simulation data management – an integration of database and pre-processor

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering

European Altair Technology Conference

Turin, April 22nd – 24th 2013

Simulation Data Management –

an Integration of Database and Pre-processor

Cong Wang

Scott Larsen

Thorsten Pohl

General Motors Engineering

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



1) Challenges for CAE

2) Data Management Strategy

3) System Development Strategy

4) Pre-Processor Integration

5) Conclusions

Overview

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Challenges for CAE

Increasing number of vehicle variants

Large increase of number of models and

results

Increasing number of Loadcases

US NCAP

China NCAP

PedPro Comfort • N&V

• Ride

…

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Challenges for CAE

Strategy to share parts and components to leverage economics of scale

Base Vehicle

Re-use of parts Re-use of CAE Models

as complex as the part share strategy itself

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Challenges for CAE

Reduced development time

Documentation required of CAE- Data Input

Models

Results

Reduction / elimination

of hardware prototypes

Quick response to trends

Fast to Market

Analytical design validation

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Challenges for CAE

PLM System

Lists

?

?

?

One Way

These challenges are too complex to handle on traditional share drives

CAE workstation

CAE share drive

CAE workstation

CAE share drive

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



SDM System

PLM System

Lists

Data Management Strategy

Simulation Data

Management System

required

Closely liked to

PLM (CAD) System

Open to link other

data sources

Bi-directional Integrated

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Selection of System for Simulation Data Management

Key Requirements A B C D E

Revision and Release Yes - Limited Yes - Limited Yes Yes - Limited Yes

Links to CAD No No Yes No Yes

CAE Data Query Yes – Limited Yes - Limited Yes Yes Yes - Limited

CAE Project Management Yes - Limited Yes - Limited Yes Yes - Limited No

External Application Integration Yes No Yes - Limited No Yes - Limited

Link to Requirements & Targets No No No No Yes

Job Submission Yes - Limited No Yes - Limited Yes - Limited Yes - Limited

(Example)

Initial pre-selection showed the most promising partner

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Teamcenter Items, Item Revisions and Datasets

CAD assembly structure

Item

Item Revision / 001

Dataset (.hm) Dataset (.jt)

Item Revision / 002

Dataset (.hm) Dataset (.jt)

New data status

CAE assembly structure

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Links show the relation between CAD items and CAE items

CAD – Structure NX and JT

Part 1

CAD Master

Assembly 1

Part 2

Assembly 11

Assembly 12

Part 3

Sub-assembly 1

Assembly 2

Part 4

Part 5

NX JT

NX JT

NX JT

NX JT

NX JT

Link between CAD and CAE

CAE Structure Pre-processor + Solver formats

Structure Map

CAE item Part 1

CAE Master

CAE Assembly 1

CAE item Part 2

CAE Assembly 11

CAE Assembly 12

CAE item Part 3

CAE Sub-assembly 1

CAE Assembly 2

CAE item Part 4

CAE item Part 5

Hypermesh / Ansa monolithic Dyna monolithic Nastran monolithic

Hypermesh / Ansa monolithic

Hypermesh / Ansa part





Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Properties of CAE data are stored as attributes of the CAE Item Revision

These attributes are the master for all subsequent processes and tools

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Teamcenter

© Siemens, Altair, EATC 2011

Launch: export

Launch: open in HM,

Run tools

Etc.

Save Re-import

Communication between TC and CAE tools via PLMXML format

Allows CAE tool maintenance cycles to be independent from rigid and formal PLM/CAD

process

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




GM engineering site

Introduction of a data management system will change the workflows

and behaviour for all CAE engineers in the global organisation

Good training will be required

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Traditional IT development:

System Development Strategy

Requirements

document IT Development &

Solution Testing and

Implementatio

n

Strategy ??

Strategy Use Cases Initial IT

Development Testing Implementatio

n

Iterations and constant

Feedback Loops

Agile Development: project divided into manageable phases, feedback loops

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



System Development Strategy

Phase 1 Phase 2 Phase 3 Phase 4

Agile Development: each phase containing iterative approach

Close link between IT and User community,

close involvement of users required

Tailored Tools addressing the Real needs

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Pre-Processor Integration

New feature in Hypermesh – Assembly browser tab:

Read in assembly structure as in .plmxml

Import CAD data or existing Hypermesh files

Attributes (e.g. PID, thickness, material, MID, …)

taken from .plmxml file, not from inside CAD data file

=> new hierarchy of information

Export of meshes on part level (i.e. several HM files)

Write new .plmxml file (for import into TC)

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Single Part Meshes Monolithic Mesh Models

HM file containing Part Mesh

HM file containing all parts of the assembly

Why?

• Certain mesh modification (e.g. removal of penetrations)

might not be good to give to ‘clean’ part mesh

• Some connections (rigids, bars) might share nodes of the part

meshes => where to store these?

Vision: work on part level meshes only, and generate connections

and

full model in solver format ‘on the fly’ for job submission only

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Generation of new generic workflows for CAE model builds

More work done in SDM-System (TC) to prepare work in the pre-processor

Detailed description for the user required

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Hypermesh Integration Strategy

Background:

1. In tandem with a top-down implementation in CAE model quality and organization standards

2. Emphasis on batch/automatic operations to take burden out of users

3. Joint development among Altair, Siemens PLM, GM CAE SMEs, and GM IT

4. Full GM IT support for rapid prototype and deployment (as compared to more rigid production CAD

PDM process)

5. Be sensitive to the strengths and gaps in end users’ skill sets

Specifics to HM4SDM:

1. Set a realistic expectation that

HM4SDM is a new development not yet always aligned with progression in other key HM core

functionality

Must keep doors open to apply non-TC integrated HM functionality and other ‘tried-and-true’ 3rd

parity tools to complete required CAE modelling tasks

2. Develop HM4SDM mainly as an integration layer, instead of a TC-encapsulated vertical application

3. Interim solution to bridge the gaps in assembly/instance hierarchy between TC/CAD and HM core

4. Added the WIP-parking capability as protection to guard again undesired loss of HM session

5. Must conduct more proactive QA of HM4SDM deployment candidates

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Issues in Hypermesh development and resolution strategy

To obtain quick common understanding of issues and agreed direction:

weekly telephone conference between Altair and GM (IT and user community)

Example: Naming Convention

Original proposal for part and module naming by Altair / Siemens

Feedback from GM users: more description required

New proposal from Altair, plus question on strategy of multi-instance parts

Direction from GM on multi-instance parts

Implementation by Altair, included in a new version

Installation of new version at GM sites

Test and Approval by GM

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering




Further / required enhancements

Align development of HM-4-TC with core functionality development

Formalize functionality to expose, isolate and resolve discrepancy between

Hypermesh FE properties and Teamcenter item attributes

Rapid part / sub-assembly replacement capability in assembled monolithic

model

Capability to initialize creation of Teamcenter CAE modules from inside

Hypermesh with proper relations

Address gaps in assembly and instance hierarchy between Teamcenter CAE

and Hypermesh core

Priorities will be given depending on the feedback of the initial productive use

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Conclusions

Simulation Data Management required to address future challenges

for CAE

Close integration of SDM system and CAE tools needed

An Agile IT Development Strategy will give the users a system

addressing their needs

Close involvement of experts from the user community is required

A cross-functional core team must guide the development

A successful productive use is possible within a

reasonable timeframe

Cong Wang

Scott Larsen

Thorsten Pohl

GM Engineering



Thank you for your attention

simulation data management – an integration of database and pre-processor

Technology

cae strategy

limited cae project

cae data query

limited link

cae data input models

cae plm system lists

share strategy

system development strategy