Optimised Engineering Design at Penso Consulting · Spyker C8 Aileron complete vehicle engineering, interior trim and convertible roof system for Spyker derivative. 2010 ISO9001 and

1 www.penso.co.uk

Optimised Engineering Design

at Penso Consulting

Chris Morrow BEng(Hons) BA Lead Engineer (Composites Group)

Penso Consulting Ltd.

2 www.penso.co.uk

Presentation Structure

Introduction to Penso Consulting 1

Penso Design Process Overview 2

Project Feasibility Phase Optimisation 3

Concept Definition Phase Optimisation 4

Virtual Series Phase Optimisation 5

Future Aspirations for Optimisation 6

Summary 7

3 www.penso.co.uk

Company Overview

Accreditation

TS16949 : 2009

ISO9001 : 2008

Core Competencies

Consulting

Composite Technologies

Special Operations

Clients

Strategic Alliances

Cytec (Oct 2015)

Pricol Technologies (Jan 2015)

ENGINEERING CENTRE

Coventry, UK

ENGINEERING OFFICE

Brentwood, UK

Pune, India

SALES AGENTS

Italy

Germany

4 www.penso.co.uk

Integrated Supply Chain

CHEMICALS

COMPOSITE MATERIALS

COMPONENT AND VEHICLE MANUFACTURE

In December 2015 Solvay acquired Cytec

Industries and simultaneously Cytec invested

in an equity stake in Penso.

This created a secure and integrated supply chain

with both CFRP pre-preg production and

part manufacturing [Coventry] centred in the UK

Midlands.

Turnover

Solvay €11bn

Cytec $2bn

Penso £30m

5 www.penso.co.uk

Company Overview

Consulting

Composite

Technologies

Project Management

Body Engineering

FEA Simulation / Crash

Lightweighting

EV Design

High Volume Composites

Cost Effective

Tooling & Machining

Integrated Composite Systems

Trim Development

Electrics & Electronics

Prototype build

Niche System Production

Series Production

Special Operations

6 www.penso.co.uk

History

2005

Management

buy out of P+Z,

Rebranded

Penso

Consulting

2006

Complete

interior design,

manufacture &

production

supply Brink

Carver ‘One’

2007

Fiat Professional

Specialist turnkey

vehicle programme

– engineer and

manufacture taxis

for UK public hire

sector

2008

Engineer and

manufacture

London Specific

Vito Taxi for

Mercedes Benz -

Full European Type

2 approval and

homologation

2009

Spyker C8 Aileron

complete vehicle

engineering,

interior trim and

convertible roof

system for Spyker

derivative.

2010

ISO9001 and

TS16949

accreditation

2011

Tier-1 supplier into JLR L538C Evoque Convertible

L405 LWB

CX75 engineering &

Composite Body

Structures

X152X Prototype, Tonneau

ETO engineering support.

Project Donington

engineering and build.

VARCITY Megacity.

2012

Supply of Production,

Interior Trim for

Morgan 3 Wheeler

2013

Re-Accreditation

of ISO9001 and

TS16949

Support Product

Launch L405 LWB

2014

L538C

L538C ADV

CDRM Models

P231

SP1 L322

SP2 L405

X261

SP = Special Project

2015

Bimini Hood

X590

X760 LCN

CF Train Door

7 www.penso.co.uk

Specialist Services

Penso Capabilities

Design & Development Prototyping & Testing

Composites

Body in W

hite

Sty

ling &

Surf

acin

g

Engin

eering F

easib

ility

Ele

ctr

ics &

Ele

ctr

onic

s

Mechatr

onic

s

Vehic

le P

ackagin

g

Sim

ula

tion &

CA

E

Tole

rance M

anagem

ent

Rapid

Technolo

gie

s

Rapid

Toolin

g

Rapid

Pro

toty

pin

g

Technolo

gy D

em

onstr

ato

r

Toolin

g D

evelo

pm

ent

Co

mp

osite P

rod

uctio

n

Qualit

y M

anagem

ent

Toolin

g &

Fix

ture

s

Pro

ject

Managem

ent

Launch S

upport

Toolin

g &

Machin

ing

Body-in-B

lack

Data

Managem

ent

Model M

akin

g

Build

Nic

he V

ehic

les

Ho

mo

log

atio

n

Type A

ppro

val

Toolin

g M

anufa

ctu

re

8 www.penso.co.uk

Design Process Overview

Iterative Process: CAD, CAE and Manufacturing Loops, underpinned at all

stages by Optimisation

Penso Design Phases

Project

Feasibility Package Exploration

Target Feasibility

Component Splits

Material Usage Estimates

Concept

Definition Load Path Development

Joint Development

Concept Generation and

Selection

Tradeoff Evaluation

Virtual

Series Component Development

Mass Reduction

Performance

Improvement / Target

Catchback

Project

Feasibility

Concept

Definition

Virtual

Series Prototype Launch

Penso

Design

Process

9 www.penso.co.uk

Project Feasibility Phase Optimisation

Deriving a basic load management strategy

- Key load paths

- Primary, secondary and tertiary joint classification

- Problematic areas

- Part splits

- Manufacturing techniques

Project Scoping: Package Exploration

Project

Feasibility

Concept

Definition

Virtual


10 www.penso.co.uk


Target feasibility: are cost, performance, mass and package constraints

compatible?

- Using a donor architecture, or a package volume, rapid assessment of feasibility

of proposed targets is possible.

- What are the limits of the structural performance of the design / concept and are

these consistent with manufacturing assumptions? What opportunities exist if

project assumptions are modified?

Project Scoping: Design Space Characterisation

Project

Feasibility

Concept

Definition

Virtual


11 www.penso.co.uk


Initial material selection and usage estimates: more resolution for project

quotation.

- Evaluation of various materials, and trade-off comparisons in terms of mass and

package.

- Identification of areas that require inserts, or additional reinforcement.

Project Scoping: Added Resolution

Project

Feasibility

Concept

Definition

Virtual


12 www.penso.co.uk


Preliminary load management strategy.

Initial panel splits, reinforcement regions and problematic areas.

Identified potential manufacturing techniques.

Material usage estimates and trade-offs.

Confidence in the feasibility of the project in terms of cost, mass, package

and performance.

This information kick starts the rapid generation of concepts in the next

design phase.

Key Phase Outcomes

Project

Feasibility

Concept

Definition

Virtual


13 www.penso.co.uk

Concept Definition Phase Optimisation

Genesis facilitates the rapid generation and evolution of design concepts.

Concept Generation

Preliminary Package Exploration:

Concept Creation (RDM/Topology)

Interpreted Concept:

Concept Development

(Sizing / Topometry)

Project

Feasibility

Concept

Definition

Virtual


14 www.penso.co.uk


Load path and joint development: incorporating the most efficient design

from the beginning of the project.

Concept Generation

Sub Model Package Exploration: Primary Loadcases

Project

Feasibility

Concept

Definition

Virtual


15 www.penso.co.uk


Concept evaluation: How much mass is required to make a proposed

architecture achieve performance targets and how does it compare to other

competing concepts?

- Rapid method of establishing relative efficiency of concepts

- Mass deltas are meaningful, absolute mass may not be.

- Identifies areas that are driving mass into the design.

Concept Selection

Thickness (mm) Project

Feasibility

Concept

Definition

Virtual


16 www.penso.co.uk


A number of potential design concepts, which have been rapidly matured.

Increased resolution on load management strategy and design of primary

load paths.

Preliminary joint design for key interfaces.

Selection of a concept which is subsequently matured through the virtual

series phase.

Key Phase Outcomes

Project

Feasibility

Concept

Definition

Virtual


17 www.penso.co.uk

Virtual Series Phase Optimisation

Productionisation of design, while incorporating manufacturing and cost

constraints.

fibre types, and mixed laminates.

- Counter Intuitive result.

Design Refinement: Composites

Project

Feasibility

Concept

Definition

Virtual


- Optimisation undertaken

comprehensive suite of load cases,

including linearised crash

loadcases, modal, stiffness and

durability.

- Multi material optimisation with a

cost objective, allowing comparison

of different fibre types, and mixed

laminates.

- Counter intuitive result in this

example: CFRP Dominant Solution

Cheaper than GFRP.

Thickness (mm)

18 www.penso.co.uk


Maturation of castings, pressings and extrusions: General geometry and

reinforcement, wall thickness, lightening features.

Design Refinement: Metallics

Project

Feasibility

Concept

Definition

Virtual


- Continuation of conceptual work, driving the

design through to prototypes and

production.

- Multiple loops of topology and RDM

followed by topometry and sizing.

- Regularly used on production projects,

delivering significant mass, cost and time

savings.

19 www.penso.co.uk

Sensitivity studies: Which components / areas are critical for performance

metrics?

- RDM, Sizing and Topometry allow rapid identification of critical regions.

- Evaluation of performance ‘ceiling’ of current design, with incorporation of

manufacturing constraints – Max panel thickness, panel stack-ups, adhesive use.

- Removal of redundant mass.

- Tweaking of panels to eliminate NVH issues (Topography)


Design Refinement: Performance Improvement

Project

Feasibility

Concept

Definition

Virtual


20 www.penso.co.uk

Production ready design

Efficient structure that achieves all performance and mass targets.

Inherent manufacturability incorporated in the design.

Minimal amount of design loops, reducing project costs and time.

Tried and tested process that has been used on many production vehicles.


Key Phase Outcomes

Project

Feasibility

Concept

Definition

Virtual


21 www.penso.co.uk

Future Aspirations for Optimisation

Increased automation during laminate development process: reduction in

manual ply rationalisation. This could be achieved by adding topometry

parameters:

- Minimum ply area.

- Maximum number of disconnected regions.

- Maximum number of unique thicknesses per panel.

Robust, automated method for fixing placement and sizing.

Interface with design software.

Enhancing Efficiency and Creativity Moving Forwards

22 www.penso.co.uk

Summary

Optimisation is used extensively to drive design at all stages of the design

process at Penso.

Facilitate rapid characterisation of the project design space, allowing for

more accurate quotation.

Allows generation, evaluation and evolution of design concepts, progressing

from a package space to a mature design in the shortest possible time

frame.

Thanks to Martin, Oliver and the team for their continued support.

VRAND Genesis + GRM Plugins

23 www.penso.co.uk

Chris Morrow

Lead Engineer – Composites Group

[email protected]

Penso Consulting Ltd

Woodhams Road

Coventry

Warwickshire

CV3 4FX

United Kingdom

T: +44 (0)2476 217760

www.penso.co.uk

www.linkedin.com/company/penso

www.twitter.com/PensoGroup

Contact

mailto:[email protected]

Documents

Optimised Engineering Design at Penso Consulting · Spyker C8 Aileron complete vehicle engineering, interior trim and convertible roof system for Spyker derivative. 2010 ISO9001 and