview
Create connections
Fully automated with tcl-script
Location from connector position file
Manual checking and correction
Assembling
Meshing
Prepare input data
CAD-Data provision
„Frame Tool Box“
PDM
Vehicle
data
sheet
Part list
Connector
position
file FE-DB
Connector
position
file
Connection type 1:
Shell / Shell
Connection type 2:
Solid / Shell
17 < > 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
Process for the analyzing of entire frame models Process overview
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
„Frame Tool Box“
PDM
Vehicle
data
sheet
Part list
Connector
position
file FE-DB Part list
18 < > 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
Process for the analyzing of entire frame models Process overview
Vehicle
data
sheet
Prepare solver input
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
„Frame Tool Box“
19 < > 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
Process for the analyzing of entire frame models Process overview
Define & apply load case data
Read model and parameter file
Define loads according to weight
distribution
Set air spring stiffness
Fully automated in APDL
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
Parameter
file model.cdb
20 < > 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
Solve Start ANSYS job
Output: ANSYS result file
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
Process for the analyzing of entire frame models Process overview
21 < > 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
Process for the analyzing of entire frame models Process overview
Result documentation
Read result file and write report (h3d format)
Fully automated in HyperView
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
model.rst
22 < > 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
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 grade:
23 < > 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
•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)
24 < > 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
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
25 < > 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
Outlook
Define properties
Assembling
Result documentation
Solve
Define & apply loadcase data
Prepare solver input
Meshing
„Frame Tool Box“
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
…
26 < > 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
• 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
27 < > 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
Mustafa Gök
+49(0)89/1580-4405
Sebastian Straube
+49(0)89/1580-4878
Dr. Andreas Kruppa
+49(0)89/1580-1760
Thank you for your attention!