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Exploring Design-To-Cost in Vehicle Engineering using Altair’s Enterprise Solution:
Bonn, 8 - 9 November 2011 Dr.-Ing. Hans Sippel CAEvolution GmbH, Carlo Serio Altair Engineering GmbH
CAEvolution
Agenda • Challenges in Vehicle Engineering
• Business Intelligence Software
• Altair‘s Enterprise Solution: – HiQube at a glance
– Advanced Data Engine
– The Dashboard Concept (Data Analytics)
– Multi - Objective Simulation & Optimization
– Reporting & Publishing
• Case Study Engineering
• Summary
Dr.-Ing. Hans Sippel 2
CAEvolution
Challenges in Vehicle Engineering
Dr.-Ing. Hans Sippel
New drive line concepts Climate Changes CO2 Emission Reduction Innovative vehicle concepts Advanced material concepts 3
CAEvolution
Dr.-Ing. Hans Sippel
Challenges in Vehicle Engineering
4
CAEvolution
Shared Data Bus
SimulationModule 1
SimulationModule 2
SimulationModule xyz …..
Dr.-Ing. Hans Sippel
Crash & Occupant Safety
NVH
…..
Mechatronics
Business Intelligence Software
5
CAEvolution
What is the
objective of the
simulation?
Status, milestone,
or study?
HiQube at a glance
Decision and Analytic Layer Allowing users to freely move & explore the design & information space
How is the performance evolving during
the project?
Which load
case or car has
no status
simulation? What are
cost
drivers?
Number of
simulation per car,
variant, milestone,
discipline, load
cases, …?
Comparison of
simulation and test
Dr.-Ing. Hans Sippel 6
CAEvolution
HiQube at a glance
Dr.-Ing. Hans Sippel 7
Source Systems (PDM, SDM, ERP, …)
Data Mart
Relational
Database
Multi-Dimensional
Database
Flat
File
Spreadsheet
File
CAEvolution
HiQube at a glance
Dr.-Ing. Hans Sippel 8
Different people have different ways of looking at and interpreting data, like: Analysts Car Line Managers Controllers Executives Investigation of multi-dimensional Qubes
CAEvolution
Cars
Car Class
Car Type
Car Model
Products Dimension
Hierarchy
Simulation Load Case
Crash
NVH
Durability
CFD
Hierarchy
Measures/facts/metrics
Product Performance
Dimension Attributes/Keys/members
Saturn
X320
X330
Focus
Dimension Attributes/Keys/members
Advanced Data Engine
Dr.-Ing. Hans Sippel 9
CAEvolution
Cars
Car Class
Car Type
Car Model
Products Dimension
Hierarchy
Simulation Load Case
Crash
NVH
Durability
CFD
Hierarchy
Measures/facts/metrics
Performance metrics
Saturn
X320
X330
Focus
Dimension Attributes/Keys/members
Crash Performance of Version xyz in Phase 1
+ + +
Advanced Data Engine
Dr.-Ing. Hans Sippel 10
Dimension Attributes/Keys/members
CAEvolution
Cars
Car Class
Car Type
Car Model
Products Dimension
Hierarchy
Simulation Load Case
Crash
NVH
Durability
CFD
Hierarchy
Measures/facts/metrics
Performance metrics
Saturn
X320
X330
Focus
Dimension Attributes/Keys/members
Progress of Version xyz
from Phase 1 to Phase 3
Performance Metrics Reports DATA
Advanced Data Engine
Dr.-Ing. Hans Sippel 11
Dimension Attributes/Keys/members
CAEvolution
The Dashboard Concept (Data Analytics)
Dashboard philosophy: „Green light says go, red light says no“
For „decision support“ data review from the requirements´perspective across • disciplines • load cases …
Dr.-Ing. Hans Sippel
Function BL Alt A Alt B Iter 3
Discipline A 50% 70% 69% 73%
Loadcase 1 50% 70% 60% 71%
Loadcase 2 40% 80% 69% 73%
Requirement a ++ + + +
Requirement b -- + - +
Loadcase 3 10% 30% 48% 88%
Discipline B 40% 45% 76% 94%
Loadcase X 30% 40% 56% 86%
Loadcase Y 50% 50% 100% 100%
Requirement Y.a pass failed pass pass
Requirement Y.b failed pass pass pass
+
+
+
-
-
--
failed
failed
Key Performance Indicators
12
CAEvolution
Reporting & Publishing
Dr.-Ing. Hans Sippel
More than 25 original and refined chart types all
provided with a multidimensional navigator.
Intuitive dashboard design.
13
Visual Analytics.
CAEvolution
Dr.-Ing. Hans Sippel
Multi-Objective Simulation & Optimization
Be aware of local minima & spikey behaviour!
Considering contradicting objectives
14
Which one is „best“? What is „best“?
Uncertainty: How „noisy“ is the system?
CAEvolution
Case Study Engineering The ULSAB-AVC Project (www.ulsab-avc.org)
Dr.-Ing. Hans Sippel 15
Automotive (R)Evolution in Steel using: High-Strength Steel Tailored Blanks Welded & Tailored Tubes …
which help to ensure
Safety
affordability
fuel Efficiency
environmental Responsibility
Performed by Porsche Engineering Services & Suppliers
CAEvolution
Cost analysis per vehicleMaterial - Total Type
Cost Scenario 1
181,60
Cost Scenario 2
175,77
Delta
-5,83
-3.2%
Ordinary Stampings
+6,73
Bulkhead Crash Box Dash R&L: 0,78Body Side Inner Rear LH: 0,65Body Side Inner Rear RH: 0,52
Reinforcement Waist B-Pillar R&L: 0,48Crossmember Kick-up: 0,46
Dash: 0,40Reinforcement Tunnel: 0,39
Support Back Panel: 0,36Gutter C-Pillar R&L: 0,33
Closeout Inner Crash Box Dash R&L: 0,32Back Panel: 0,31
A-Post Inner R&L: 0,30Reinf Rail Rear Suspension Crossmember R: 0,30
Wheelhouse Outer R&L: 0,26Bracket Support Front Seat Rear (x2): 0,21
A-Brace Cowl Front: 0,17Reinforcement Rail Rear Spring Attachmen: 0,14
Crossmember Roof: 0,13A-Brace Cowl Rear: 0,10
Crossmember Tunnel: 0,09Reinforcement B-Pillar Lower R&L: 0,02
Bracket C-Member Instrument Panel Attach: 0,01Rail Rear Outer Floor Extension R&L: -0,03Crossmember Back Panel: -0,06Plate Crash Box Rail Front Attachment (x: -0,07Header Front: -0,07Crossmember Support Front Seat Front R&L: -0,10Reinforcement Waist B-Pillar Outer R&L: -0,11Closeout Outer Crash Box Dash R&L: -0,15Bracket Member Body Side Inner Attach Re: -0,20Header Rear: -0,22Assembly Reinf Rail Rear Suspension Atta: -0,23Support Header Front R&L: -0,24Closeout Lower Crash Box Dash R&L: -0,41Crossmember Rear Suspension: -0,75C-Pillar Inner RH: -0,88Cowl Front: -0,90B-Pillar Inner R&L: -0,96Reinf Crash Box Dash R&L: -0,97Roof: -1,58Floor Front R&L: -2,23Tunnel: -2,40
-12,56
Dr.-Ing. Hans Sippel
Case Study Engineering
16
„Drill-Down“
CAEvolution
Dr.-Ing. Hans Sippel
Case Study Engineering
17
Cost analysis per vehicleMaterial - Total Type
Cost Scenario 1
181,60
Cost Scenario 2
175,77
Delta
-5,83
-3.2%
Ordinary Stampings
Tunnel 19.1%
Floor Front R&L 17.7%
Roof 12.6%
Reinf Crash Box Dash R&L 7.7%
B-Pillar Inner R&L 7.7%
Cowl Front 7.2%
C-Pillar Inner RH 7.0%
Crossmember Rear Suspension 6.0%
Bulkhead Crash Box Dash R&L 11.7%
Body Side Inner Rear LH 9.7%Body Side Inner Rear RH 7.7%Reinforcement Waist B-Pillar R&L 7.1%Crossmember Kick-up 6.8%
+6,73
-12,56
Further Options …
CAEvolution
Dr.-Ing. Hans Sippel
Case Study Engineering
18
Cost analysis per vehicleMaterial - Total Type
Cost Scenario 1
146,87Cost Scenario 2
141,52
Delta
-5,35
-3.6%
Tailored Blanked Stampings
+4,95
Rocker Inner R&L (unattached): 2,95
Floor Rear: 1,99
Wheelhouse Inner R&L: -0,46
Rear Rail R&L (unattached): -1,39
Reinforcement B-Pillar Rocker Rear R&L (: -2,19
Body Side Outer RH: -6,25
-10,30
„Slice“ for Tailored Blanked Stampings
CAEvolution
Dr.-Ing. Hans Sippel
Case Study Engineering
19
Cost analysis per vehicleMaterial - Total Type
Cost Scenario 1
58,01Cost Scenario 2
55,82
Delta
-2,19
-3.8%
Tubular Hydroformed Parts
+2,04
Member Body Side Inner LH: 2,04
Member Body Side Inner RH: -0,40
Member Rail Front RH: -0,57
Member Rail Front LH: -3,25
-4,22
„Slice“ for Tubular Hydroformed Parts
CAEvolution
„Human Being“ is centric
Engineering tasks are changing CAE Technology is indispensible:
High Prognosis Quality Ease of Use Predictive
Summary
Dr.-Ing. Hans Sippel 20
Business Intelligence Software is considered critical to ensure a reliable decision making going forward.