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Online-SeminarEffizientes Testen der Betriebsfestigkeit mechanischer
Komponenten, Systeme und Fahrzeuge
Andreas Langmann
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Page 2 Siemens PLM Software
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Page 3 Siemens PLM Software
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Page 4 Siemens PLM Software
Durability Load Data Analysis Tasks
Office
Analysis Report & share
Test schedule creation
Test engineer
Office
Roads
Simulation
Measure
Simulation engineer
Test engineer
Roads/Office
Validate
Test engineer
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Test
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Challenges
• Acquire & synchronize wide range of different sensor
types
• Limited space in vehicle
Data Acquisition with Siemens SCADAS
01011
10010
11010
Universal signal conditioning
• Complete range of embedded
universal signal conditioning
• Fit for high channel count
• Channel flexibility
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Distributed setup with SCADAS Satellites
• Distributed setup mounts acquisition units near sensors
• One single (green) cable carrying data and power
for 12 channels simplifies instrumentation and repair
Centralized setup
60 (long) cables 5 (green) cables
Distributed setup
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SCADAS Satellites - Certified and rugged equipment
IEC 60529: IP66 and IP67
• Dust-tight (IP6x)
• Power water jet (IPx6)
• Immersion up to 1m (IPx7)
MIL-STD-810F
• Vibration: 7.7grms
• Shock: 100g shock
Wide range
• -40 ºC up to 85 ºC
-40 ºF up to 185 ºF
Water and dust Shock and vibration Temperature
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Sensor database
Step: Test setup
Feature: Powerful channel setup with embedded sensor checks
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Trackside validation of test quality
Step: Measure & validate
Feature: Technician-friendly trackside validation
Generate and run processes up to 50%
faster than traditional solutions
Validate Analysis Test schedule creation Report & Share
Validate your acquired data
Validate Analysis Test schedule creation Report & Share
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Automate
processes
Standardize on procedures
to eliminate human errors
Channel & run
comparison
Compare large amount of
channels in quick and
efficient way
Validate your acquired data
Challenges
Traceability of
data processing
Store relevant information
about the process
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Maximize productivity with instant data visualization and test
procedure check
Fast, easy and intuitive validation of raw time signals including a broad set of analysis
Productivity
Quick channel and run comparison thanks
to Pivot table and instant data visualization
Advanced validation of test procedure after
measurement
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Automatic documentation of
consolidation result & steps
Gaining confidence and productivity with the Anomaly
Library
RAW load data
Signal Failures
Artefact Identification
Spike Identification
Drift & Offset
Correction
Rename or Calculate
Channels
CONSOLIDATED
load data Productivity
Securing best,
high-grade
consolidated
and accurate
load data Confidence
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Demo Simcenter Testlab
Step: Validate your acquired data
Feature: Instant data visualization & Automatic documentation of processes
Analyze durability potential
Validate Analysis Test schedule creation Report & Share
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Create realistic
targets
Increase realism
by creating correct targets
Valuable
insights
Qualify and quantify
the durability potential
of vehicle loads
Analyze durability potential
Challenges
Fatigue life
prediction
Compare design options by
estimating fatigue life from
measured stress or strain
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LoadsLoads (force, disp., …)
Failure
t, time
σ, F
S-N curve for
CA loading
Generic S-N curve
Define slope-k
How to understand fatigue content of loads ?
Pseudo-damage
Geometry Material
Damage
Fatigue life (= 1/Damage)
Rainflow counting
Cycles, range & mean
Stress-concentration KtStress-concentration Kt = 1
Pseudo-damage
Damage accumulation
𝑖=1
𝐼𝑛𝑖𝑁𝑖
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Page 19 Siemens PLM Software
Getting insights with innovative load analysis
Qualify and quantify the durability potential of vehicle loads
with innovative load analysis technology
shown as either Range Pair vs. Damage or as Pseudo Damage valuesInsights
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Increase realism by creating correct targets
Take market and customer into account
by using rainflow superposition to create realistic targets
Confidence
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Compare different design options by using in-depth fatigue
analysis
Compare design options for
long-term quality by
estimating fatigue life from
measured stress or strain
histories combined with
material data
Insights
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Page 22 Siemens PLM Software
Demo Simcenter Testlab
Step: Analyze durability potential
Feature: Durability load analysis & Fatigue life prediction
Accelerated test schedule
creation
Validate Analysis Test schedule creation Report & Share
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Compress time
signals
Design accelerated
damage equivalent
test schedules
Test more
at the same time
Less testing during early
design phases, more
problems in final validation
Accelerated test scenarios creation
Challenges
Create constant
amplitude tests
Create simplified block
cycle tests for relevant
test benches
Block cycle test
https://www.youtube.com/watch?v=sDIM83jTuwk
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Page 25 Siemens PLM Software
How can you accelerate a test?
Omit non-damaging events - Multi-axial – RP-filtering
Vertical
Lateral
Longitudinal
Longitudinal
Uni-axial rainflow channel-per-channel is not OK
Phase relation lost !
Vertical
Lateral
Different loads !
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How can you accelerate a test ?
Omit non-damaging events – Uni-axial
Acceleration of x14 !
100070
All cycles below 4000N only contribute
less than 0.5% of the total damage
If you remove these from the loading, you end
up with 70 cycles instead of 1000
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How can you accelerate a test?
Omit non-damaging events - Multi-axial – RP-filtering
0 152 4 6 8 10 12 14Zeit [s] 1
-2000
3000
-1500
-1000-500
0500
1000
15002000
2500
FO
RC
E_
lon
g N
1
-3000
2000
-2500
-2000-1500
-1000-500
0
5001000
1500
FO
RC
E_
lat N
2
-2000
12000
-600
8002200
36005000
6400
78009200
10600
FO
RC
E_
ve
rt N
3
Attribute Name Unit
C:\Programme\LMS\TW 3.3 QC\demo\general\nature.dmd,FORCE_long NC:\Programme\LMS\TW 3.3 QC\demo\general\nature_edt.dmd,FORCE_long NC:\Programme\LMS\TW 3.3 QC\demo\general\nature.dmd,FORCE_lat NC:\Programme\LMS\TW 3.3 QC\demo\general\nature_edt.dmd,FORCE_lat NC:\Programme\LMS\TW 3.3 QC\demo\general\nature.dmd,FORCE_vert NC:\Programme\LMS\TW 3.3 QC\demo\general\nature_edt.dmd,FORCE_vert N
Small amplitudes/
little damage
Large amplitudes/
high damage
0.0 27.75.0 10.0 15.0 20.0 25.0Zeit [s] 1
-3510.1
3510.1
-3000.0
-2000.0
-1000.0
0.0
1000.0
2000.0
3000.0
FO
RC
E_lo
ng N
1
-2062.6
2062.6
-1500.0
-1000.0
-500.0
0.0
500.0
1000.0
1500.0
FO
RC
E_la
t N
2
-10509.7
10509.7
-7500.0
-5000.0
-2500.0
0.0
2500.0
5000.0
7500.0
FO
RC
E_vert
N3
Attribute Name Unit
C:\Programme\LMS\TW 3.3 QC\demo\general\nature.dmd,FORCE_long N
C:\Programme\LMS\TW 3.3 QC\demo\general\nature_edt_edt.dmd,FORCE_long NC:\Programme\LMS\TW 3.3 QC\demo\general\nature.dmd,FORCE_lat N
C:\Programme\LMS\TW 3.3 QC\demo\general\nature_edt_edt.dmd,FORCE_lat N
C:\Programme\LMS\TW 3.3 QC\demo\general\nature.dmd,FORCE_v ert NC:\Programme\LMS\TW 3.3 QC\demo\general\nature_edt_edt.dmd,FORCE_v ert N
Phase relation kept !
Create damage equivalent and accelerated test profiles
Insights
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Page 28 Siemens PLM Software
How can you accelerate a test?
Simplify the test – Block cycle test
Mix of different ‘Constant-amplitude’ tests for more representative results
Original time series
Normal/incidental/accidental(automatic or user-defined)
Damage calculation(Standard S-N curve or user-defined)
Rainflow matrix
Block cycle test
Damage equivalent 3 36
12
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Page 29 Siemens PLM Software
Demo Simcenter Testlab
Step: Accelerate durability test scenarios
Feature: Omitting non-damaging events (RP-filter)
Report and share
Validate Analysis Test schedule creation Report & Share
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Page 31 Siemens PLM Software
Time-consuming
reports
Accelerate decisions
during team meetings
Correlate
test & simulation
Correlate test & simulation
load data using proven
data analysis
Report and share
Challenges
Direct access to
various data types
Avoid data conversion
when using 3rd party input
data for processing
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Enable Collaboration within Simulation and Test
Open Software by avoiding
conversion when using 3rd
party input data for
processing.
Collaboration
Delivering Continuity
Create actionable reports to
accelerate decisions
Correlate test and
simulation load data using
proven data analysis
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Actionable reports
Demo Simcenter Testlab
Step: Report and share
Feature: Correlating test and simulation & creating actionable reports
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Collaboration
Become a frontrunner in the global innovation race
with Simcenter Testlab Load Data Analysis
Productivity
Insights
Confidence
➢ Generate and run processes
up to 50% faster
➢ End-to-end durability
platform for acquisition and
analysis
➢ Consistency and quality
with standardized
procedures and reports
➢ Increase realism by
creating correct targets
➢ Valuable & precise insights
to optimize the durability
performance of your next
designs
➢ Create damage equivalent
and accelerated test profiles
➢ Team effectiveness by
reducing learning effort
for novice and expert
users
➢ Correlate test and
simulation load data
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Conducting complete fatigue analysis
Fiat Group Automobiles S.P.A.
Using Simcenter Simulation & Test to verify and validate durability virtually
• Reduced margin of error in real
loads between 8 and 15 percent
• Reduced overdesign by performing
simulation prior to building a
prototype
• Diminished costs by developing
equivalency between two proving
grounds
“Although we can’t measure the improvement because we previously didn’t use
virtual data, the results that we have received by using both Simcenter products
are absolutely excellent.”Marco Spinelli, Head of the Chassis CAE Department
• Long-term partnership between Fiat and Siemens PLM Software
• The ability of Siemens PLM Software to deliver customized solutions
Virtual prediction and use experimental data
for model validationProving grounds in Turin, Italy
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Conducting customer correlated procedures
Ford Otosan
Cut time to reproduce 1.2 million kilometers of customer usage
• Reproduced 1.2 million kilometers
of customer usage in a condensed
proving ground test period
• Developed 4-week accelerated rig
test to represent 1.2 million
kilometers of customer usage
• Provided opportunity to optimize
cost and weight
“We selected Siemens PLM Software for its capabilities and experience in
durability field testing, load data analysis and test schedule development for
virtual simulation and durability track and rig testing.”
Vehicle Durability Supervisor
• Qualify and quantify the durability potential of vehicle loads with innovative analysis
• Replace time-consuming and costly tests by deriving compressed load time histories
with an equivalent damage potential for uniaxial and multi-axial loading conditions
Cabin rig test to represent 1.2 million
kilometersCustomer correlated proving ground test
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Page 37 Siemens PLM Software
Simcenter for Vehicle Performance Engineering
Vehicle Strength & Durability
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Page 38 Siemens PLM Software
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