Dr. Ulrich Fox, Ralf FachbachFord Motor CompanyCAE PLM Solution and integration withCAE Pre-Processor Software2011 Europea...
IntroductionPage 2   November 14, 2011
Drivers for CAE PLM @ Ford• Efficiency         – CAE Model Build effort         – CAE Model Quality and Reliability       ...
Ford C3P SystemPage 4   November 14, 2011
Ford C3P Sites                                                     Gothenburg                                             ...
CAE PLM History1997: Deployed Metaphase for „CAE PIM“         – CAE Model storage assigned to Product data2000: CAE Model ...
CAE PLM History cont.2008: TCSim Project         – Teamcenter for Simulation (TCSim) Selected as Strategic CAE Data       ...
Ford Global Strategic SolutionDevelopment                                       = Teamcenter Simulation         Ford EU Ta...
ScopePage 9   November 14, 2011
TCSim Project Scope (2008-2010)                                                        Simulation Process     Product     ...
CAE PLM Development Scope (2011-2014)Page 11   November 14, 2011
ArchitecturePage 12   November 14, 2011
Data Model – “EBOM embedded in CAE str/”Product Structure                         CAE Structure                           ...
Data Model – “CAE embedded in EBOM”Product Structure                              CAE Structure, Composite ViewPage 14   N...
Data Model – Classification                              •   Classification is used to create and                         ...
Tool Architecture Server/Client                    Client „TCSim tool set“           Teamcenter                      tc_in...
Interface Format          • Siemens PLM XML Format Selected              – Versatile Format              – Configurable vi...
CAE Pre-Processor IntegrationPage 18   November 14, 2011
Pre-Processor Integration –Crash Vehicle Assy                                                          &                  ...
Pre-Processor Integration Modes          • Full Data (Metadata+Bulk)               – Geometry / No FE Model               ...
Summary & OutlookPage 21   November 14, 2011
Summary & Outlook• Efficient, global CAE PLM implementation in place  Key success factors :          –    Business driven ...
Thank YouPage 23   November 14, 2011
Backup MaterialPage 24   November 14, 2011
Data ModelPage 25   November 14, 2011
Use CasesPage 26   November 14, 2011
Use Cases1.            Body-in-Prime CAE model build          –        Batch meshing CAD data (including Catia V5/JT CAD  ...
Use Case #1                      1   2       4   6   7                                         3(details)1.        Create/...
Pre-Processor Integration – Model Build   • Export CAE structure from Teamcenter via PLM XML Export   • Launch Pre-Process...
ExperiencesPage 30   November 14, 2011
Experiences• Rollout successful w/o show stopper issues          – Memory limitations unveiled          – Remote data tran...
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CAE PLM Solution and integration with CAE Pre-Processor Software

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CAE PLM Solution and integration with CAE Pre-Processor Software

  1. 1. Dr. Ulrich Fox, Ralf FachbachFord Motor CompanyCAE PLM Solution and integration withCAE Pre-Processor Software2011 European HyperWorks Technology ConferenceBonn, November 8–9, 2011
  2. 2. IntroductionPage 2 November 14, 2011
  3. 3. Drivers for CAE PLM @ Ford• Efficiency – CAE Model Build effort – CAE Model Quality and Reliability – Process Automation• ONE FORD – Global CAE Process – Global Sharing of Data and WorkPage 3 November 14, 2011
  4. 4. Ford C3P SystemPage 4 November 14, 2011
  5. 5. Ford C3P Sites Gothenburg Sweden Dearborn Michigan, USA Shanghai Dunton China England Hiroshima Japan Merkenich, Germany Cuautitlan Mexico Camacari Brazil Chennai India • 7,600 Teamcenter • 5,100 CAD • 14,500 Digital Buck Broadmeadows • 310+ Supplier Connects AustraliaPage 5 November 14, 2011
  6. 6. CAE PLM History1997: Deployed Metaphase for „CAE PIM“ – CAE Model storage assigned to Product data2000: CAE Model Build and Management with I-DEAS/TDM – CAE Model creation based on CAD authoring tool2004: Teamcenter Deployment for CAE PIM – CAE Data management as first Teamcenter Deployment worldwide2006: Teamcenter CAE Customization – CAE Process Automation – Pre-Processor IntegrationPage 6 November 14, 2011
  7. 7. CAE PLM History cont.2008: TCSim Project – Teamcenter for Simulation (TCSim) Selected as Strategic CAE Data Management Tool – Developed Solution for CAE Model Build ManagementApril 2010: Deployed TCSim for CAE PIM – OOTB CAE Data Management SolutionJan 2011: CAE PLM Strategy workshop – Defined set of global CAE PLM Principles (e.g. on sync. & mapping w/ product structure, knowledge capture, etc)Page 7 November 14, 2011
  8. 8. Ford Global Strategic SolutionDevelopment = Teamcenter Simulation Ford EU Tactical Solution = Local Customization C3P NG TS2.0 2010 2009 2008 2007 2006 2005 2004 2003 2002 2001Page 8 November 14, 2011
  9. 9. ScopePage 9 November 14, 2011
  10. 10. TCSim Project Scope (2008-2010) Simulation Process Product CAE Collect Sub- Collect Build CAE Standard Secondary Configuration Marking Assemblies Connections Assemblies Results Results Post- Test Product Pre-Processing Assembling Solve Processing Correlation Structure Populate Eng. Component Build CAE Job Job Mapping Properties Meshing Sub-Assembly Submission Control Phase 1 Phases 2+Page 10 November 14, 2011
  11. 11. CAE PLM Development Scope (2011-2014)Page 11 November 14, 2011
  12. 12. ArchitecturePage 12 November 14, 2011
  13. 13. Data Model – “EBOM embedded in CAE str/”Product Structure CAE Structure CAE Structure, Composite ViewPage 13 November 14, 2011
  14. 14. Data Model – “CAE embedded in EBOM”Product Structure CAE Structure, Composite ViewPage 14 November 14, 2011
  15. 15. Data Model – Classification • Classification is used to create and maintain a structured library based on CAE specific classification attributes • Classification of CAE Data makes required data easier to find and retrieve • Search the classification hierarchy based on different criteria to find the CAE data you need • View data associated with your CAE item in the viewers. (jt, text, etc) • Control complexity of growing CAE LibraryPage 15 November 14, 2011
  16. 16. Tool Architecture Server/Client Client „TCSim tool set“ Teamcenter tc_inspector for Simulation • Create/Maintain Structure • Change mgmt. • Notification • Manage EPs • Customer specific utilities tc_xyz / Preproc. • Maintain/Document Data Sets • Advanced functionality tc_hm • Work Packaging • Fix Minor Bugs • Share Data • CAE Pre-Processor •… •CAE Pre-Processor • Read Structure •Read Structure • Read Data sets •Read Data sets • Start Processes •Start Processes • Modify Data Sets •Modify Data • Modify EPs Sets •Modify EP‘sD/B Common PLM XML w/ PDMPage 16 November 14, 2011
  17. 17. Interface Format • Siemens PLM XML Format Selected – Versatile Format – Configurable via „Transfer Modes“ – Provides Image of the Selected Structure • Structure & Metadata • Paths of Included Data Sets • Copies of the Files Attached Package to Data Sets in Native FormatPage 17 November 14, 2011
  18. 18. CAE Pre-Processor IntegrationPage 18 November 14, 2011
  19. 19. Pre-Processor Integration –Crash Vehicle Assy & • Modify mcf‘s • Realize connections • Modular library • Modify Meshes • Generic Models PLM XML • Position Modules • Manage mcf‘s • Quality Checks • Module selection • Numbering • Model content • Mass Trimming / Balancing • Instances • Loadcase Setup • Module Positions • Output Request • … • Final DeckPage 19 November 14, 2011
  20. 20. Pre-Processor Integration Modes • Full Data (Metadata+Bulk) – Geometry / No FE Model – FE Model / No Geometry – Geometry & FE Model • Separate Bulk / Metadata – Metadata / No Bulk data – … • „Parallel“ Build – Incremental Packages – …  Develop more sophisticated integration (based on API’s)Page 20 November 14, 2011
  21. 21. Summary & OutlookPage 21 November 14, 2011
  22. 22. Summary & Outlook• Efficient, global CAE PLM implementation in place Key success factors : – Business driven development approach – Full integration with PDM solution, small extra IT effort – Use Out of the box, uncustomized solutions where possible – CAE s/w integration provides user efficiency gain of initial solution – Ground up scoping, implementing CAE model build solution first and growing to wider process steps gradually• 2011-2014 Extension Proposals – Analysis management, process automation – CAE / Test integration – Generic mapping of CAE and product data – Business process integrationPage 22 November 14, 2011
  23. 23. Thank YouPage 23 November 14, 2011
  24. 24. Backup MaterialPage 24 November 14, 2011
  25. 25. Data ModelPage 25 November 14, 2011
  26. 26. Use CasesPage 26 November 14, 2011
  27. 27. Use Cases1. Body-in-Prime CAE model build – Batch meshing CAD data (including Catia V5/JT CAD conversion, automated mid-surfacing) – Automated assigning of CAE engineering properties to CAE parts (PID, part thickness, part material, MID etc) – Automated creation of CAE connections via Master Connection File2. CAE Module Management – Store, maintain and share CAE System Modules3. Vehicle CAE Model Build – Automated assembly of CAE Modules, incl. connectionsPage 27 November 14, 2011
  28. 28. Use Case #1 1 2 4 6 7 3(details)1. Create/Clone/Update 5 CAE Structure2. Populate EP’s3. Export & Send PLMXML Pkg4. Create & Debug mcf5. Mesh & Assemble6. Create Connections7. Freeze & Share ModelPage 28 November 14, 2011
  29. 29. Pre-Processor Integration – Model Build • Export CAE structure from Teamcenter via PLM XML Export • Launch Pre-Processor integration and import CAE structure PLM XML Package • Perform automated Data Preparation Steps (e.g. Translation, positioning, instancing, mid-surfacing, structuring, ...) • Export CAE PLM XML package from Pre-Processor, containing CAE model data • Import CAE PLM XML package into associative CAE structure in TeamcenterPage 29 November 14, 2011
  30. 30. ExperiencesPage 30 November 14, 2011
  31. 31. Experiences• Rollout successful w/o show stopper issues – Memory limitations unveiled – Remote data transfer issues – Dependency from PDM tree integrity• 8 x Performance increase of key steps compared to previous Teamcenter CAE PIM solution – Initial „Overhead“ for CAE Data Management of BIW CAE model is close to 0 – Overhead is more than offset by downstream benefits• Technology still evolving – Configuration (Data Model, Key PLM Behaviors) is stable – TCSim “Tool Set” improving, 2 releases / month since April – Improvements realized in Teamcenter 8.3 and planned for Teamcenter 9 and beyondPage 31 November 14, 2011

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