Expanding the Role and Application of Design ... - Siemensmdx2.plm.automation.siemens.com/sites/default/files/Presentation/SJC... · With title bar or without... From mechanical components

Expanding the Role and Application of Design ExplorationRanny SidhuVP of HEEDS Product Development

Unrestricted © Siemens AG 20172017.07.07Page 2 Siemens PLM Software

The world is evolving…

With title bar or without...

From mechanical components to Smart systems integrating mechanical, electrical, controls

From defined options to mass customization and personalization

From internet connectivityto system of systems and internet of things

From known material and production methodsto mixed materials, novel production methods


To Be Successful in this Environment…

“If you focus on really great products, then the profits will

follow”Steve Jobs

Apple “Any company that … stays stationary with their technology will be exceeded by their

competitors”

Elon Musk Tesla-SpaceX

“Businesses that grow by development

and improvement don’t die”

Henry FordFord Motor Company


Discover Better Designs, Faster

4

Process Automation

Distributed Execution

Efficient SearchInsight & Discovery

Validated CAE Models

m cores per node

n nodes


c

Process Automation – Integration with Tools

Proc

ess

Auto

mat

ion

28 portals/2 OS/2 Major versions!Expanding every release


c

Process Automation – Flexible Workflow Definition

Proc

ess

Auto

mat

ion

HEEDS allows you to the execution workflow needed for your process by arranging the tool execution in parallel or serial.


c

Process Automation – Conditional Execution (Branching)

Proc

ess

Auto

mat

ion

HEEDS allows you to quickly and easily setup of complex process flows by eliminating the need for script writing to handle branching logic


c

Process Automation – Nesting/Looping

Proc

ess

Auto

mat

ion


Full Vehicle Body Weight Reduction

• Re-design body-in-white to minimize mass

Goals:

• Capture and automate entire workflow

• Minimize Body-In-White weight

• Maintain manufacturability

• Obtain the same or better performance

• Constrain increases in cost

After 250 design iterations, found 49 feasible designs. Resulted in 20% reduction in weight with only 5% increase in cost.


Full Vehicle Body Weight Reduction

• Re-design body-in-white to minimize mass

• Modified: Shape, gage, material variables (>400)

• Used collaborative design feature

• Unsuccessful use of other design exploration tools earlier After 250 design iterations, found 49 feasible designs. Resulted in 18% reduction in

weight with only 5% increase in cost.

TARGET WEIGHT (20% saving) TARGET COST

(10% up)

BODY NVH

FRONT CRASH (all load cases)

OCCUPANT RESTRAINTS (all load cases)

SIDE CRASH (all load cases)

REAR CRASH (all load cases)

ROOF CRUSH (all load cases)

DURABILITY

BODY STIFFNESS (global and local)

HEEDS PERFORMANCE ASSESSMENT

BASELINE


Distributed Execution – Parallel Execution

Dis

tribu

ted

Exec

utio

n 6

101 1


Distributed Execution – Different Compute Resources

Dis

tribu

ted

Exec

utio

n


Distributed Execution – Resource Pre-allocation

Dis

tribu

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Exec

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By pre-allocating all the resources needed for the duration of the study, once allocated, HEEDS bypasses waiting in the queue for all analysis jobs.

Submit Analysis

Wait in Queue

Resource Available

Without Pre-allocation


Distributed Execution – Resource Pre-allocation

Dis

tribu

ted

Exec

utio

n

By pre-allocating all the resources needed for the duration of the study, once allocated, HEEDS bypasses waiting in the queue for all analysis jobs.

Submit Allocation

Wait in Queue

Resource Available

With Pre-allocation

Submit Analysis


Traditional design exploration techniques failed to identify a single feasible design over six months. In two weeks, HEEDS identified 3 high-performing design alternatives.

• Find a design that yields outlet temperatures below 36°C

Challenge Design feasible undersea heat exchanger:

• Intake oil at 50°C; Outlet oil < 36°C

• Maximize flow; minimize pressure drop

• Ensure robust performance

Streamlining the Design Exploration ProcessCustomer case study: Designing efficient subsea heat exchangers



Leveraged existing models/tools:

• Parametric NX CAD model to vary geometry and materials

• Parametric STAR-CCM+ CFD model to simulate steady-state fluid flow and heat transfer


Validated CAD/CAE Models

Parametric NX CAD Model Parametric STAR-CCM+ CFD Model




Considered:

• 10 geometry design variables

• 1 material design variable

• 1 constraint: pressure drop < 40 psi

Process Automation

Parametric NX CAD Geometry STAR-CCM+ CFD Analysis

Simulation

Responses

Design

Variables

HEEDS Intelligent Design Search





Utilized:

• 4 designs evaluated at a time in parallel

• 48 cores for CFD simulation

• 1 core for CAD modifications

Distributed Execution

Linux Cluster Head Node Linux Cluster

12 cores on each of 4 nodes



Windows workstation CFDCAD



Efficient Search

Parametric NX CAD STAR-CCM+ CFD

Response

Change design variables


Searched:

• 150 designs in 12 days

• 75% of designs were feasible

Identified:

• 3 high performance feasible designs


Efficient Search

Parametric NX CAD STAR-CCM+ CFD

Response

Change design variables

Outstanding Designs

Monitor responses



Identified Design with:

• Outlet oil temp reduced 35% to 32.3°C

• Minimal pressure drop of 0.288 psi

• Excellent flow rate over 22 gpm

Efficient Search-- Top Three Designs --

#145Outlet Temp 32.26°CFlow Rate 22.55 gpm

SuperDuplex


Inconel


SuperDuplex

4 Groups4 Tubes/GroupMax Height

5 Groups1 Tube/GroupMax Height

3 Groups3 Tubes/GroupMax Height




Efficient Search - SHERPA

Mountain Climbing AnalogyUnknown Terrain (Design Space):

• Would you really feel safe to only rely on one strategy and set of equipment?

--- That’s the traditional approach

Icy?

Rocky?

Loose gravel?

Heavy snow?

Steep cliff face?

Walking path?

Crevasse?

• What you need is a SHERPA who knows all of the strategies, carries all your equipment, and tailors the approach to the terrain encountered

--- That’s the modern HEEDS approach

Effic

ient

Se

arch


Efficient Search – Proposed Exploration Workflow

Effic

ient

Se

arch x1

x2

Perform Optimization

x1

x2

Direct/Surrogate based

DOE/Reliability

Design space points evaluated by HEEDS (SHERPA)


Efficient Search – Other Exploration Techniques

Effic

ient

Se

arch


Military Vehicle Design

Challenge:• Find vehicle ride elements that:

• Satisfy 40 constraints• Improve 44 ride factor variables• Subject to 7 vehicle maneuvers• Minimize sum of absorbed power and max vertical acceleration

• Previously, after 12 man weeks of manual effort using DOEs, no feasible designs were found

Results:• After 200 evaluations, HEEDS discovered 61 feasible designs• Identified design with best performance after 123 evals• Stellar vehicle performance! “HEEDS® is superior to anything else

on the market today.” - Jesper Slattengren, Pratt & Miller

Simulation Constraint #10" half-round GCW Vertical accel 410" half-round CVW Vertical accel 4

Drop-off GVW Ride frequencies 4Ride damping 4

Drop-off CVW Ride frequencies 4Ride damping 4

Offroad CVW Absorbed power 4Offroad GVW Absorbed power 4

Step steer

Yaw overshoot 1Roll overshoot 1Yaw damping 1Roll damping 1

Constant radiusUndersteer gradient 2Max lateral accel 1Roll gradient 1

Total 40

Factors

Front

Dual rate spring 5Position sensitive damper 12Anti-roll bar 3Geometry 3

Rear

Dual rate spring 5Position sensitive damper 12Anti-roll bar 3Geometry 1

Total 44

“That’s the best vehicle I’ve ever ridden in.” - Frank Sturek, Infantry Battalion Commander

Designed with HEEDS!


Insight & Discovery – Plotting & Discovery Tools

Insi

ght

& D

isco

very


Insight & Discovery – Report Generation

Insi

ght

& D

isco

very


Improving suspension control arm design process

• Design suspension control arm shape to minimize mass and satisfy constraints

Challenge Quickly design control arm to:

• Minimize mass (weight)

• Satisfy all loading conditions

• Maintain constraints on stress and permanent set

Control arm

“HEEDS revolutionized our design process.”



Automated Virtual Prototype Building:

• Packaging space sliced

• Parametric cross-sections designed

• Linear, nonlinear, and fatigue finite element simulations performed

Process Automation


Packaging space sliced

Packaging space CAD

HEEDS Intelligent Design Search

Sections designed

Geometry defined

FE mesh and loads

Linear Stress Analysis

Nonlinear FE Analysis

Fatigue Analysis

OEM requirements

Control arm




Searched for high performing designs:

• 1375 design evaluated

• 66 shape variables explored

• Minimized mass

• Satisfied constraints on stress, deflection, permanent set, fatigue life

Design Exploration


Control arm




Searched for high performing designs:

• 1375 design evaluated

• 66 shape variables explored

• Minimized mass

• Satisfied constraints on stress, deflection, permanent set, fatigue life

Design Exploration


0

5

10

15

20

25

30

Manual Process HEEDS Process

Tim

e (W

eeks

)

Control Arm Design ProcessControl arm




Identified high performing designs:

• Reduced mass by >31%

• Satisfied all constraints

• Lofted by CAD and casted

• Ready for production in under 4 weeks

Insight & Discovery


Topology Based Design HEEDS Based Design

Better, Faster

Control arm




Identified high performing designs:

• Reduced mass by >31%

• Satisfied all constraints

• Lofted by CAD and casted

• Ready for production in under 4 weeks

Insight & Discovery


Control arm



Summary

Innovative Companies are Extracting Higher Value

From Simulation

Redefining Simulation Strategy to Focus on Driving Performance

Discover Better Designs, Faster

Documents

Expanding the Role and Application of Design ... - Siemensmdx2.plm.automation.siemens.com/sites/default/files/Presentation/SJC... · With title bar or without... From mechanical components