OPEL CAE OPTIMIZATION CENTER

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  • 1. www.opel.comStrategic application of optimization methodsOPEL CAE OPTIMIZATION CENTERAdam Opel AGBoris Künkler/Karsten Bohle/Lothar HarzheimAltair Engineering GmbHBernhard Wiedemann
  • 2. 1. Scope of Optimization Center2. Application Example: Concept Development Phase3. Application Example: Concept Refinement Phase4. Summary and ConclusionsCAE OPTIMIZATION CENTER
  • 3. SCOPE OF OPTIMIZATION CENTER• General idea: Strategic implementation of numerical optimization methods in ALL VehicleCAE areas (e.g. Crash, NVH, Body Structure, Vehicle Dynamics, Thermal, Aero)• Identify synergies by cross functional optimization and analysisStrategic application of optimization methods
  • 4. SCOPE OF OPTIMIZATION CENTER• General idea: Strategic implementation of numerical optimization methods in ALL VehicleCAE areas (e.g. Crash, NVH, Body Structure, Vehicle Dynamics, Thermal, Aero)• Identify synergies by cross functional optimization and analysis• Support frontloading due to optimized design proposals delivering required performance• Increase efficiency by reducing “manual” development loopsStrategic application of optimization methods
  • 5. SCOPE OF OPTIMIZATION CENTER• General idea: Strategic implementation of numerical optimization methods in ALL VehicleCAE areas (e.g. Crash, NVH, Body Structure, Vehicle Dynamics, Thermal, Aero)• Identify synergies by cross functional optimization and analysis• Support frontloading due to optimized design proposals delivering required performance• Increase efficiency by reducing “manual” development loops• Generate additional insight into system performance (correlations, performance drivers, ..)• Support target setting and balancing of conflicting requirementsStrategic application of optimization methods
  • 6. SCOPE OF OPTIMIZATION CENTER• General idea: Strategic implementation of numerical optimization methods in ALL VehicleCAE areas (e.g. Crash, NVH, Body Structure, Vehicle Dynamics, Thermal, Aero)• Identify synergies by cross functional optimization and analysis• Support frontloading due to optimized design proposals delivering required performance• Increase efficiency by reducing “manual” development loops• Generate additional insight into system performance (correlations, performance drivers, ..)• Support target setting and balancing of conflicting requirements• Optimization Center as joint project between Opel and AltairStrategic application of optimization methods
  • 7. SCOPE OF OPTIMIZATION CENTER• Increase efficiency regarding resources / duration invehicle development processStrategic application of optimization methods
  • 8. SCOPE OF OPTIMIZATION CENTER• Increase efficiency regarding resources / duration invehicle development process• Crossfunctional, coordinated and proactive optimizationduring all phases of development planStrategic application of optimization methods
  • 9. SCOPE OF OPTIMIZATION CENTER• Increase efficiency regarding resources / duration invehicle development process• Crossfunctional, coordinated and proactive optimizationduring all phases of development plan• Identification of right optimization methods & tools atright point in time for right parts/subsystemsStrategic application of optimization methods
  • 10. SCOPE OF OPTIMIZATION CENTER• Increase efficiency regarding resources / duration invehicle development process• Crossfunctional, coordinated and proactive optimizationduring all phases of development plan• Identification of right optimization methods & tools atright point in time for right parts/subsystems• Development of new optimization tools / methods andapplication to productive program workStrategic application of optimization methods
  • 11. SCOPE OF OPTIMIZATION CENTER• Increase efficiency regarding resources / duration invehicle development process• Crossfunctional, coordinated and proactive optimizationduring all phases of development plan• Identification of right optimization methods & tools atright point in time for right parts/subsystems• Development of new optimization tools / methods andapplication to productive program work• Develop balanced solutions with respect to performance,package, mass, costStrategic application of optimization methods
  • 12. OPTIMIZATION CONCEPT FOR MPVREAR COMPARTMENTApplication Example: MPV Rear Compartment• Global MPV architecture modular approach, mix of c/o and new subsystems• Major scope of optimization: BIW rearend, rear chassis
  • 13. Application Example: MPV Rear CompartmentArchitectureDefinition & ApprovalArchitectureConfig. & FramingPFI AAPFIASSIAFIIDRDSIProgramFramingProgramDevelopmentProgram ExecutionPFI VPI SORPPFIArchitectureConfig. & FramingPFI PFIASSIAFI
  • 14. Application Example: MPV Rear CompartmentArchitectureDefinition & ApprovalArchitectureConfig. & FramingPFI AAPFIASSIAFIIDRDSIProgramFramingProgramDevelopmentProgram ExecutionPFI VPI SORPPFIArchitectureConfig. & FramingPFI PFIASSIAFIConcept / Design definition phaseInput:Vehicle Concepts, strategicapproaches (e.g. axle, c/o parts)Initial performance requirementsRough package boundary conditionsMain actions:Optimization layout of axle systems incl. att. locationsOptimization layout of body structure (e.g. topology opt.)Concept studies (e.g. different rear axles), Support BalancingResult:CAE master model, based on interpretedoptimization results
  • 15. Application Example: MPV Rear CompartmentArchitectureDefinition & ApprovalArchitectureConfig. & FramingPFI AAPFIASSIAFIIDRDSIProgramFramingProgramDevelopmentProgram ExecutionPFI VPI SORPPFIArchitectureConfig. & FramingPFI PFIASSIAFIConcept / Design definition phaseInput:Vehicle Concepts, strategicapproaches (e.g. axle, c/o parts)Initial performance requirementsRough package boundary conditionsMain actions:Optimization layout of axle systems incl. att. locationsOptimization layout of body structure (e.g. topology opt.)Concept studies (e.g. different rear axles), Support BalancingResult:CAE master model, based on interpretedoptimization resultsDesign refinement phaseInput:CAE master modelRefined performance requirementsRefined package boundary conditionsMain actions:„Proof of concept“ (assessment of all relevant loadcases)Identify mass reduction / performance improvement potentialsFurther and more detailed concept/package studiesResult:Balanced ASSI status, assessed alternatives in backup
  • 16. Application Example: MPV Rear CompartmentRefinementDesign spacegeneration(Chassis, Body)Chassig geom.optimization(adams) Chassis topologyoptimization(optistruct)Body topologyoptimization(optistruct) CAD generationbasedonoptimization res. Chassis sizing/shapeoptimization(optistruct)Body sizing/shapeoptimization(optistruct) CAD updatebasedonoptimization res.ConceptDefinitionWorkflow Overview:OPTIMIZATION CONCEPT FOR MPVREAR COMPARTMENT
  • 17. REAR AXLE CONCEPTS, PRE-OPTIMIZATION• Pre-Optimization of kinematic layout fortwo rear axle variants• Identification of main BIW contributors toRide/Handling/NVH Performance• Weighted Contribution Criterionmeasuring parameter impact on ~60 rearaxle loadcasesApplication Example: MPV Rear Compartment
  • 18. REAR AXLE CONCEPTS, PRE-OPTIMIZATION• Pre-Optimization of kinematic layout fortwo rear axle variants• Identification of main BIW contributors toRide/Handling/NVH Performance• Weighted Contribution Criterionmeasuring parameter impact on ~60 rearaxle loadcases0%20%40%60%80%100%120%weightedcontributionw/ Watt Linkage w/o Watt LinkageApplication Example: MPV Rear CompartmentP1 P2 P3 P4 P5 P6 P7 P8 P9Different set of mainimportant BIW coupling pointstiffnesses for two rear axleconcepts
  • 19. REAR AXLE CONCEPTS, PRE-OPTIMIZATION• Pre-Optimization of kinematic layout for tworear axle variants• Identification of reasonable BIW stiffnesstargets for main important parameters to fulfillVehicle Dynamics requirementsApplication Example: MPV Rear Compartment
  • 20. REAR AXLE CONCEPTS, PRE-OPTIMIZATION• Pre-Optimization of kinematic layout for tworear axle variants• Identification of reasonable BIW stiffnesstargets for main important parameters to fulfillVehicle Dynamics requirementsApplication Example: MPV Rear Compartment0,070,170,280,380,490,592 7 12 17 22 27 32 37ValueofLateralCompl.atWCc[kN/mm]Main Effect Plots(WithOverall Mean Added In)Datenreihen10CPS_ABu_yCPS_Strut_mount_yCPS_ABu_xCPS_BBu_xCPS_Strut_mount_xCPS_ABu_zCPS_BBu_yCPS_BBu_zCPS_Strut_mount_zTarget proposal forconsidered parameterLower bound Upper bound
  • 21. Design SpaceCarry Over PartsChassis AttachmentsLoads and TargetsBIW CONCEPT OPTIMIZATION MODELStyling Surface
  • 22. Vertical damper local stiffness70% of initial targetConcept Optimization Rear End: Phase 1DAMPER-Z STIFFNESS VARIATIONS - PERFORMANCE STUDYVertical damper local stiffness100% of initial target
  • 23. Vertical damper local stiffness70% of initial targetincreased complexity:wheel house extensionand lateral stiffenerincreasedcomplexity:Upper wheel houseConcept Optimization Rear End: Phase 1DAMPER-Z STIFFNESS VARIATIONS - PERFORMANCE STUDYVertical damper local stiffness100% of initial target
  • 24. Vertical damper local stiffness100% of initial targetConcept Optimization Rear End: Phase 1DAMPER-Z STIFFNESS VARIATIONS - PERFORMANCE STUDYVertical damper local stiffness130% of initial target Torsional stiffness 70% above target„3D frame“for performance improvement eatingup space for Rear End Carrier or spare tire
  • 25. Vertical damper local stiffness100% of initial targetConcept Optimization Rear End: Phase 1DAMPER-Z STIFFNESS VARIATIONS - PERFORMANCE STUDYVertical damper local stiffness130% of initial target Torsional stiffness 70% above target„3D frame“for performance improvement eatingup space for Rear End Carrier or spare tireIncreased stiffness requirement would drive• modest improvements for vehicle dynamics• significant amount of mass• complexity of structure, disabling customer relevant concepts
  • 26. C-column width 100% and 200%“C-ring”C-column width 55%“C-ring” reduced in sizeadditional “D-ring”Concept Optimization Rear End: Phase 1DESIGN SPACE STUDIES: C-COLUMN WIDTH
  • 27. C-column width 100% and 200%“C-ring”C-column width 55%“C-ring” reduced in sizeadditional “D-ring”Concept Optimization Rear End: Phase 1DESIGN SPACE STUDIES: C-COLUMN WIDTHReduced C-column width would drive• improved visibility, entry/egress• different overall rear structure concepts, maybe tradeoffswith trunk volume or component package space required
  • 28. Based on results and findings of phase 1 ‘Concept Optimization’, essential design features for abalanced steel panel design are determined (balanced w.r.t. performance, complexity,manufacturing,...)The FE models of the new design are used as basis for further optimization and as ‘proof of concept’.Concept Optimization Rear End: Phase 2CONCEPT REFINEMENT PHASE
  • 29. Based on results and findings of phase 1 ‘Concept Optimization’, essential design features for abalanced steel panel design are determined (balanced w.r.t. performance, complexity,manufacturing,...)The FE models of the new design are used as basis for further optimization and as ‘proof of concept’.‘Proof of Concept’• Analysis results will show, if the new design meets the performance and weight estimates of thetopology results. If not, the design interpretation must be checked and corrected.Concept Optimization Rear End: Phase 2CONCEPT REFINEMENT PHASE
  • 30. Based on results and findings of phase 1 ‘Concept Optimization’, essential design features for abalanced steel panel design are determined (balanced w.r.t. performance, complexity,manufacturing,...)The FE models of the new design are used as basis for further optimization and as ‘proof of concept’.‘Proof of Concept’• Analysis results will show, if the new design meets the performance and weight estimates of thetopology results. If not, the design interpretation must be checked and corrected.Further Optimization RunsDifferent optimization approaches are used to outline possible measures for further improvements, e.g.• gauge optimization → panel thicknesses• topology and free size optimization → lightning holes and local stiffeners for inner panels• topography optimization → bead patternsConcept Optimization Rear End: Phase 2CONCEPT REFINEMENT PHASE
  • 31. BIW Model Creation based on Optimization ResultsSFE conceptmodelTopologyoptim. resultsFE BIW MastermodelInterpretation of ResultsConcept Optimization Rear End: Phase 2
  • 32. Refinement Phase: Gauge Optimization• Stiffness performance targets of predecessor fulfilled: -16kg (savings cmp. to predecessor)• Stiffness performance targets of new vehicle: -10.5 kg (savings cmp. to predecessor)• Further mass saving potentials due to lightning holes, beads etc.Concept Optimization Rear End: Phase 2REFINEMENT PHASEUpper BoundLower Bound
  • 33. SUMMARY• The Optimization Center provides a framework for strategic application of optimizationmethods, processes and resources• Strategic use of optimization methods helps the project management to make balanceddecisions and to identify target conflicts• Optimization Center leads to higher maturity of the design at the end of the concept phase, less“conventional” design loops• Structural optimization is a design driver in the CAE based development process• Variant & trade-off studies help to understand the implications and interactions onto theoptimum concept• Optimization Driven Design increases the efficiency in the overall vehicle development processOpel CAE Optimization Center
  • 34. 35Boris Künkler/Karsten Bohle/Lothar Harzheim/Bernhard WiedemannTHANK YOU.