Seoul Intercontinental COEX Hotel rdOctober 23 , 2015event-regist.com/3ds/2015/Track3_Multi-body...
Transcript of Seoul Intercontinental COEX Hotel rdOctober 23 , 2015event-regist.com/3ds/2015/Track3_Multi-body...
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2015 SIMULIA Regional User Meeting Korea Seoul Intercontinental COEX Hotel
October 23rd , 2015
Simulation powers Innovation
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15 Multi-Body Simulation
Simpack Introduction
Qiqi Jiang
MBS business development, SIMULIA AP
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MBS Overview
Use case 1: Driveline NVH Investigations at Mercedes Benz
Use case 2: 3D MBS gearbox NVH analysis
Seamless Simpack co-simulation workflow with SIMULIA products
Simpack Highlights and Conclusions
Agenda
Simpack applications in Real Time
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DS Acquired SIMPACK in July 2014
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MBS vs FEA Higher abstraction level enables MBS to be faster than FEA
Hydrodynamic bearing
Gear contact
Valve train components Chain guides
E.g. linear, nonlinear or frequency dependent bushing
Rigid or modally reduced flexible bodies
Special contact elements e.g. Gear Pair, Rail Wheel
Special bearing elements, e.g. Rolling Bearing, Friction
Bearing (EHD)
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MBS Overview
Use case 1: Driveline NVH Investigations at Mercedes Benz
Use case 2: 3D MBS gearbox NVH analysis
Seamless Simpack co-simulation workflow with SIMULIA products
Simpack Highlights and Conclusions
Agenda
Simpack applications in Real Time
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Gas pedal tip in/tip out dynamics Gear shift comfort Run up NVH investigation
Automotive application
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Driveline booming vs. beating
- Optimize sound pressure due to shaft mount
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Beating of three-parted prop shaft
measurement vs. simulation
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Investigation of driveline load levels
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Investigation of sound pressure level
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Homo-kinematic condition of three parted prop shaft
Nonlinear optimization problem
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Optimized driveline layout
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Sensitivity of optimized driveline layout
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Purpose
Model
Result
Driveline Investigations at Mercedes Benz
> Conclusion
⇒ The sensitivity of an optimized driveline layouts is shown.
⇒ Optimized driveline layout is generated by solving the nonlinear
homo-kinematic conditions.
⇒ The excitation and chain of effects of driveline beating is
explicitly illustrated and well understood using Simpack.
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MBS Overview
Use case 1: Driveline NVH Investigations at Mercedes Benz
Use case 2: 3D MBS gearbox NVH analysis
Seamless Simpack co-simulation workflow with SIMULIA products
Simpack Highlights and Conclusions
Agenda
Simpack applications in Real Time
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
➢ Source/Reason
• Fluctuation in stiffness (transmission error)
• Macro geometry of gear (Spur bevel- and
Helix Gearwheel)
• Micro geometry (Gear teeth flank correction)
• High load/torque (Pretension)
• Bending stiffness of the shafts
• Structural behavior of housing
• Oil viscosity and temperature
➢ Source/Reason
• Impulsive hits at the gear backlash limits
• Loose gear oscillation of unloaded gearwheels
(also synchrobodies) because of gear backlash
• Torsional vibration excitation of the driven gear
• Angular acceleration amplitude is responsible
for taking off loose gear from the driven flank
of the fix gear
• Oil viscosity and temperature
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
> Methodology for NVH-Simulation
Simpack Pre Simpack Post
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
> Methodology for NVH-Simulation
Linear and nonlinear analysis method options based on the
same model
Time
Domain
(nonlinear)
Frequency
Domain
(linear)
- Eigen frequency calculation
- Mode shape animation
- Linear system analysis
- Linear system matrix export
- Efficient nonlinear time domain integration
- Time domain result analysis and export
- Time domain and ODS animations
- All kind of coupled system dynamics simulation
General nonlinear
SIMPACK
3D MBS Model:
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
> Typical analysis results definitions Rotational acceleration
of rotating parts
Intersection forces /torques
between gear pairs
/shafts/housing; bearing
forces
Accelerations on
gearbox housing
comparison with
measurements on real
test rig
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
Rotational velocity
excitation at gearbox
input
Constant torque
at gearbox output Rotational velocity runup
at gearbox output
Constant torque
at gearbox input
Torque Torque
Velocity
Velocity Gear whine
Gear rattle
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
> Result
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Purpose
Model
Result
Simulation Methods for NVH-Development of a
Double Clutch Transmission Gearbox
> Result: Applied countermeasure based on system understanding
obtained by simulation → reduce input shaft Eigen frequency
SIMPACK Simulation Test
Original
Modified Original
Modified
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MBS Overview
Use case 1: Driveline NVH Investigations at Mercedes Benz
Use case 2: 3D MBS gearbox NVH analysis
Seamless Simpack co-simulation workflow with SIMULIA products
Simpack Highlights and Conclusions
Agenda
Simpack applications in Real Time
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FEA Multiphysics
Simulation
Abaqus
Non-parametric Optimization
For Fluids and Structures
Tosca
Durability &
Fatigue
fe-safe
Process Integration &
Design Optimization
Isight
SIMULIA: The Power of the Portfolio
Multi-body Simulation
Simpack SLM
Simulation Lifecycle
Management
Note: Simpack and SLM not included in Extended Packaging
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Simpack and Isight
Extending the “Power of the Portfolio”
Simpack component model parameter identification using Isight
Set up communication between Simpack testrig model and Isight
Identify and optimize Simpack element parameters based on test data
reference with Isight
results with initial
element parameters
component element model
testrig optimized component within complete
system simulation
results with optimized
element parameters
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Structural Optimization – Simpack, Abaqus, Tosca
Extending the “Power of the Portfolio”
Determine dynamic load with Simpack
Apply load data to component model in Abaqus
Define design space and optimization criteria in Tosca
Optimize shape in Tosca
Validate new design with Simpack dynamic load simulation
Simpack Abaqus Tosca Simpack
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Co-simulation with Abaqus/Explicit,
is available now in Simpack 9.9
New feature: Co-simulation with Abaqus
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MBS Overview
Use case 1: Driveline NVH Investigations at Mercedes Benz
Use case 2: 3D MBS gearbox NVH analysis
Seamless Simpack co-simulation workflow with SIMULIA products
Simpack Highlights and Conclusions
Agenda
Simpack applications in Real Time
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SIMPACK Realtime Key Features
Use of latest off-the-shelf hardware
no expensive specialized realtime hardware needed
SIMPACK Realtime (Solver) enables to directly use existing Offline MBS models
“Offline = Online Model”
part based models without model reduction and without redundant model data
zero turnaround time after model changes
Built-in multi-core support e.g. for comfort tire models
Enables also detailed ride simulation realtime applications
Benefits Realtime SOLVER Realtime ANIMATION Realtime LOGGING
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Virtual product development (VPD): Simulate physical properties of Vehicle
→ Analyze, evaluate and improve (optimize) design states
Full-Vehicle Real-Time-Simulation with an advanced
flexible Tire-Model on Fraunhofer’s Driving-Simulator
Development of driver/operator
models for detailed offline
simulations
Visualization of simulation
results: motion, visual, sound
Development of assistance
systems
Application: construction and
agriculture machines, passenger
cars, trucks
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Engine, ECU, Transmission, TCU as physical hardware
Optimizing NVH performance of load change and gear shift maneuvers
Real time Use Case Daimler Truck: Handling
Simulator
simulator man-in-the-loop
vehicle sensor signals
driver input, road conditions, etc.
simulation tool
realtime
Virtual Truck
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Hardware-in-the-Loop (HIL) testing
Exported SIMPACK model (> 100 DOFs)
Longitudinal accelerations up to 20 Hz
2009 High-Dynamic Engine Test Bench, Realtime
Application Examples
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Driving simulator at Fraunhofer ITWM:
Application Examples
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MBS Overview
Use case 1: Driveline NVH Investigations at Mercedes Benz
Use case 2: 3D MBS gearbox NVH analysis
Seamless Simpack co-simulation workflow with SIMULIA products
Simpack Highlights and Conclutions
Agenda
Simpack applications in Real Time
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Conclusion
Highlight compare with other MBS software:
Elaborated Consideration of Flexible Bodies
Huge Library of Application Specific Modeling Elements
Sophisticated Analysis Methods & Optimum Calculation Performance and Stability
Unique Real Time Solution for Detailed MBS Models
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Conclusion
Further Synergy :
More Nonlinear flex. body behavior in
SIMPACK integrate with ABAQUS
Improved SIMPACK fatigue solution
based on ABAQUS and FE-Safe
Multi physics simulation solution together
with Dymola
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All Relevant Links
www.SIMPACK.com
Conference and user meeting
presentations
Newsletter articles
Users, videos
SIMPACK Website
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Selected references
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1993 SIEMENS and Bosch start using Simpack
2007 Vestas, Winergy, Hansen and FVA choose Simpack
2011 First release of Simpack 9
2013 JLR adopts Simpack 9
1987 DLR and MAN Technology starts developing Simpack
1998 BMW, Daimler, Land Rover start using Simpack
2005 Daimler and BMW use Simpack Engine
More than 30 years MBS experience,
R&D and Engineering!
2003 Simpack Rail became worldwide market leader
2014 SIMPACK acquired by Dassault Systemes
SIMPACK History: Select Milestones 3D
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Focus of MBS Multi-Body Simulation
Eigen frequencies
Nonlinear motion
Transients
Chaotic behavior
Flexible bodies
System simulation
0.50 Hz
0.32 Hz 0.76Hz 1.27Hz
0.07 Hz
advance
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Focus of MBS Vibration Analysis
Analysis of non-linear system behavior
Resonance analysis
Determine maximum motion and loads
Design of experiments (DOE)
Optimization
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Focus of MBS System Behavior
Coupled effects Internal and external
excitations System behavior
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Focus of MBS System Behavior
Coupled effects Internal and external
excitations System behavior
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Response Surface Modelling
FEA / Durability
Abaqus
fe-safe
ANSYS
Nastran
PERMAS
FEMFAT
CACE-Programs
FMI (model exchange and co-simulation)
Dymola, Simulink, Amesim, SimulationX
CAD-Programs
CATIA
SOLIDWORKS
Pro/ENGINEER
Optimization
Isight
ModeFrontier
Matlab\
Real-Time
dSpace
Etas
Mathworks xPC
Etc.
Aerodynamics
AeroDyn
AeroModule
Flex5
vsAero
Flower
Etc.
Focus of MBS
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Simpack Highlights Solver
Fast, accurate, robust, versatile
Flexible body integration
Drivetrain applications
High frequency analysis
Almost zero numerical damping
Multi-core support
Real-time
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Simpack Highlights Gear Pair element
Helical, Ring, Bevel, Rack and Pinion
Fast analytical contact
Micro geometry corrections, profile and flank
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3D
S.C
OM
/SIM
UL
IA ©
Das
saul
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tèm
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Con
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| 10/
26/2
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| re
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14
Simpack Highlights Realtime for hardware in the loop (HiL),
software in the loop (SiL), and man in the loop (MiL)
Many DOF (degrees of freedom) with higher frequency content
Direct use of high-fidelity parameterized models, i.e. no model reduction
Permits use of non-linear and frequency dependent bushings and mounts
Not restricted to predefined template models
Automatic parallelization
Model Fidelity
Look-up table
model
Basic component
model
High fidelity
component model
Low frequency model
testing
(static suspension)
Model correlation up to
high frequencies.
Virtual component
analysis and testing
< 20
> 200
Attainable
Goals DoF
Other Solutions
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FE Model
• Nodes: 400,000
• DOF: 2,400,000
• File size: 60 MB
• Linear
MBS Flexible Body
• Modal representation
• DOF 5 (or more)
• File size: 0.8 MB
• Linear
Modal Reduction
MBS Model
• Complete system and environment
• Flexible and rigid bodies
• DOF: 100
• File size: 4.4 MB (CAD 40 MB)
• Non- linear
Flexible Bodies
0 5 10 15 20 250
0.5
1
1.5
Seat rail acceleration, RHS
Frequency (Hz)
Acce
lera
tio
n (
m/s
2)
SIMPACKTest
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Simbeam
Flexible structures using beam elements
Euler-Bernoulli, Timoshenko
Parameterization
2nd order bending and stiffening
Non-linear Simbeam (large deformations)
Flexible Bodies
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SIMPACK Automotive/Engine/Rail/Wind
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Simpack Pre
Model creation and modification
Icon driven Intuitive User Interface
2D/3D view
Easy to understand regardless
of model complexity
Rich element library
Interfaces to industry standard
CAD/CAE applications
Model Tree
Message Log
View Control
Toolbars
3D/2D Model View
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Simpack Post MBS model results
Easy to navigate interface
Data handling
Export/import
Curve data and filters
Multi-model management
Animation
State Plots
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Simpack Wizard Scalable deployment
Simpack Wizard
Enables easy setup of standardized models and analysis processes for “deployment mode” of Simpack
Non-expert Simpack users can carry out company-specific standard analyses and review the results without difficulty
Based on standard Simpack model databases which can be adapted using Simpack Pre
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Simpack Automotive Applications
Suspension analysis
Powertrain, gearbox and
driveline
Handling, ride and NVH
SiL, HiL and MiL
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Simpack Engine Applications
Complete system simulation
Valve train and crank train
analysis
Timing mechanism
Accessory drive
NVH
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SIMPACK Rail
Applications
Simulation of forces on wheels and rails
Derailment, profile wear
Passenger comfort
Switches and crossings
Crosswind, gauging and crash
Pantograph—catenary interaction
Homologation
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SIMPACK Wind
Application
Load calculations
Resonance analysis
Simulation of extreme
events, e.g. wind gust,
voltage dip, emergency
braking
Detailed drivetrain analysis
Offshore