CAE PLM Solution and integration with CAE Pre-Processor Software
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Transcript of CAE PLM Solution and integration with CAE Pre-Processor Software
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Dr. Ulrich Fox, Ralf Fachbach
Ford Motor Company
CAE PLM Solution and integration with
CAE Pre-Processor Software
2011 European HyperWorks Technology Conference
Bonn, November 8–9, 2011
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Introduction
November 14, 2011 Page 2
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Drivers for CAE PLM @ Ford
November 14, 2011 Page 3
• Efficiency
– CAE Model Build effort
– CAE Model Quality and Reliability
– Process Automation
• ONE FORD
– Global CAE Process
– Global Sharing of Data and Work
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Ford C3P System
November 14, 2011 Page 4
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Merkenich,
Germany
Shanghai
China
Cuautitlan
Mexico
Chennai
India
Dearborn
Michigan, USA
Broadmeadows
Australia
Hiroshima
Japan
Camacari
Brazil
Gothenburg
Sweden
Dunton
England
• 7,600 Teamcenter
• 5,100 CAD
• 14,500 Digital Buck
• 310+ Supplier Connects
Ford C3P Sites
November 14, 2011 Page 5
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CAE PLM History 1997: Deployed Metaphase for „CAE PIM“
– CAE Model storage assigned to Product data
2000: CAE Model Build and Management with I-DEAS/TDM
– CAE Model creation based on CAD authoring tool
2004: Teamcenter Deployment for CAE PIM
– CAE Data management as first Teamcenter Deployment worldwide
2006: Teamcenter CAE Customization
– CAE Process Automation
– Pre-Processor Integration
November 14, 2011 Page 6
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CAE PLM History cont. 2008: TCSim Project
– Teamcenter for Simulation (TCSim) Selected as Strategic CAE Data
Management Tool
– Developed Solution for CAE Model Build Management
April 2010: Deployed TCSim for CAE PIM
– OOTB CAE Data Management Solution
Jan 2011: CAE PLM Strategy workshop
– Defined set of global CAE PLM Principles (e.g. on sync. & mapping w/
product structure, knowledge capture, etc)
November 14, 2011 Page 7
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Development
November 14, 2011 Page 8
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
C3P NG TS2.0
Ford EU Tactical Solution
= Local Customization
Ford Global Strategic Solution
= Teamcenter Simulation
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Scope
November 14, 2011 Page 9
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Simulation Process
Post-
Processing Solve
Job
Submission
Job
Control
Test
Correlation
Standard
Results
Secondary
Results
TCSim Project Scope (2008-2010)
November 14, 2011 Page 10
Collect Sub-
Assemblies
Product
Product
Configuration Build CAE
Assemblies
Collect
Connections
Build CAE
Sub-Assembly
Pre-Processing
Component
Meshing
Populate Eng.
Properties
Structure
Mapping
Assembling Post-
Processing Solve
Job
Submission
Job
Control
Test
Correlation
Standard
Results
Secondary
Results
CAE
Marking
Phase 1 Phases 2+
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CAE PLM Development Scope (2011-2014)
November 14, 2011 Page 11
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Architecture
November 14, 2011 Page 12
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Data Model – “EBOM embedded in CAE str/”
November 14, 2011 Page 13
Product Structure
CAE Structure, Composite View
CAE Structure
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Data Model – “CAE embedded in EBOM”
November 14, 2011 Page 14
Product Structure
CAE Structure, Composite View
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Data Model – Classification
November 14, 2011 Page 15
• Classification is used to create and
maintain a structured library based on
CAE specific classification attributes
• Classification of CAE Data makes
required data easier to find and
retrieve
• Search the classification
hierarchy based on different
criteria to find the CAE data
you need
• View data associated with
your CAE item in the
viewers. (jt, text, etc)
• Control complexity of
growing CAE Library
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tc_hm
tc_xyz / Preproc.
•CAE Pre-Processor
•Read Structure
•Read Data sets
•Start Processes
•Modify Data Sets
•Modify EP‘s
Tool Architecture
November 14, 2011 Page 16
• Create/Maintain Structure
• Change mgmt.
• Notification
• Manage EPs
• Maintain/Document Data Sets
• Work Packaging
• Share Data
• …
• Customer specific utilities
• Advanced functionality
• Fix Minor Bugs
• CAE Pre-Processor
• Read Structure
• Read Data sets
• Start Processes
• Modify Data Sets
• Modify EPs
Teamcenter
for Simulation
tc_inspector
Server/Client Client „TCSim tool set“
PLM XML D/B Common
w/ PDM
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Interface Format
November 14, 2011 Page 17
• Siemens PLM XML Format Selected
– Versatile Format
– Configurable via „Transfer Modes“
– Provides Image of the Selected Structure
• Structure & Metadata
• Paths of Included Data Sets
• Copies of the Files Attached
to Data Sets in Native Format
Package
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CAE Pre-Processor Integration
November 14, 2011 Page 18
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Pre-Processor Integration –
Crash Vehicle Assy
November 14, 2011 Page 19
• Modular library
• Generic Models
• Manage mcf‘s
• Module selection
• Model content
• Instances
• Module Positions
• …
• Modify mcf‘s
• Realize connections
• Modify Meshes
• Position Modules
• Quality Checks
• Numbering
• Mass Trimming / Balancing
• Loadcase Setup
• Output Request
• Final Deck
&
PLM XML
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Pre-Processor Integration Modes
November 14, 2011 Page 20
• Full Data (Metadata+Bulk)
– Geometry / No FE Model
– FE Model / No Geometry
– Geometry & FE Model
• Separate Bulk / Metadata
– Metadata / No Bulk data
– …
• „Parallel“ Build
– Incremental Packages
– …
Develop more sophisticated
integration (based on API’s)
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Summary & Outlook
November 14, 2011 Page 21
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Summary & Outlook
November 14, 2011 Page 22
• Efficient, global CAE PLM implementation in place
Key success factors :
– Business driven development approach
– Full integration with PDM solution, small extra IT effort
– Use Out of the box, uncustomized solutions where possible
– CAE s/w integration provides user efficiency gain of initial solution
– Ground up scoping, implementing CAE model build solution first and
growing to wider process steps gradually
• 2011-2014 Extension Proposals
– Analysis management, process automation
– CAE / Test integration
– Generic mapping of CAE and product data
– Business process integration
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November 14, 2011 Page 23
Thank You
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November 14, 2011 Page 24
Backup Material
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Data Model
November 14, 2011 Page 25
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Use Cases
November 14, 2011 Page 26
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Use Cases
November 14, 2011 Page 27
1. Body-in-Prime CAE model build
– Batch meshing CAD data (including Catia V5/JT CAD
conversion, automated mid-surfacing)
– Automated assigning of CAE engineering properties to CAE
parts (PID, part thickness, part material, MID etc)
– Automated creation of CAE connections via Master
Connection File
2. CAE Module Management
– Store, maintain and share CAE System Modules
3. Vehicle CAE Model Build
– Automated assembly of CAE Modules, incl. connections
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Use Case #1
(details)
1. Create/Clone/Update
CAE Structure
2. Populate EP’s
3. Export & Send
PLMXML Pkg
4. Create & Debug mcf
5. Mesh & Assemble
6. Create Connections
7. Freeze & Share Model
November 14, 2011 Page 28
1 2 3
4
5
6 7
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Pre-Processor Integration – Model Build
November 14, 2011 Page 29
• Export CAE structure from Teamcenter via PLM XML Export
• Launch Pre-Processor integration and import CAE structure PLM XML Package
• Perform automated Data Preparation Steps
(e.g. Translation, positioning, instancing, mid-surfacing, structuring, ...)
• Export CAE PLM XML package from Pre-Processor, containing CAE model data
• Import CAE PLM XML package into associative CAE structure in Teamcenter
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Experiences
November 14, 2011 Page 30
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Experiences
November 14, 2011 Page 31
• Rollout successful w/o show stopper issues
– Memory limitations unveiled
– Remote data transfer issues
– Dependency from PDM tree integrity
• 8 x Performance increase of key steps compared to previous
Teamcenter CAE PIM solution
– Initial „Overhead“ for CAE Data Management of BIW CAE model is
close to 0
– Overhead is more than offset by downstream benefits
• Technology still evolving
– Configuration (Data Model, Key PLM Behaviors) is stable
– TCSim “Tool Set” improving, 2 releases / month since April
– Improvements realized in Teamcenter 8.3 and planned for Teamcenter
9 and beyond