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Airbag Development Process Using HyperWorks Automation - Autoliv

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Design and development of airbags involves initial designing, optimizing, prototyping and testing. This process could be time consuming and costly since multiple iterations are performed before a …

Design and development of airbags involves initial designing, optimizing, prototyping and testing. This process could be time consuming and costly since multiple iterations are performed before a final design is achieved. CAE tools can effectively be used in the airbag development process to reduce the design cycle time and to reduce development costs. Furthermore, in a CAE driven development process, higher productivity gains could be achieved by automating the routine CAE processes. In this presentation, some of the efficiency gains achieved on the airbag design process by using Altair HyperWorks Automation are presented.

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  • 1. Airbag Development Process UsingHyperWorks AutomationNirmal NarayanJill BentzHarry ParkTerry SellaRuss Morris
  • 2. Agenda• About Autoliv• Airbag Development Process• Typical Airbag CAE Analysis• Simulation Based Volume Analysis• Demo- Automation of Volume Analysis using TCL/TK• Future steps and Summary• Q&A
  • 3. Objective• Understand the airbag development process.• Demonstrate an example of the automation using Altair TCL/TK.
  • 4. Autoliv – Vision & MissionThe Worldwide leader in Automotive Safety Systems
  • 5. Autoliv in Brief Sales By Region
  • 6. Autoliv Products
  • 7. Having an Impact - US Highway Fatality Rate Drops to 62 Year Low - For 2011, the highway fatality rate was 32,300 people.
  • 8. PAB Development ProcessStep 1: Start with vehicle data  Centerline cross-section  Occupant size and positions  Pulse information
  • 9. PAB Development ProcessStep 2: System or application engineer defines cushion profile orprofiles:  Incorporate best practices for different crash scenarios  Select main panel shape or define 3D shape Try 1 Try 2
  • 10. PAB Development ProcessStep 3: CAE analyst creates a cushion model  Volume calculation at 1 psi. for inflator sizing  Static deployment in environment for deployed shape Volume @ 1psi. Static deployment Satisfied with cushion volume and shape?
  • 11. PAB Development ProcessStep 4: Run system model with new PAB designs  Belted AF05 (new NCAP), Unbelted AM50  Tune vent sizes, tether length, inflator output, adaptive vent, belt load Satisfied with cushion performance? “No” → redesign “Yes” → now we need cushions for testing
  • 12. PAB Development ProcessStep 5: Kick off drawing to build prototype cushions  Once we have a good candidate design …  CAE analyst “unwraps” 3D model to 2D flat panels  Geometry based (mathematical scripts)  Simulation based  2D line data becomes basis for cushion assembly drawing 3D model 2D flat pattern
  • 13. PAB Development ProcessStep 6: Prototype cushions  Prototype cushions for integrity testing  Fold and tether confirmation  If QA okay, then proceed with on to OOP or sled testing
  • 14. Typical Airbag CAE Analysis• Airbag Volume Analysis• Coverage Study COMPLEXITY• Stress Analysis• Linear Impactor• Sled Systems Simulation• Full Vehicle Crash Analysis
  • 15. 3D to 2D Simulation Based Method 3D to 2D SIMULATION CAD DATA GENERATION
  • 16. Volume Analysis using Simulation Methods 3D CAD GENERATE FEA SOLVER VOLUME DATA MESH 2D CAD GENERATE AIRBAG FEA SOLVER VOLUME DATA MESH STITCHING
  • 17. Case Study: Automation of Airbag Stitching• Performing volume analysis using 2D panels, involves stitching of panels together to create 3D enclosed volume.• Automation achieved by Altair TCL/TK scripts.• Manual stitching takes hours and is a tiresome process.• With automation the stitching could be done in minutes. TCL/TK SCRIPTS
  • 18. Automation Demo
  • 19. Volume Analysis Report
  • 20. Future Steps• Identity routine simple CAE analysis which can be easily automated.• Develop a one click application to get the highest productivity • For example, the volume analysis is performed routinely and sometimes can be time consuming. • Develop a stand-alone application which reads CAD data and can create the volume report. • Make the application simple enough, so that any non CAE persons in the organization can use it. CREATE SELECT APPLYCATIA CAD MESH MATERIAL PRESSURE GENERATE SUBMIT TO REPORT SOLVER STAND ALONE APPLICATION
  • 21. Summary• Airbag development is a multi step iterative process.• CAE is extensively used in the airbag development in each of the steps.• Automation can be used to effectively reduce the development time and increase productivity.

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