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Addressing the Challenges of Electric

Autonomous Mobility in a Holistic Way

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Current Mobility ChallengeTRENDS IN PASSENGER TRANSPORT ACTIVITY

AND ENERGY CONSUMPTION

EU reference scenario 2016, European Commission

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Current Mobility Challenge

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Benefits to Citizens provided by ACES Vehicles

Esteem

Love and

belonging

Safety needs

Physiological needs

Self-actualization

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Addressing the Challenges of Electric

Autonomous Mobility in a Holistic Way

Thomas REIMER

SIMULIA Senior Industry Solutions Manager

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Electro-Chemistry

Materials Modeling

Structural Performance

Electromagnetics

1D Simulation Libraries

System Analysis

Fluid Dynamics

Behavior Modeling

Model Order Reduction

Mechanical Design

Acoustics

Multi-body Dynamics

Model

Based

System

Engineering

Method

Industry

Business

Processes

ProcessesRequirement

Functional

Logical

Physical

Tools

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Multi-scale systems

ExperienceDigital

Continuity

R F L P

Standard Support

& Openness

= Disciplines Federation + Agile Collaboration + Virtual Trust

1 2 3

Dassault Systemes Strategy for MBSE

…

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TRANSPORTATION & MOBILITY | Industry Trends

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TRANSPORTATION & MOBILITY | Portfolio

DRIVE EMOTIONCREATE 3D SKETCHES AND VALIDATE VIRTUAL

DESIGNS IN A FULLY-IMMERSIVE ENVIRONMENT

VIRTUAL GARAGEBOOST MARKETING CAMPAIGNS AND ENHANCE

BUYING EXPERIENCES

LEAN PRODUCTION RUNIMPROVE VISIBILITY, EFFICIENCY AND CONTROL

OF MANUFACTURING OPERATIONS, WITHIN AND

ACROSS PLANTS

GLOBAL MODULAR ARCHITECTUREENHANCE COLLABORATION AND MASTER

COMPLEXITY TO DRIVE PROFITABILITY

SMART, SAFE & CONNECTEDDESIGN, VALIDATE, DELIVER THE INTELLIGENT

VEHICLE EXPERIENCE

EFFICIENT MULTI-ENERGY PLATFORMDEVELOP AND INDUSTRIALIZE VERSATILE AND

COMPLIANT CHASSIS AND POWERTRAINSELECTRO-MOBILITY ACCELERATOR

ENABLES EV INNOVATORS TO ACCELERATE

INNOVATIONS TO MARKET AT COMPETITIVE COST

AND OPTIMAL QUALITY

ON-TARGET VEHICLE LAUNCHRAPIDLY ENGINEER AND INDUSTRIALIZE VEHICLES

WITH OPTIMIZED PERFORMANCE, COMFORT AND

SAFETY

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1-CHASSIS AND SUSPENSION CONCEPT ENGINEERING2-CHASSIS AND SUSPENSION ENGINEERING3-CHASSIS AND SUSPENSION PERFORMANCE4-BRAKE SYSTEM ENGINEERING5-ASSEMBLY LINE DEFINITION & VALIDATION6-ASSEMBLY ROBOT PROGRAMMING & SIMULATION7-POWERTRAIN CONCEPT ENGINEERING8-POWERTRAIN ENGINEERING9-POWERTRAIN CONTROL SYSTEMS ENGINEERING10-POWERTRAIN STRUCTURAL PERFORMANCE11-POWERTRAIN THERMAL PERFORMANCE12-ENGINE AERODYNAMIC PERFORMANCE13-POWERTRAIN LUBRICATION PERFORMANCE14-POWERTRAIN DYNAMICS PERFORMANCE15-POWERTRAIN ASSEMBLY PROCESS ENGINEERING & VIRTUAL BUILD16-POWERTRAIN PART FABRICATION PROCESS ENGINEERING17-POWERTRAIN NC PROGRAMMING & SIMULATION18-EXHAUST SYSTEM ENGINEERING19-ELECTRIC POWERTRAIN SYSTEM ENGINEERING20-BATTERY ENGINEERING21-ELECTRIC DRIVE ENGINEERING22-POWER ELECTRONICS ENGINEERING

1-MOBILITY SYSTEMS ARCHITECTURE2-VEHICLE SYSTEM ARCHITECTURE]3-PERFORMANCE DRIVEN ARCHITECTURE & MULTI-DISCIPLINARY TRADE-OFF4-ELECTRICAL, ELECTRONICS AND SOFTWARE ARCHITECTURE5-VEHICLE FUNCTIONAL SAFETY6-INTEGRATED SOFTWARE ENGINEERING7-EMBEDDED SOFTWARE ENGINEERING8-ELECTRONICS DESIGN INTEGRATION9-STRUCTURAL ELECTRONICS DESIGN10-WIRE HARNESS ELECTRICAL11-ADAS/AV SENSORS PERFORMANCE12-CONNECTED VEHICLE COMMUNICATION PERFORMANCE13-ELECTRONICS SI/PI PERFORMANCE14-ELECTRONICS EMC/EMI PERFORMANCE15-ELECTRONIC THERMAL MANAGEMENT16-CONTINUOUS EMBEDDED SYSTEMS TESTING & VALIDATION

1-VEHICLE PACKAGING & COMPLIANCE2-BODY STRUCTURE CONCEPT ENGINEERING3-BODY STRUCTURE ENGINEERING4-STAMPING DIE ENGINEERING5-BODY STRUCTURE NVH PERFORMANCE6-BODY STRUCTURE DURABILITY PERFORMANCE7-BODY STRUCTURE SAFETY PERFORMANCE8-STAMPING LINE DEFINITION & SIMULATION9-PAINTING LINE DEFINITION & SIMULATION10-ASSEMBLY ROBOT PROGRAMMING & SIMULATION11-BODY LINE DEFINITION & VALIDATION12-COMPOSITE ENGINEERING & MANUFACTURING PREPARATION13-INTERIOR & EXTERIOR EQUIPMENT ENGINEERING14-CABIN COMFORT15-MOLD ENGINEERING16-MOLD & DIE MACHINING17-ASSEMBLY LINE DEFINITION & VALIDATION18-VEHICLE THERMAL PERFORMANCE19-VEHICLE NVH & ACOUSTIC PERFORMANCE20-VEHICLE PERFORMANCE IN ADVERSE CONDITIONS21-VEHICLE DYNAMICS PERFORMANCE22-VEHICLE STRUCTURE & SAFETY PERFORMANCE23-VEHICLE ELECTROMAGNETIC PERFORMANCE24-VEHICLE ENERGY PERFORMANCE25-FINAL ASSEMBLY PROCESS ENGINEERING & VIRTUAL BUILD

01-DEMAND PLANNING (S&OP)02-SUPPLY PLANNING (S&OP)03-MASTER PRODUCTION SCHEDULE04-WAREHOUSE MANAGEMENT05-LINE SUPPLY MANAGEMENT06-QUALITY MANAGEMENT07-TRANSIT PRODUCT INSPECTION

01-MARKETING INTELLIGENCE02-CAMPAIGN DASHBOARD & MARKETING ASSET MANAGEMENT03-MARKETING MODEL PREPARATION04-MARKETING ASSET CREATION05-AGENCY DATA COLLABORATION06-MARKETING INTERACTIVE TOUCHPOINT07-CUSTOMIZED CAMPAIGN

00-OPERATIONS INTELLIGENCE

08-PRODUCTION SCHEDULING09-PRODUCTION EXECUTION10-MAINTENANCE EXECUTION11-TRANSPORTATION PLANNING12-ORDER PROMISING13-DISTRIBUTION RESOURCE PLANNING14-LEAN OPERATIONAL MANAGEMENT

TRANSPORTATION & MOBILITY | Portfolio

VIRTUAL GARAGE

LEAN PRODUCTION RUN

SMART, SAFE & CONNECTEDON-TARGET VEHICLE LAUNCHEFFICIENT MULTI-ENERGY PLATFORM

DRIVE EMOTION

OWNERSHIP

1-BUSINESS DRIVEN PORTFOLIO & PRODUCT PLANNING2-COLLABORATIVE PLANNING EXECUTION & ANALYTICS3-COLLABORATIVE PLANNING, EXECUTION & ANALYTICS (PLANNING FOR ALL)4-PRODUCT COSTING & COST INTELLIGENCE5-WEIGHT & BALANCE6-MOBILITY SYSTEMS ARCHITECTURE7-VEHICLE SYSTEM ARCHITECTURE8-PERFORMANCE DRIVEN ARCHITECTURE & MULTI-DISCIPLINARY TRADE-OFF9-PERFORMANCE VALIDATION STRATEGY DEFINITION, EXECUTION & ANALYTICS10-V+R TEST RESOURCES & SCHEDULING11-PHYSICAL PRODUCT ARCHITECTURE12-COMPONENT SOURCING13-CONTINUOUS PRODUCT DEVELOPMENT14-STANDARD COMPONENT & TEMPLATE MANAGEMENT15-3D DIGITAL MOCKUP VALIDATION16-CONTINUOUS MANUFACTURING DEVELOPMENT17-COLLABORATIVE ENTERPRISE RELEASE18-EXTENDED ENTERPRISE19-CERTIFICATION & APPROVAL

GLOBAL MODULAR ARCHITECTURE

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TRANSPORTATION & MOBILITY | Industry Trends

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1-CHASSIS AND SUSPENSION CONCEPT ENGINEERING2-CHASSIS AND SUSPENSION ENGINEERING3-CHASSIS AND SUSPENSION PERFORMANCE4-BRAKE SYSTEM ENGINEERING5-ASSEMBLY LINE DEFINITION & VALIDATION6-ASSEMBLY ROBOT PROGRAMMING & SIMULATION7-POWERTRAIN CONCEPT ENGINEERING8-POWERTRAIN ENGINEERING9-POWERTRAIN CONTROL SYSTEMS ENGINEERING10-POWERTRAIN STRUCTURAL PERFORMANCE11-POWERTRAIN THERMAL PERFORMANCE12-ENGINE AERODYNAMIC PERFORMANCE13-POWERTRAIN LUBRICATION PERFORMANCE14-POWERTRAIN DYNAMICS PERFORMANCE15-POWERTRAIN ASSEMBLY PROCESS ENGINEERING & VIRTUAL BUILD16-POWERTRAIN PART FABRICATION PROCESS ENGINEERING17-POWERTRAIN NC PROGRAMMING & SIMULATION18-EXHAUST SYSTEM ENGINEERING19-ELECTRIC POWERTRAIN SYSTEM ENGINEERING20-BATTERY ENGINEERING21-ELECTRIC DRIVE ENGINEERING22-POWER ELECTRONICS ENGINEERING

1-MOBILITY SYSTEMS ARCHITECTURE2-VEHICLE SYSTEM ARCHITECTURE]3-PERFORMANCE DRIVEN ARCHITECTURE & MULTI-DISCIPLINARY TRADE-OFF4-ELECTRICAL, ELECTRONICS AND SOFTWARE ARCHITECTURE5-VEHICLE FUNCTIONAL SAFETY6-INTEGRATED SOFTWARE ENGINEERING7-EMBEDDED SOFTWARE ENGINEERING8-ELECTRONICS DESIGN INTEGRATION9-STRUCTURAL ELECTRONICS DESIGN10-WIRE HARNESS ELECTRICAL11-ADAS/AV SENSORS PERFORMANCE12-CONNECTED VEHICLE COMMUNICATION PERFORMANCE13-ELECTRONICS SI/PI PERFORMANCE14-ELECTRONICS EMC/EMI PERFORMANCE15-ELECTRONIC THERMAL MANAGEMENT16-CONTINUOUS EMBEDDED SYSTEMS TESTING & VALIDATION

1-VEHICLE PACKAGING & COMPLIANCE2-BODY STRUCTURE CONCEPT ENGINEERING3-BODY STRUCTURE ENGINEERING4-STAMPING DIE ENGINEERING5-BODY STRUCTURE NVH PERFORMANCE6-BODY STRUCTURE DURABILITY PERFORMANCE7-BODY STRUCTURE SAFETY PERFORMANCE8-STAMPING LINE DEFINITION & SIMULATION9-PAINTING LINE DEFINITION & SIMULATION10-ASSEMBLY ROBOT PROGRAMMING & SIMULATION11-BODY LINE DEFINITION & VALIDATION12-COMPOSITE ENGINEERING & MANUFACTURING PREPARATION13-INTERIOR & EXTERIOR EQUIPMENT ENGINEERING14-CABIN COMFORT15-MOLD ENGINEERING16-MOLD & DIE MACHINING17-ASSEMBLY LINE DEFINITION & VALIDATION18-VEHICLE THERMAL PERFORMANCE19-VEHICLE NVH & ACOUSTIC PERFORMANCE20-VEHICLE PERFORMANCE IN ADVERSE CONDITIONS21-VEHICLE DYNAMICS PERFORMANCE22-VEHICLE STRUCTURE & SAFETY PERFORMANCE23-VEHICLE ELECTROMAGNETIC PERFORMANCE24-VEHICLE ENERGY PERFORMANCE25-FINAL ASSEMBLY PROCESS ENGINEERING & VIRTUAL BUILD

01-DEMAND PLANNING (S&OP)02-SUPPLY PLANNING (S&OP)03-MASTER PRODUCTION SCHEDULE04-WAREHOUSE MANAGEMENT05-LINE SUPPLY MANAGEMENT06-QUALITY MANAGEMENT07-TRANSIT PRODUCT INSPECTION

01-MARKETING INTELLIGENCE02-CAMPAIGN DASHBOARD & MARKETING ASSET MANAGEMENT03-MARKETING MODEL PREPARATION04-MARKETING ASSET CREATION05-AGENCY DATA COLLABORATION06-MARKETING INTERACTIVE TOUCHPOINT07-CUSTOMIZED CAMPAIGN

00-OPERATIONS INTELLIGENCE

08-PRODUCTION SCHEDULING09-PRODUCTION EXECUTION10-MAINTENANCE EXECUTION11-TRANSPORTATION PLANNING12-ORDER PROMISING13-DISTRIBUTION RESOURCE PLANNING14-LEAN OPERATIONAL MANAGEMENT

TRANSPORTATION & MOBILITY | Portfolio

VIRTUAL GARAGE

LEAN PRODUCTION RUN

SMART, SAFE & CONNECTEDON-TARGET VEHICLE LAUNCHEFFICIENT MULTI-ENERGY PLATFORM

DRIVE EMOTION

OWNERSHIP

1-BUSINESS DRIVEN PORTFOLIO & PRODUCT PLANNING2-COLLABORATIVE PLANNING EXECUTION & ANALYTICS3-COLLABORATIVE PLANNING, EXECUTION & ANALYTICS (PLANNING FOR ALL)4-PRODUCT COSTING & COST INTELLIGENCE5-WEIGHT & BALANCE6-MOBILITY SYSTEMS ARCHITECTURE7-VEHICLE SYSTEM ARCHITECTURE8-PERFORMANCE DRIVEN ARCHITECTURE & MULTI-DISCIPLINARY TRADE-OFF9-PERFORMANCE VALIDATION STRATEGY DEFINITION, EXECUTION & ANALYTICS10-V+R TEST RESOURCES & SCHEDULING11-PHYSICAL PRODUCT ARCHITECTURE12-COMPONENT SOURCING13-CONTINUOUS PRODUCT DEVELOPMENT14-STANDARD COMPONENT & TEMPLATE MANAGEMENT15-3D DIGITAL MOCKUP VALIDATION16-CONTINUOUS MANUFACTURING DEVELOPMENT17-COLLABORATIVE ENTERPRISE RELEASE18-EXTENDED ENTERPRISE19-CERTIFICATION & APPROVAL

GLOBAL MODULAR ARCHITECTURE

WHAT I WILL MAINLY TALK ABOUT TODAY

REGULATION, COMPLIANCE and SAFETY

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Regulation, Compliance and Safety

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Regulation, Compliance and Safety

Traceability, Safety Analysis, and Report Generation

•

•

•

•

•

•

•

•

•

•

•

SENSORS

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WHY?

• Ensuring safe vehicle operations

• Make sure sensors work better

• Taking installed position into

account

• In any weather conditions

• Limiting costs

ADAS / AV SENSORS | Overview

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“Which is the

best sensor

position?”

“Can we identify

different objects?”

ADAS / AV SENSORS | EMAG Performance

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ADAS / AV SENSORS | EMAG Performance

77 GHz

Radar

Lidar

(Light)

Video

Distance measurement 2-150m ++ + -

Angular resolution 0 ++ ++

Velocity measurement ++ -- --

Function in case of rain + 0 0

Function in case of snow / fog ++ - -

Function in case of sensor

contamination

++ -- --

Simulation model of a radar

antenna inside of a housing

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+ 36 km/h, 30m

- 54 km/h, 50.5m

Velocity-Distance-Diagram

The Challenge

Support the development of sensor for

autonomous driving systems

Electromagnetically highly performant

Compatible with installation space

Invisible or emphasizing the car design

System compliant (EMC/EMI)

Requirement Definition by OEM

Detection of

Distance

Velocity

Angle

Placement

Error probability

Development by Supplier

Radar (Lidar / Camera) sensor

Signal processing

System Integration by OEM

The Development Process

The Solution

► Simulation of antenna, electronics,

housing and placement in the car

ADAS / AV SENSORS | Sensor Fusion

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Ptx

Prx

Prx

Object σ

Gain: Grx, Gtx Range R Damping d

𝑃𝑟𝑥= 𝑃𝑡𝑥𝑮𝒕𝒙 ∗ 𝑮𝒓𝒙∗ 𝜆𝑜

2 ∗ 𝜎

𝑅4∗ 4𝜋 3∗𝛿

Power: Prx, Ptx Wavelength l

Ptx

ADAS / AV SENSORS | Radar basics

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0.5 0.9 1 0.9 0.5

Feed optimization

Vertical adjustment Horizontal adjustment

Housing

ADAS / AV SENSORS | Antenna Design

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Snow

Road Spray

Mud

Example Environmental Challenges

Approximately 50% of the time

ADAS / AV SENSORS | Soiling

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Solution: Cleaning Systems

Required

Cleaning needs to be automated

Impossible to ensure functionality

Coatings don’t last

Minimize weight

Sprayer: Pump, reservoir, tubing

Air jet: Compressor

Wiper: Reduce wear

ADAS / AV SENSORS | Soiling

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Proliferation of Sensors

Windscreen Mirror Face

Backup Camera

Rear Latch & License PlateRear Lights

Door

Handles

Side Glass

Rear

Glass

Important Soiling Regions: Today’s Typical Gas Vehicle

ADAS / AV SENSORS | Soiling

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Proliferation of Sensors

Rear Object Laser

Blind Spot

Detection

Cross Traffic Alert

Side Curtain Sensor

Front Object Laser

Night time

Pedestrian

IR Sensor

Front Object Camera Night

Vision

Parking

Assist

Rear Object

Camera

Windscreen Mirror Face

Rear Latch & License PlateRear Lights

Side Glass

Rear

Glass

Door

Handles

Important Soiling Regions: Autonomous Electric Vehicle

ADAS / AV SENSORS | Soiling

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Knowing where dirt will be allows for smarter sensor placement

Sensor on side should be

placed above soiling line

Sensor here would

require constant

cleaning

Sensor here would

require occasional

Reduce

reservoir by

more than 90%

ADAS / AV SENSORS | Soiling

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Real-world conditions that cannot be reproduced in climatic wind tunnels

ADAS / AV SENSORS | Soiling

Ideal Conditions Real World Conditions

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Understanding Tradeoffs

Place sensors where they won’t get dirty

Limit visibility

Change car to keep sensor location clean

Aerodynamics, acoustics trade offs

Add a cleaning system

Cost, the need to work at all speeds, maintenance

Limiting the impact on vehicle styling

Styling that Sells

Sensor Performance

Greater Aerodynamic

Efficiency

ADAS / AV SENSORS | Soiling

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ADAS / AV SENSORS | Summary

EGO CAR BEHAVIOR

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Comprehensive Vehicle Dynamics Offering

1D multiphysics systems and mechatronics simulation tool

PASSENGER EXPERIENCE

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How do you know how passengers feel?

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Ride & Comfort simulation in realtime requires:

High-fidelity model with flexible chassis

to accurately describe ego car behavior

Realtime accurate tire model

Fast, accurate & stable solver

Unprecedented performance of SIMULIA Simpack Technology

Partners network for visualization, terrain, network and traffic

High Fidelity Realtime Simulation

ELECTRIC POWERTRAIN

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Air Cooling

Liquid Cooling

ELECTRIC POWERTRAIN | Processes Overview

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Electrified Powertrain Library

Controller “field-oriented

control (FOC)“

Sine-triangle-space-vector

modulation

Inverter, converters, rectifiers

Energy consumption / Range estimation

Power cycle efficiency

Overload capability estimation

Driving Cycle (NEDC, WLTP, …)

AIM, PSM, ESM

physical, energy/table-based

• Speed/torque controller design

• Loss estimation of inverters and electric

machines for thermal simulations

• Voltage and current ripple effect studies

• Integrated vehicle models enabling energy

consumption simulations for electric vehicles

• Generating parameters for table-based

models from physical models

Cover system simulation design steps during the

entire process of developing electrified powertrains.

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Cell Module & Pack Vehicle

Dassault Systèmes Solutions for BATTERIES

3D

1D

Molecular

Battery

Materials

Design

Battery

Cell

Engineering

Battery

Module & Pack

Engineering

Full

Vehicle

Integration

Battery Management

System Design

Battery System Modelling

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BATTERY Module & Pack | Realistic Model

Structural Analysis with realistic model

The detailed cell model has very large size of DOF. This is not suitable for module level

analysis. Therefore, people use homogenized model or RVE type approach to treat the each

cell in the module/pack level.

This is very critical procedure for module/pack level structural analysis.

Battery Cell Battery Module Battery Pack

400-500 cells 12-14 modules

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BATTERY Module & Pack | Realistic Model

Structural Analysis with realistic model

The detailed cell model has very large size of DOF. This is not suitable for module level

analysis. Therefore, people use homogenized model or RVE type approach to treat the each

cell in the module/pack level.

This is very critical procedure for module/pack level structural analysis.

Battery Cell Battery Module Battery Pack

400-500 cells 12-14 modules

SOC=0.1

SOC=0.9

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POWER ELECTRONICS ENGINEERING

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POWER ELECTRONICS | IGBT

DC IN + DC IN – DC IN + DC IN – DC IN + DC IN –

Motor U Motor V Motor W

Thermal management

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POWER ELECTRONICS | Powertrain EMC Analysis

IN +IN –

CM current path

through bracket 2

CM current path

through bracket 1

CM current path

through drive shaft

Current path through

PCB and cables

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POWER ELECTRONICS | Powertrain EMC Analysis

𝑓𝑟 = Τ1 2𝜋 𝐿𝐶

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POWER ELECTRONICS | Powertrain EMC Analysis

CM current path

through bracket 2

CM current path

through bracket 1

CM current path

through drive shaft

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ELECTRIC DRIVE ENGINEERING

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ELECTRIC DRIVE | Characteristics

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

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ELECTRIC DRIVE | Electromagnetic Performance

Key Facts

Efficiency & Losses

Operating Points

Torque Ripple

Radial Forces

Reduced Order Models

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ELECTRIC DRIVE | Thermal Management

Key Facts

Eliminate thermal

hotspots

Avoid demagnetization

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ELECTRIC DRIVE | Lubrication Performance

Key Facts

Lubricated surfaces

Drag torque

Oil distribution

Oil pressure

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ELECTRIC DRIVE | NOISE AND VIBRATION

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System Performance Design using MBSE

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