Samy Panneerselvam Caresoft Global, Inc.

1. Confidential Property
Copyright Information: © 2019 Caresoft Global. This document may contain confidential information pertaining to strategic plans, data and business relationships between Caresoft Global and its customers. This document is provided only for the intended recipients . Please do not
distribute or copy the content in any form without a written authorization from Caresoft Global.
Digital Twin Benchmarking using
High Energy Scan Technology

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Disclaimer
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This document is for the intended recipient(s) and the organization employing the recipient(s)
(“Organization”) only. No part of this document in whole or in part shall be shared with any third-party apart
from the recipient(s) and the Organization.
Caresoft Global Inc. and all its operating units, subsidiaries, and its authorised representatives claim no
responsibilities and/or obligations of any kind against any harm or perceived harm caused to the recipient
and the Organisation by sharing this document in whole or in-part to parties other than the intended
recipient(s).
Caresoft Global Inc. and all its operating units, subsidiaries acknowledge the rights of all the registered
trademarks and names used in this document. Caresoft Global Inc. and all its operating units do not claim
affiliation or arrangements of any kind with the OEM of the vehicles referred in this document.
By reading the contents of this document, storing, and distributing this document, the intended recipient is
understood to have agreed to the terms in this disclaimer.

3. Caresoft Global Confidential
Today’s Agenda
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❑ Caresoft – Who we are?
❑ What is High Energy Scan Technology?
❑ What is the impact of High Energy Scan Technology in Automotive Sector?
• Digital Twin Methodology
• Analysis & Simulation
• Electric Vehicle Technology
• Light Weighting
• Cost Optimization

4. Caresoft Global
Who we are?

5. Confidential Property
About Caresoft
Founded in 2007 Headquartered in Detroit 2000+ Engineers
ISO / IEC 27001:2013
Information Security
Management Systems
ISO 9001:2015
USA
UK
France
Germany
Italy
Sweden
Brazil
Mexico
Belgium
Austria
India
China
South Korea
Japan
UAE
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Caresoft’s Business Pillars – Products & Services
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Helps in Benchmarking,
Cost reduction & Design
Optimization
Technology
Products
Digital-Twin Technology Cost Reduction Analysis
Benchmarking and Cost Reduction
HE Scan
CAD
CAE
Teardown Analysis
Idea Generation for
Cost Reduction
Technical Review Sessions
Product Development
Engineering Solutions
Mechanical
CAE Manufacturing
Technical Information Virtual Reality
Electrical
Technical Placement

7. Automotive Benchmarking
Current Methodology

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Current Methodology
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Teardown Photos
of Systems
Optical Scan Key
Systems
Manufacturer
Information
Material
Information
Vehicle Picture
Package Optical Scanning
Vehicle
Measurements Weighing
PRE-TEARDOWN
TEARDOWN
Traditional Way
Pre-Teardown
Document
Teardown
Optical Scan

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Limitations of Current Methodology
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▪ No actionable intelligence
▪ Data limited only to photographs,
Bill of materials and elementary
optical scan data sets
▪ No notes on strategic choices
made by OEMs
▪ Non existent advance engineering
data – CAD and Analysis
▪ OEMs cannot decipher costing
data
Traditional way Traditional way

10. How has Caresoft Changed the Game?

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Benchmarking using High Energy Scan Technology
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Post-processing of High Energy Scan Output
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Post-processing of High Energy Scan Output
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HE Scan Output Raw Format Postprocessing of HE Scan Output to Differentiate Components and Materials
The Tesla Model 3 is fully operational after the high energy scan

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Digital-Twin Technology: High-Energy Scan to 3D CAD Model
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High-Energy Scan
Output Raw Format
Post-processing of High-Energy Scan Output to
Differentiate Components and Materials
Full Vehicle
Engineering Data
Full vehicle Mesh Model
Detailed 3D CAD Crash Simulation and Analysis Electrical Systems Routing
Engineering Data extracted from High Energy Scan Output
Full Vehicle DeltaCostingTM

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Exponential Acceptance of Digital Twin Technology
Number of Customers Implemented this Technology
0
20
40
60
80
100
120
2016 2017 2018 2019 2020 2021
100+ Global
Automotive
Customers
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Actions, Integrated Approach, Global Learning, Speed and Flexibility
Integrated Strategic Benchmarking
• Strategic benchmarking from a Design,
Manufacturing, Parts, Tooling, Costing and
Serviceability perspective
• Deep Technical insight of competitor vehicle/s
enable by Digital Twin
• Global learnings across platform
• Risk sharing approach
• Focus on Actionable Results
Cost
Design
Performance
1
2
3

17. HE Scan to Digital Twin
▪ Full Vehicle Engineering CAD

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BIW 3D CAD Model
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HE Scan Input 3D CAD Model
All engineered internal features are captured through HE scan

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BIW 3D CAD Model
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HE Scan Input
All the components are captured and modeled to greater detail and higher accuracy

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Sheetmetal
Extrusion
Rivet
Fillet Weld
Seam
Weld
Extrusion
Extrusion
BIW 3D CAD Model - Detailed BIW CAD
SILL SECTION
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Full Vehicle 3D CAD Model
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Cut Section View

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Full Vehicle 3D CAD Model with Electrical Harness Routing
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Harness Topology – Top View

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Full Vehicle Electrical and Electronics Architecture
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Separate Channel for Signal wires
Separate Channel for Power wires
Space claim strategy
Wire harness serviceability study
Special routing and channel system
Interface with other systems like BIW & Chassis
Safety Strategy (HV Cables)
Routing and fixation methodology

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Electrical Topology – Comparative Analysis
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The entire routing and topology is captured to a greater detail and higher accuracy

25. CAE – Virtual Validation
▪ Analysis and Simulation

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CAE - BIW Intelligent Mesh Model and Analysis
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Torsional Stiffness Analysis Bending Stiffness Analysis Modal Analysis
BIW-Shell –
xx Hz
BIW Shell +
CCB – xx Hz
BIW Shell +
Bumper – xx
Hz
BIW Shell +
Windshield – xx
Hz
BIW Shell +
Subframe - xx
Hz
BIW Shell +
Battery – xx Hz
BIW Shell + CCB +
Bumper +
Windshield +
Subframe + Battery
xx Hz

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CAE - Material Distribution
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High Strength Steel
Mild Steel Ultra High Strength Steel Extruded Aluminium
6xxx Aluminium
5xxx Aluminium Cast Aluminium

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CAE - Full vehicle Crash Model and Analysis
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CAE - Frontal Crash Simulation Vs Test Results
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CFD - External Aerodynamic Analysis
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CFD - External Aerodynamic Analysis
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32. Electric Vehicle Systems
▪ High Voltage Battery
▪ Electric Powertrain

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HV Battery CAD Model
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HE Scan Input
HE Scan data can be converted to 3D CAD models at higher accuracy using our unique process and product experts

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HV Battery CAD Model
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Structure details, Coolant
details, Cell arrangement etc.
can be studied in detail
Section from Front View
Coolant
pipe
Battery
Cells
Structure

35. Confidential Property
HV Battery CAE Simulations
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Coolant Flow Analysis
• The coolant Flow distribution analysis has
been carried out at different flow rates to
identify flow rate at each channel, Pressure
drop and velocity of coolant.
Thermal Performance Analysis
• Thermal performance of the HV-Battery
cooling plate and the Temperature of Battery.
High Temperature Cooling Analysis
(Rapid Charging)
• Cooling performance of the HV-Battery
cooling plate and the Temperature of Battery
with respect to time at rapid charging)
Low Temperature Heating
Analysis
• Heating performance of the HV-
Battery cooling plate and the
Temperature of Battery at low
environment temperature (-20℃)

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HV Battery CAE Simulations
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Modal & FRF Analysis
• Modal & FRF Analysis Carried out to find the
Mode Shapes and Vibration behavior of the
system
Frontal Impact Analysis
• Impact Analysis has been performed to
investigate the Energy absorption and crush
behavior of the system.
Side Impact & Side Pole
Analysis
• Side Pole Analysis carried out to
check the maximum intrusion, crush
behavior of the system.
Torsion & Bending Stiffness
• Stiffness Analysis carried out for the HV
Battery assembly Structure to find the
Structural Strength & Stability

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Electric Powertrain CAD Model
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Electric Powertrain CAD Model
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Tesla Model 3
Jaguar IPace
All the components are captured & modeled to greater detail and higher accuracy

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Electric Powertrain - EMC Analysis
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▪ Torques vs Speed Curve
▪ Electro Magnetic Performance Analysis
▪ No load Back EMF Analysis
▪ Cogging Torque Analysis
▪ Load Torque Analysis
▪ Flux Density Contour
▪ Electro Magnetic Force Analysis
▪ Iron Loss Contour
▪ Characteristics Curve
▪ Load Analysis based on PWM current
▪ Efficiency Map
▪ Thermal Analysis
▪ Harmonic Analysis
EMC Analysis
EMC Model Deliverables
Electromagnetic density
Harmonics Cogging torque
Efficiency Map

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Light weighting & Cost Reduction
Digital-Twin Data Design Optimization and Validation Benefits to Customer
Liftgate of Audi E-tron
Design Validation
Baseline Solution
Design Optimization
Baseline Solution
Parameters
Baseline
Design
Modified
Design
Savings
Gross Material
(kg)
11.23 9.70 1.53 Kg
Gross Material
Cost ($)
$50.55 $43.65
Proposed
Concept design
- $7.89
Manufacturing
and assembly
process
$21.75 $13.62
Total cost $72.3 $65.16 $7.14
Net weight (kg) 5.66 5.21 0.45Kg
Die tooling
investment ($)
$2.9M $2.15M $750K

41. Thank you