Spring 2003

ME 457 Special Lecture: Introduction to Virtual Product Development

Steve [email protected]

Spring 2003

ME457 Mechatronic Modeling

OutlineMath ModelsVirtualMath-Based ProcessProduct Development ProcessesBenefitsExamplesHistory


The Significance of Modeling & SimulationModeling and simulation are emerging as key technologies to support manufacturing in the 21st century, and no other technology offers more potential . . . for improvingproducts, perfecting processes, reducing design-to-manufacturing cycle time, and reducing product realization costs.Finding of Integrated Manufacturing Roadmapping Initiative,May 21, 1999. Sponsored by NIST, DOE, NSF, & DARPA


Examples of ModelsClay, styrofoam or fiberglass models Plastic modelsBuilding/city modelsArtists modelsClothing modelsElectric circuit analogiesAnalog computer models Math models


What is a Math Model?Mathematics - the scientific study of quantities, including their relationships, operations, and measurement, expressed by numbers and symbols. - Academic Press Dictionary of Science TechnologyMath Models - mathematical representations of physical or abstract entities which capture their form / their functional behavior / or other aspects of their behavior.


Examples of Math ModelsEconomic/world modelsEnterprise modelsMarketing modelsFinancial modelsComputer system modelsChemical reaction modelsHuman anatomy/physiology modelsPhysics modelsBiometric modelsProduct engineering modelsManufacturing engineering models


Examples of Math Model Use in GM


Virtual reality Virtual - "of, relating to, or possessing a power of acting without the agency of matter- Webster's Third New International Dictionary Virtual reality creation of an environment which seems real in important respects; usually computer-based.Movies Total Recall Brainstorm


Virtual Reality


MarketingDefinitionFormFitFunctionProcessSales & ServiceThe Virtual Vehicle ParadigmVirtual clinicsVirtual studioVirtual mock-upVirtual test labVirtual proving groundsVirtual tool-roomVirtual factoryExtensive use of math-models to guide decisions:


Math-based Processes

Process - a series of actions, changes, or functions that bring about an end or result. - The American Heritage Dictionary Math-based process - a process based upon or enabled by the use of mathematical models. A math-based process is usually implemented using a computer.


A Product Development ProcessThe set of all activities required to define, design, and engineer a product including its manufacturing and assembly processes.


The Good Old Days. . .

The Modern Automotive Vehicle


Major Automotive Vehicle SubsystemsPowertrainAccessoriesBrakesSteeringSuspensionBody


Automotive Vehicle Subsystem Interactions Powertrain Body

Brakes

Accessories

Suspension Steering Accelerator Pedal Shift Lever Clutch Pedal Accessory Controls Brake Pedal Steering Wheel RoadBody Linear &Angular Motion,Heat Flow in/outVehicle ConfigurationLoadingWindows up/downFuel ConsumptionEmissions



Brakes

Accessories

Suspension Steering Accelerator Pedal Shift Lever Clutch Pedal Accessory Controls Brake Pedal Steering Wheel RoadBody Linear &Angular Motion,Heat Flow in/outVehicle ConfigurationLoadingWindows up/downFuel ConsumptionEmissionsComputer(s) & Intelligence

Math-Based Engineering ProcessHour 2-3


Traditional Product Development ProcessBuild Fix Iteration For Complex Products: Cycle Time Too Long Facility Intensive Cost High Convergence Not AssuredForm Function Test


Math-Based Design ProcessMath-based design: The process of designing and refining vehicles and components on sophisticated computer systems. Once approved, the designs are sent electronically to machines that cut tools and dies for the vehicle, minimizing the chance of errors. Computers can also simulate the performance of components and modules, as well as assembly line systems. --The Detroit News December 21, 1998


1964 DC-9 Program Savings via Math*1. Increased reliability and maintainability of product2. Program cost decreased 50%3. Increased quality and quantity of results4. Fewer drawing changes after initial release5. Improved competitive position*from Use of Computer Programs in Aircraft Design by Melvin Stone, Douglas Aircraft Co., SAE 1964 referring to DC-9 stuctureBottomlineInvestment: $300KSavings: $2.5MTime Reduction: >50%


Why move to math now?


Advanced Technology Vehicles


Benefits of Math-Based Technology 50% productivity improvement in last several years Over $109 savings VDP time reductions >18 months

CAE today is 7-10 times faster than hardware verification CAE costs are a fraction of test verification costsCAE will become the principle design verification & direction methodology!

Identified CAE as a critical element in product developmentWelcome the merger of the combined capabilities of visualization and supercomputers for Digital Prototyping total solution


The Math AdvantageHardware test learnings are limited to what can be made visible

Example: For a durability test to be useful it must run to failure


The Math AdvantageIn math tests we can see both causes and effects & track things that we cant measure!

Example: We can see the flow of energy & the final shape during a crash test


Some Relative Costs

How do we implement math based design?


Answer: Using Systems Engineering!Systems Engineering:Top down vs. Bottoms upRequirements drivenIs a phased, iterative processInteractions between systems & components are explicitly addressedUses math-models extensively


Define FunctionsCustomer NeedFormUnderstandSynthesize(Design)The Top-Down Design Concept


Automotive Vehicle Functions


Vehicle Functional & Physical Decompositions Safety Information Management Enjoyment Energy Management Transportation VEHICLE FUNCTIONS Chassis Powertrain Body HVAC Electrical Interior Comfort Info & Cntls. VEHICLE What the Vehicle DoesHow It Does ItVehicle Subsystems


Vehicle Functional to Physical Mappings: Example Safety Information Management Enjoyment Energy Management Transportation VEHICLE FUNCTIONS Chassis Powertrain Body HVAC Electrical Interior Comfort Info & Cntls.What the Vehicle DoesHow It Does ItFormFollowsFunction VEHICLE Vehicle Subsystems



Brakes

Accessories

Suspension SteeringHeat, Noise, Vibration, Engine Vibration TorqueEngine SpeedCoolant Temp.Accessory Torque LoadBattery VoltageCoolant Flow & Heat LossTorque Delivered to Driven WheelsDriven Wheel Rotational SpeedsHeat, Noise, Driver Visibility, AirflowHydraulic/Pneumatic PressureHydraulic Flow, Electrical VoltageVacuum Electrical VoltageVacuum Load Electrical CurrentHeating & Cooling LoadsHydraulic/Pneumatic FlowHydraulic Pressure, Electrical CurrentBraking TorqueWheel Rotational SpeedSteering Angle Steering Forces Suspension GeometrySuspension Forces VibrationNoiseBody Attitude & PositionAerodynamic drag


Systems Engineering Based VDP


The Cost Of Change** John Krouse, 1993


The use of mathematical representations (models) to:Design/configure (synthesis) Understand & validate behavior (analysis)Math-Based Synthesis & Analysis


AnalysisGiven a DesignANALYSISWhat is the response?Given a DesignckFxmFrequencyResponsec1,k1c2,k2Given the Design GoalSubject to Constraints:

ResponseFunctionPackagingCostManufacturingWhat is the Best Design ?SynthesisSYNTHESISFrequencyResponseDamping , cStiffness, kc*,k*?ManufacturingConstraintsPackagingConstraintsAnalysis vs. Synthesis


Synthesis & Analysis in the VDP


100%50%0PHASE 0PHASE 1SYNTHESIS MODEANALYSIS MODEFREEDOMINFORMATIONSynthesis & Analysis at Various Phases of the VDPTime$ Spent $ Committed


Use of Math: Medical Analogy


Virtual Product Development: GMT360

There has been concern and confusion in NAO over what is a process, so lets look at the definition:stress the words action, changes, function, its about doingno reference to time (process can stand alone without timing)Stress the term common which is underlined.Common processes are liberating (when designed properly):we can focus on doing the thing we enjoy, working on cars and truckswe shouldnt have to spend our time wrestling with, or creating new processesCommon means identical Note the date!

Spring 2003

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Transcript of Spring 2003