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Computer Aided Engineering at BMW, Powered by High Performance Computing 2nd

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Computer-aided-engineering (CAE), e.g. virtual modeling and simulation, has become a very important part in the automotive engineering process to achieve the necessary high quality. At the BMW Group a strong contributor is the progressive use of HPC to support the engineering process in many aspects of vehicle development, e.g. passive safety, aerodynamic drag and engine performance. The approach to provide HPC services is built around “cells” – modular, portable units of defined capability. After the talk of Mr. Burke, Fujitsu presents its concept of standardized HPC units; provides lessons for an SME community battling against hurdles to HPC adoption; how to consolidate HPC skills, ensure productivity and widen the HPC workforce.

Speaker:
Wolfgang Burke
Ian Godfrey

Published in: Technology
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Computer Aided Engineering at BMW, Powered by High Performance Computing 2nd

  1. 1. HIGH PERFORMANCE COMPUTING @ BMW Wolfgang Burke, BMW Group, 19.11.2015
  2. 2. High Performance Computing @ BMW, 17.11.2015 Page 2 AGENDA. 1 BMW Group – The company 2 HPC demands 3 HPC Cluster @ BMW 4 HPC Colocation
  3. 3. High Performance Computing @ BMW, 17.11.2015 Page 3 BMW GROUP – THE COMPANY. KEY FIGURES.  The BMW Group is one of the ten largest industrial enterprises in Germany.  Brands: BMW, MINI, Rolls-Royce, BMW Motorrad.  Sales BMW Group 2014: 80,4 bn. Euro.  Profit before tax 2014: 8,71 bn. Euro.  Deliveries of 2,118 m. cars in 2014.  Deliveries of 123.000 motorcycles in 2014.  30 manufacturing and assembly plants in 14 countries.  Presence in more than 140 countries.  116.324 employees at 31.12.2014.
  4. 4. High Performance Computing @ BMW, 17.11.2015 Page 4 Moses Lake Spartanburg Cairo Shenyang RayongChennai Kulim Jakarta RosslynAraquari Manaus Production Plants Assembly Plants Engines / Components BMW Group Joint Venture Contract Production Regensburg Dingolfing Berlin Eisenach Leipzig Wackersdorf Landshut Munich Kaliningrad Born Steyr Graz Hams Hall Oxford Swindon Goodwood San Luis Potosí (2019) 01/2015 BMW GROUP PRODUCTION NETWORK WORLDWIDE. 30 PRODUCTION SITES IN 14 COUNTRIES.
  5. 5. High Performance Computing @ BMW, 17.11.2015 Page 5 BMW GROUP – THE COMPANY. POSITIVE IMPULSES BY NEW MODELS. BMW X6 M and X5 M BMW 2 Series Gran Tourer BMW 2 Series Convertible BMW Mini 5 Doors Rolls-Royce Ghost Series II
  6. 6. AGENDA. 1 BMW Group – The company 2 HPC demands 3 HPC Cluster @ BMW 4 HPC Colocation Page 6High Performance Computing @ BMW, 17.11.2015
  7. 7. High Performance Computing @ BMW, 17.11.2015 Page 7 HPC DEMANDS. CHALLENGES BY INCREASING HPC USAGE. Corehours Computation time demands per month July 2015: 810.000 core-h/day 3.400 jobs/day
  8. 8. Page 8 HPC DEMANDS. INCREASING NUMBER OF APPLICATION AREAS USING SIMULATION. Aerodynamics Stiffness, structural dynamics Passive Safety Operating strength Power train Production High Performance Computing @ BMW, 17.11.2015 Visualization
  9. 9. Page 9 HPC DEMANDS. EXAMPLE FROM PASSIVE SAFETY SIMULATION (CRASH). High Performance Computing @ BMW, 17.11.2015
  10. 10. Page 10 HPC DEMANDS. EXAMPLE FROM FLUID DYNAMIC SIMULATION. High Performance Computing @ BMW, 17.11.2015
  11. 11. High Performance Computing @ BMW, 17.11.2015 Page 11 HPC DEMANDS. INCREASING NUMBER OF USE CASES PER APPLICATION AREA.
  12. 12. High Performance Computing @ BMW, 17.11.2015 Page 12 HPC DEMANDS. SIMULATION MODELS GETTING MORE DETAILED.
  13. 13. High Performance Computing @ BMW, 17.11.2015 Page 13 HPC DEMANDS. PREDICTIVENESS IN MATERIAL BEHAVIOR.
  14. 14. High Performance Computing @ BMW, 17.11.2015 Page 14 HPC DEMANDS. SIMULATION REDUCES PROTOTYPES IN THE DESIGN PROCESS. design stage 2design stage 1 industrialization 1 2 3 Reduced prototype driven design process (schematically): “close to production” cars design stage 2design stage 1 industrialization 1 2 3 Old prototype driven design process (schematically): prototypes “design evaluation” prototypes “design validation” “close to production” cars prototypes “design validation” (only in case of high innovations) Benefits of the new process:  Straightforward design process.  Reduced number of prototypes and cost savings.
  15. 15. High Performance Computing @ BMW, 17.11.2015 Page 15 HPC DEMANDS. NUMBER OF LEGAL REQUIREMENTS INCREASE. Heute 1990 1997 2005 FMVSS 208 old FMVSS 208 new Phase I FMVSS 208 new Phase II FMVSS 214 static FMVSS 214 static + dynamic FMVSS 214 new MDB + Pole FMVSS 301 old rear crash FMVSS 301 new Offset rear crash FMVSS 216 roof crush test FMVSS 216 new Occupant Containm. ECE R95 side crash ECE R95 AE-MDB Advanced European Movable Barrier 2003/102/EC PDB or TRL Barrier NHTSA Front to Front BMW model USAECEUSAECEUSAECEUSAUSAECE Frontal impact Side impact Rear impact Fuel tightness Rollover Pedestrian safety Compatibility ECE R12 steering column displacement ECE R94 Offset frontal crash 2011
  16. 16. High Performance Computing @ BMW, 17.11.2015 Page 16 BMW product portfolio (status July 2015)  Increasing number of models, variants, facelifts  Diversity per model (e.g. left/right hand drive, motorization) BMW market introduction 2015 HPC DEMANDS. INCREASING NUMBER OF MODELS AND VARIANTS.
  17. 17. AGENDA. 1 BMW Group – The company 2 HPC demands 3 HPC Cluster @ BMW 4 HPC Colocation Page 17High Performance Computing @ BMW, 17.11.2015
  18. 18. High Performance Computing @ BMW, 17.11.2015 Page 18 HPC CLUSTER @ BMW. HPC SERVICE WITH AN EXTENSIBLE RESOURCE POOL. Shared, extensible resource pool Optimized computational architecture & technologies Transparent access Job flow & workload management control Overall operations framework (e.g. installation, administration, monitoring) High availability of HPC service, 24 x 7 operation High flexibility in resource allocation
  19. 19. High Performance Computing @ BMW, 17.11.2015 Page 19 HPC CLUSTER @ BMW. HPC SERVICE WITH AN EXTENSIBLE RESOURCE POOL. Workload-Management HPC Cluster Engineers, Virtual Dev.
  20. 20. HPC CLUSTER @ BMW. HPC SERVICE WITH AN EXTENSIBLE RESOURCE POOL. • Global resource pooling • Modular architecture • Capacity scalability • Maximum utilization • Technological adaptability • Commodity components • Vendor independence • Best price purchasing Intel Xeon E5-2670 Infiniband Intel Xeon E5-2680 V2 Infiniband Intel Xeon E5-2660 V3 Infiniband High Performance Computing @ BMW, 17.11.2015 Page 20 Intel Xeon E5-2680 V2 Infiniband, GPU Intel Xeon E5-2680 V2 Infiniband, SSD
  21. 21. High Performance Computing @ BMW, 17.11.2015 Page 21 HPC CLUSTER @ BMW. IMPACT OF HIGHER VIRTUAL SIMULATION USAGE. Floor space of HPC installation Goals of the BMW HPC decisions  enable a scalable model for data center space requirements  deal with the increasing electricity prices  address carbon footprint caused by higher energy consumption 0% 10% 20% 30% 40% 50% 60% 70% 80% Electricity price Core-h per month
  22. 22. High Performance Computing @ BMW, 17.11.2015 Page 22 HPC CLUSTER @ BMW. HPC CLUSTER DEVELOPMENT STEPS. HPC private cloud • On-demand resource reservation • Transparent access (self-service portal) • Standardized applications (services) • Fully automated • Zero downtime approach • Cluster capacity scalability • Maximum cluster utilization • Cluster technological adaptability • Cluster vendor independence • Cluster best price purchasing
  23. 23. High Performance Computing @ BMW, 17.11.2015 Page 23 HPC CLUSTER @ BMW. HPC CLUSTER DEVELOPMENT STEPS. HPC public cloud • Flexible capacity scalability • Best price purchasing • “HPC as a service” Challenges: • Remote location • Unclear cloud model (IaaS, PaaS, SaaS, …) • Cloud integration • Data security • Organizational aspects • … HPC Co-Location • Space capacity scalability • DC technology adaptability • DC best price purchasing Challenges: • Remote location • Data security • Organizational aspects HPC private cloud • On-demand resource reservation • Transparent access (self-service portal) • Standardized applications (services) • Fully automated • Zero downtime approach • Cluster capacity scalability • Maximum cluster utilization • Cluster technological adaptability • Cluster vendor independence • Cluster best price purchasing
  24. 24. AGENDA. 1 BMW Group – The company 2 HPC demands 3 HPC Cluster @ BMW 4 HPC Colocation Page 24High Performance Computing @ BMW, 17.11.2015
  25. 25. High Performance Computing @ BMW, 17.11.2015 Page 25 HPC COLOCATION. ICELAND FOR HPC COLOCATION. Data center operation with 100% CO2 emission free, renewable energy (geothermal, hydro) Free air cooling nearly the whole year Fixed low power cost for up to 20 years High scalability in data center floor space High bandwidth network connections available Power Usage Effectiveness (PUE) < 1,2 1 1,2 1,43 1,8 0 0,5 1 1,5 2 Average PUE BMW Data Center PUE Iceland Colocation PUE Physical minimal PUE
  26. 26. High Performance Computing @ BMW, 17.11.2015 Page 26 1200 0 200 400 600 800 1000 1200 1400 Coal Fired Grid Natural Gas Grid Iceland Data Center Carbon Usage Effectiveness (CUE) HPC COLOCATION. DATACENTER ICELAND: CARBON POC. g/kWh BMW HPC Cell Carbon Report (with Coal Utility Source) Start of Period 1-Sep-13 End of Period 30-Sep-13 IT Energy 23.760 kWh Non-IT Energy 5.107 kWh Total Energy 28.867 kWh PUE (Power Usage Effectiveness) 1,21 Utility CEF (Carbon Efficiency Factor) 944 g / kWh Average Transmission Losses 4,55% Total Utility CEF 987 g / kWh Utility CUE (Carbon Usage Effectiveness) 1.199 g / kWh Diesel Engine-Generator Carbon 30,1 kg Utility Carbon 28.490 kg Customer Total Carbon 28.520 kg Customer Total CUE 1.200 g / kWh Hypothetical Analysis. Not Actual Carbon Emission Data
  27. 27. High Performance Computing @ BMW, 17.11.2015 Page 27 1200 704 0 200 400 600 800 1000 1200 1400 Coal Fired Grid Natural Gas Grid Iceland Data Center Carbon Usage Effectiveness (CUE) HPC COLOCATION. DATACENTER ICELAND: CARBON POC. g/kWh BMW HPC Cell Carbon Report (with Natural Gas Utility Source) Start of Period 1-Sep-13 End of Period 30-Sep-13 IT Energy 23.760 kWh Non-IT Energy 5.107 kWh Total Energy 28.867 kWh PUE (Power Usage Effectiveness) 1,21 Utility CEF (Carbon Efficiency Factor) 553 g / kWh Average Transmission Losses 4,55% Total Utility CEF 578 g / kWh Utility CUE (Carbon Usage Effectiveness) 702 g / kWh Diesel Engine-Generator Carbon 30,1 kg Utility Carbon 16.690 kg Customer Total Carbon 16.720 kg Customer Total CUE 704 g / kWh Hypothetical Analysis. Not Actual Carbon Emission Data
  28. 28. High Performance Computing @ BMW, 17.11.2015 Page 28 1200 704 2,1 0 200 400 600 800 1000 1200 1400 Coal Fired Grid Natural Gas Grid Iceland Data Center Carbon Usage Effectiveness (CUE) HPC COLOCATION. DATACENTER ICELAND: CARBON POC. g/kWh BMW HPC Cell Carbon Report Start of Period 1-Sep-13 End of Period 30-Sep-13 IT Energy 23.760 kWh Non-IT Energy 5.107 kWh Total Energy 28.867 kWh PUE (Power Usage Effectiveness) 1,21 Utility CEF (Carbon Efficiency Factor) 0,65 g / kWh Average Transmission Losses 4,55% Total Utility CEF 0,68 g / kWh Utility CUE (Carbon Usage Effectiveness) 0,83 g / kWh Diesel Engine-Generator Carbon 30,1 kg Utility Carbon 19,6 kg Customer Total Carbon 49,7 kg Customer Total CUE 2,1 g / kWh
  29. 29. High Performance Computing @ BMW, 17.11.2015 Page 29 HPC COLOCATION. CHALLENGE LATENCY. Batch jobs: Only one big bulk (result) data transfer Optimization of TCP stack parameters  Communication performance for bulk data transfer sufficient Distance Munich-Keflavik: 2.850 km (straight line), 5.000 km (real line) Latency (roundtrip): 0,3 ms (BMW local), 53 ms (BMW – Iceland) BMW capacity: 2 x 4 Gbit/s (fully redundant) Transfer-Server Cluster Workload Management Storage system Job submit Result (bulk) data transfer WAN connection WAN connection
  30. 30. Page 30 THANK YOU VERY MUCH FOR YOUR ATTENTION. Imprint: Published by: BMW Group Corporate and Governmental Affairs 80788 Munich No reproduction, in whole or in part, without the express permission of Bayerische Motoren Werke Aktiengesellschaft, München ©2015 Bayerische Motoren Werke Aktiengesellschaft

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