simulation process industrialisation - ipg automotive · 2018. 9. 18. · •standardised...

SIMULATION PROCESS INDUSTRIALISATION

Krzysztof Kowalski

Opel Automobile

Vehicle CAE

Karlsruhe, Apply & Innovate, 12 September 2018

Industrialisation of CarMaker suspension model parametrisation and validation process

AGENDA

1. Industrialisation context

2. Application scope

3. Process elements

4. Summary

3

INDUSTRIALISATION

Current simulation needs are same as industrialisation back then – efficiency

improvements, quality assurance, variant complexity handling, cost reduction

4

APPLICATION SCOPE

• Focus on MapNL CarMaker suspension model

5

Multi-Body Simulation SW

2D+2D1D+1D+1D

2D+1D1D+1D

MOTIVATION

6

• Model up-to-date, many variants, validated

• ECE R13-H, NCAP, Automated Driving

• Traceability of simulation results

• Validation of Automated Driving

• Digital twin

• Legal aspects

• Important to validate systems before moving to full vehicle validation

HIGH LEVEL VIEW

7

K&C test rig

MBS model

CarMaker

model

Evaluation

report

& compare

Parameter

golden

source

4-post test

rig

Parametrisation Validation

A

D

A

P

T

E

R

S

S

T

A

N

D

A

R

D

I

S

E

D

S

T

A

N

D

A

R

D

I

S

E

D

Kinematics,

Compliance

Vertical

Dynamics

Depart

ment 1

Depart

ment 2

Depart

ment n

GOLDEN SOURCE

Simulation engineer life now:

• Are the hard points still the same?

• Is the MBS model up-to-date?

• Is the mass variant chart up-to-date?

• Are the springs, dampers, bump-stops data

up-to-date?

• New data came but is in .pdf!

• New data came but is in different units

and coordinate system!

8

From: ‚simulation team handles all

vehicle data required‘ To: data is always available in one place, up-

to-date, in a standardised format that can

be accessed by external tools automatically

More efficient environment

• Central database, with meta data and

version control

• All involved teams (incl. non-simulation)

keep data up to date

• Automatic notification system exist for

subscribed database entries

• Data format is standardised (e.g. ASAM /

VDA 5550)

STANDARDS FOR DATA

Industrialisation by standardisation of data formats for:

• Component, system, vehicle data

• Controller calibration / model parameter data

• Measurement data (including big data)

Good examples include:

9

• ASAM ODS, CDF

• ASAM XIL-API

• ASAM MDF

• HDF5 (big data)

• Open CRG

• Open DRIVE

• Open SCENARIO

• FMU

HIGH LEVEL VIEW

10

K&C test rig

MBS model

CarMaker

model

Evaluation

report

& compare

Parameter

golden

source

4-post test

rig

Parametrisation Validation

A

D

A

P

T

E

R

S

S

T

A

N

D

A

R

D

I

S

E

D

S

T

A

N

D

A

R

D

I

S

E

D

Kinematics,

Compliance

Vertical

Dynamics

Depart

ment 1

Depart

ment 2

Depart

ment n

MBS SIMULATION

• High quality CarMaker simulation results (ECE R13-H, NCAP, AD) achieved

only from good MBS models, reliable conversion process and advanced

chassis models (CarMaker MapNL)

• MBS models should be up to date with prototype vehicles

11

COMPOSER

12

Control Systems

Model

Multi Body Simulation (MBS)

Axle Full vehicle

SiL

HiL

DiL

CarMaker

vehicle info files

Component

Database

ASCII

(CM-Info file)

Component Data

Measurements

Design Data

Component Models

CM-Models

Simulink Models

S-functions

c-Code

© fkfs.de

Ref: ,A Semi-Automated Approach of Composing Virtual Vehicles in Projects with Large Numbers

of Vehicle Variants, M. Borsdorf, Opel, Apply & Innovate 2016

HIGH LEVEL VIEW

13

K&C test rig

MBS model

CarMaker

model

Evaluation

report

& compare

Parameter

golden

source

4-post test

rig

Parametrisation Validation

A

D

A

P

T

E

R

S

S

T

A

N

D

A

R

D

I

S

E

D

S

T

A

N

D

A

R

D

I

S

E

D

Kinematics,

Compliance

Vertical

Dynamics

Depart

ment 1

Depart

ment 2

Depart

ment n

SUSPENSION PERFORMANCE METRICS

14

Output data conversion & filtering

Standardised Suspension Performance Characteristics Report

Suspension Performance Metrics

Evaluation Tool

SUSPENSION PERFORMANCE METRICS

15

HIGH LEVEL VIEW

16

K&C test rig

MBS model

CarMaker

model

Evaluation

report

& compare

Parameter

golden

source

4-post test

rig

Parametrisation Validation

A

D

A

P

T

E

R

S

S

T

A

N

D

A

R

D

I

S

E

D

S

T

A

N

D

A

R

D

I

S

E

D

Kinematics,

Compliance

Vertical

Dynamics

Depart

ment 1

Depart

ment 2

Depart

ment n

4-POST RIG SIMULATION

17

Ref: ‚ Validation Concept for Vertical Dynamic Vehicle

Characteristics‘, M. Viehof, H. Niemann, M. Kochem, H. Winner, 2017

HIGH LEVEL VIEW

18

K&C test rig

MBS model

CarMaker

model

Evaluation

report

& compare

Parameter

golden

source

4-post test

rig

Parametrisation Validation

A

D

A

P

T

E

R

S

S

T

A

N

D

A

R

D

I

S

E

D

S

T

A

N

D

A

R

D

I

S

E

D

Kinematics,

Compliance

Vertical

Dynamics

Depart

ment 1

Depart

ment 2

Depart

ment n

SUMMARY REPORT TO COMPARE

19

• Standardised:

• Chassis metrics & units

• Evaluation routines

• Standardised for:

• CarMaker

• MBS software

• Vehicle K&C rig

ROOM FOR MORE AUTOMATION

20

K&C test rig

MBS model

CarMaker

model

Evaluation

report

& compare

Parameter

golden

source

4-post test

rig

A

D

A

P

T

E

R

S

S

T

A

N

D

A

R

D

I

S

E

D

S

T

A

N

D

A

R

D

I

S

E

D

Report

Depart

ment X

TEAM WORK

• Standardised suspension metrics tool requires:

• CarMaker team, MBS team

• Vehicle K&C team

• Vehicle, management, simulation & programming skills

• ‚Industrialising simulation‘ requires change in the organisation

• Beyond ‚silo‘ mentality needed

• Storage systems, conventions and standards!

• Company-wide ‘system owners’ buy-in

21

SUMMARY

Ingredients for efficient & industrialised simulation process:

• CarMaker, MBS, K&C rig

• Committed & Experienced Teams

• Good tools with good interfaces (standards)

• Clear, documented & transparent process guidelines & RASIC

• Teams outside CAE ‚must go digital‘ and use central database

Simulation teams alone will not solve the challenge of ‚company digitalisation‘

Whole organisation must change

22

Industrialisation of CarMaker suspension model

parametrisation and validation process

THANK YOU