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Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
Challenges and requirements for automated processes in Commercial Vehicle Development
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Challenges and requirements for automated processes in Commercial Vehicle Development

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Increasing customer requirements regarding a commercial vehicle’s economical features such as lower fuel consumption and a better payload/weight ratio, but also a rising demand for more comfort and a …

Increasing customer requirements regarding a commercial vehicle’s economical features such as lower fuel consumption and a better payload/weight ratio, but also a rising demand for more comfort and a more flexible use of the vehicles, lead to complex challenges in engineering. The variant diversity, the number of finite element models and the need for parallel product development are a great challenge for the CAE departments. Consequently it is necessary to use the advantages of the modular principle in the virtual development. Shorter product development time involves, that the truck manufacturers start to automate and standardize the manual processes increasingly. A good example of how to benefit from automated development processes can be found at MAN’s Truck & Bus Simulation department. Here the process to analyze frame structures of trucks was automated in large part, to meet the increased requirements with shorter processing times, a higher density of coverage and improved result quality. This presentation will introduce the Software “Frame Tool Box” which was developed in collaboration with Altair. It includes the entire process from building the FE-model of frame structures to the evaluation of results by combining existing Hyperworks tools in automated processing steps.

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  • 1. Challenges and Requirements for an Automated Process in Commercial Vehicle Development 2014 European Altair Technology Conference Munich, 26th June 2014 Mustafa Gök Sebastian Straube Dr. Andreas Kruppa MAN Truck & Bus AG
  • 2. 2< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Power Engineering Business areas Divisions Commercial Vehicles MAN Truck & Bus MAN Latin America MAN SE The MAN Group in 2013: €15.7 billion revenue, 53,509 employees Investments Sinotruk, Scania MAN Diesel & Turbo Renk Company Structure
  • 3. 3< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Long-haul transport Traction Short-haul transport Long-haul transport Traction Short-haul transport Traction Short-haul transport Short-haul transport 18 t – 41 t 18 t – 41 t 18 t – 41 t 12 t – 26 t 8 t – 12 t TGX TGS TGS WW TGM TGL Truck product portfolio
  • 4. 4< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG 4x24x46x2-6x2/6x46x4-8x2- TGX TGS TGS WW TGM TGL 4x2 4x46x2-6x2/6x4 6x4- 6x6 6x68x2- 8x4 8x4 8x4/ 8x4- 8x6 8x8 Type list
  • 5. 5< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Type list  Different load distribution  Different strength level  Driving dynamics  loads from the road to the structure
  • 6. 6< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Why a lot of types? Body types and customer usage
  • 7. 7< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Modular Kit Truck Product structure in development and BoM Building blocks Suspension Cabin type Transmission Frame length Axles Engine power Max. weight 7-12t 13-26t 18-41t Product Decomposition Model / type TGL TGM TGS TGX TGS WW Simplified visualization Suspension front Engine Side member Front axle 1 Gearbox Cabin Cross member Rear axle 1 Suspension rear Options / Properties
  • 8. 8< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Modular Kit Truck Product structure in development and BoM Suspension Cabin type Transmission Frame length Axles Engine power Options / Properties Max. weight 7-12t 13-26t 18-41t Product Decomposition Model / type TGL TGM TGS TGX TGS WW Building blocks Suspension front Engine Side member Front axle 1 Gearbox Cabin Cross member Rear axle 1 Suspension rear Simplified visualization
  • 9. 9< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Disadvantages of the current course of action:  high manual effort in meshing and generation of connections  long training period for new employees (complexity of the process)  compliance with standards depend on the person in charge Process for the analyzing of entire frame models General approach 25 % 50 % 5 % 5 % 15 % Preparation of input data Generating of FE-model Preparation of Analysis Simulation Evaluation of results
  • 10. 10< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Reduction of efforts Preparation of input data Generating of FE-model Preparation of analysis Simulation Evaluating of results 25 % 50 % 5 % 5 % 15 % Manual FTB current CAD new 25 % 15 % 100 % 65 % FTB current CAD in DB 10 % 5 % 5 % 15 % 50 % 15 % 15 % Potential entire process 5 % 2,5 % 2,5 % 5 % 25% 10 % 5 % 5 %
  • 11. 11< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Result documentation Solve Define & apply load case data Prepare solver input Define properties Create connections Assembling Meshing Prepare input data Parameter file CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file model.cdb -APDL FE-DB model.rst Report automated task manual task Color legend automation degree:
  • 12. 12< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview CAD-Data provision  CAD – Model of complete vehicle  Provided by package department via PDM-System PDM
  • 13. 13< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview FE-DB … Prepare input data  Parts already in FE-DB?  Prepare new parts  Create list of parts to be used  Create connector position file  Create Vehicle data sheet CAD-Data provision Vehicle data sheet Part list Connector position file FE-Database: „Prepare once and use it again“. Prepare new parts:  Mostly Catia (mid) surface and solid models  partly automated with Catia macro  Meshes also possible for more complex parts
  • 14. 14< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview FE-DBFE-DB Meshing  Fully automated in BatchMesher and Simlab  Manual checking and correction Prepare input data CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file Part list
  • 15. 15< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Assembling  Fully automated in HyperMesh  Part position from part list Meshing Prepare input data CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file FE-DB Part list
  • 16. 16< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Create connections  Fully automated with tcl-script  Location from connector position file  Manual checking and correction Assembling Meshing Prepare input data CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file FE-DB Connector position file Connection type 1: Shell / Shell Connection type 2: Solid / Shell
  • 17. 17< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Define properties  Fully automated with tcl-script  Thickness information from partname  Material information from part list Create connections Assembling Meshing Prepare input data CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file FE-DB Part list
  • 18. 18< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Vehicle data sheet Prepare solver input  Mass balancing  Overall quality check  Write ANSYS parameter file  Write model file Define properties Create connections Assembling Meshing Prepare input data Parameter file CAD-Data provision PDM Vehicle data sheet Part list Connector position file model.cdb FE-DB „Frame Tool Box“
  • 19. 19< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Define & apply load case data  Read model and parameter file  Define loads according to weight distribution  Set air spring stiffness  Fully automated in APDL Prepare solver input Define properties Create connections Assembling Meshing Prepare input data Parameter file CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file model.cdb -APDL FE-DB Parameter file model.cdb
  • 20. 20< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Solve  Start ANSYS job  Output: ANSYS result file Define & apply load case data Prepare solver input Define properties Create connections Assembling Meshing Prepare input data Parameter file CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file model.cdb -APDL FE-DB model.rst Process for the analyzing of entire frame models Process overview
  • 21. 21< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Result documentation  Read result file and write report (h3d format)  Fully automated in HyperView Solve Define & apply load case data Prepare solver input Define properties Create connections Assembling Meshing Prepare input data Parameter file CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file model.cdb -APDL FE-DB model.rst Report model.rst
  • 22. 22< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Process for the analyzing of entire frame models Process overview Result documentation Solve Define & apply load case data Prepare solver input Define properties Create connections Assembling Meshing Prepare input data Parameter file CAD-Data provision „Frame Tool Box“ PDM Vehicle data sheet Part list Connector position file model.cdb -APDL FE-DB model.rst Report automated task manual task Color legend automation grade:
  • 23. 23< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG •Concept analysis •Tooling release for Prototypes •Detailed analysis for series •Tests - Optimization •Tooling release series •Final virtual clearance Simulation in Development Process Product definition Concept development Series development Pre development •Concept analysis Type evaluation Selection of the vehicle types for FEA Selection of the vehicle types for tests (measurements, rough road)
  • 24. 24< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Advantages  Reproduction of the whole process in Software „Frame Tool Box“  Modular kit, in this way it is possible to reuse the components  Significant time savings through automation of process steps (i.e. meshing and generation of the connections)  Standards are anchored in the software, thereby ensuring the model quality and comparability  User guide and shortening the training time Risks  A high degree of automation leads to late identification of bad design  CAD audit Advantages & Risks
  • 25. 25< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Outlook Define properties Assembling Result documentation Solve Define & apply loadcase data Prepare solver input Meshing „Frame Tool Box“  Integrate FE-Database into PDM/PLM system for better change tracking  Further automation of input data preparationPrepare input data CAD-Data provision PDM FE-DB Create connections  Introduce new connection types to increase results quality  Integrate further user requirements  MBS intersection  …
  • 26. 26< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG • Increasing requirements and more flexible use of the commercial vehicles lead to complex challenges in engineering. • Variant range, the number of FE models and the need for parallel product development are a great challenge in CAE. • It‘s necessary to use the advantages of the modular principle in the virtual development • Frame tool box was developed with ALTAIR • It includes the entire process from building the FE model to the evaluation of results in automated and standardized process. • CAD audit is necessary • This meets the requirements with shorter time, higher density of coverage and improved result quality. • Reduction and specification of the test vehicles for validation Simulation makes a great contribution in the development Conclusion
  • 27. 27< >Challenges an Requirements for an Automated Process in Commercial Vehicle Development 26th June 2014M. Gök / S. Straube / Dr. A. KruppaMAN Truck & Bus AG Mustafa Gök +49(0)89/1580-4405 Mustafa.Goek@man.eu Sebastian Straube +49(0)89/1580-4878 Sebastian.Straube@man.eu Dr. Andreas Kruppa +49(0)89/1580-1760 Andreas.Kruppa@man.eu Thank you for your attention!

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