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Automotive

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SIMPACK Usage in Automotive Industry

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2 SIMPACK GmbH, a Dassault Systèmes Company All rights reserved.

SIMPACKTechnology (Solver)

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SIMPACK Usage in Automotive IndustrySolver - Analysis Methods

NonlinearSIMPACK

Model

Linearization

Linear SystemAnalysis

• Frequency Response

• System Response

• Power Response

Eigenvalues

• Eigenfrequencies• Eigenmodes• Modal energies

State-Space-Matrices Export

• Matrices export in Matlab format

Time DomainAnalysis

• Operational Deflection Shapes (ODS)

• NLFP• Order Analysis

(Run-up/ Frequency sweep)


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SIMPACK Usage in Automotive IndustrySolver Efficiency + Accuracy + Stability

Solver Fast, accurate, robust, versatile

Flexible body integration

Drivetrain applications

High frequency analysis

Almost zero numerical damping

Multi-core support

Real-time


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SIMPACKTechnology

(GUI+ Data Structure)

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General Purpose MBS Expert User GUI--> SIMPACK “PRE”

General purpose model setup for expert users based on MBS Elements, e.g. Bodies, Joints, Sensors, etc.Can be used for all kind of MBS tasks(incl. GUI + solver scripting)

Vertical Application GUI--> SIMPACK “Wizard”

Based on application specific standard model databases designed for non MBS expert standard users. Databases can be created and modified using SIMPACK PRE--> easy and efficient customization

“PRE” and “WIZARD”


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3D/2D Model View

Toolbars

Model Tree

Message Log

“PRE” - General Purpose MBS Expert User Model Set-up

SIMPACK PRE Graphical User Interface:

View Control



3D View:


2D View:

“PRE” - General Purpose MBS Expert User Model Set-up

SIMPACK PRE: 3D-2D-Tree GUI based, automatable (script based) model setup:


Analysis Scenario

Component Models

Load Case

Sub Model(s)

Data Structure - Substructures

Multiple hierarchy levels of substructures, e.g. complete vehicle

Main Model



Analysis Scenario

Main Model Load Case

Sub Model(s)

Component Models

Data Structure - Substructures

Multiple hierarchy levels of substructure, e.g. complete engine:


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SIMPACK Usage in Automotive IndustryElaborated Flexible Body Integration

Easy and sophisticated integration of flexible bodies:


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flex driveline shafts leaf springs suspension arms/wheel carriers/axles

valvetrain components chain guidespiston and conrod

Elaborated Flexible Body Integration

e.g. Chassis/driveline/engine components:


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…. applicable to all kind of SIMPACK applications

Completely new “WIZARD” GUI Concept

SIMPACK WIZARD ?

Completely new SIMPACK 9 easy to use GUI mode option designed for non MBS expert usersin order to perform customer specific standardizedMBS tasks.


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COMPONENTS(SIMPACK WIZARD Database) MODEL

LOADCASE

SCENARIO RESULTS

“WIZARD” - Vertical Application GUI for Standard MBS Use Cases

SIMPACK WIZARD: Vertical Application GUI for Standard MBS Use Cases

Based on a WIZARD DATABASE the SIMPACK WIZARD GUI enablesa non SIMPACK MBS expert “STANDARD” USER to:

- Configure and parameterize standardized MODELS- Configure and parameterize standardized LOADCASES- Create and run SCENARIOS (= MODEL + LOADCASE)- Review according standard RESULTS


SIMPACK Usage in Automotive Industry“POST”

SIMPACK Post: general and automatable (script based) MBS result postprocessing--> 3D animations, (moved marker) 2D plots, 3D Plots, tables, …


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SIMPACKApplication Examples

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Vehicle Oscillations

Low

High

Large

Small

Amplitude

Quasi-

Statics

(e.g. suspensio

n kinematic

s and elasto-

kinematics)

Secondary Ride

(e.g. mainly rigid oscillations of engine, trans-

mission, driveline,

subframes ...)

Comfort, NVH

(e.g. flex. vibrations

of engine, transmissio

n, driveline,

subframes, steering, exhaust system,

seat rail,....

Dynamic Loads,

Durability

Primary Ride

(e.g. oscillations

of suspension components

)

Handling

(e.g. g loba

l chass

ismoveme

nt)

Frequency

Acoustics(e.g.

engine block, chain drive,

brakes, hydraulics, ...)

Plastic Deformation, Abuse, Crash


Amplitudes and Frequencies Covered by SIMPACK MBS Technology


Engine and Gearbox Block

Gear Drive

Clutch and Flywheel

Drive Line

Internal EngineDynamics

ExhaustSystem

Engine andGearbox Block

Suspension Design

Chassis Dynamics

Steering System


Overview www.pro-sim.com



Engine Mount Variant 1Engine Mount Variant 2


Engine Mount Optimisation:

- Vehicle Model incl. flex. Chassis and Dynamic Bushing Element

- Hydropuls Testrig with FrequencySweep Excitation

- Engine (Hydro) MountCharacteristics Optimisation


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Engine/Gearbox Acustics(acustic SIMPACK postprocessing of coupled simulation results)

Complete Subsystem

ExcitationDynamics

assembly behaviour

modal participationfactors

--> surface velocities (FEM or MBS)

sound power level(BEM Acoustics)



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Gear DriveGear Drive

Clutch and Flywheel

Drive Line


ExhaustSystem


Suspension Design

Chassis Dynamics

Steering System


Overviewwww.pro-sim.com



0

0

0

No Gear Rattle Condition:


Gear Rattle:Rattle Condition:

Gear Drivewww.pro-sim.com


SIMPACK Usage in Automotive IndustryGear Drive

Gear Whine:

Modulation effect due to out of plane running of one part of a gear pair


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SIMPACK Usage in Automotive IndustryGear Drive

Simulation Methods for NVH-Development of a Double Clutch Transmission Gearbox (Daimler, SIMPACK User Meeting 2014)


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Drive LineDrive LineGear Drive

Clutch and Flywheel


ExhaustSystem


Suspension Design

Chassis Dynamics

Steering System




SIMPACK Usage in Automotive IndustryDrive Line

Driveline Run Up Resonance Analysis and Optimisation: Light Truck Example


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Driveline Investigations at Mercedes Benz (Daimler, SIMPACK User Meeting 2011)


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Complete Vehicle Gear Shifting with Human Body Model (Biomotion)


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Chassis DynamicsChassisDynamics

Gear Drive

Clutch and Flywheel

Drive Line


ExhaustSystem


Suspension Design

Steering System




SIMPACK Usage in Automotive IndustryChassis Dynamics

General Handling Dynamics (Open Loop, Closed Loop, Controlled Systems, HIL/SIL …)

- Compelte Vehicle Models including flex. componets (chassis, frame, wheel carrier …)

- Various Handling Tyre Models

-> All kind of Handling Dynamics Application


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Complete Vehicle Simulation on Testrig using Measured Road Excitation

- Vehicle Model incl. flex. Components and Dynamic Bushing Element

- Measured Road Excitation or SinusSweep Signals

--> Ride and NVH Optimisation Load Data Calculation

- rigid- flexible


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Simplifying a Chassis Test Bench by Virtual Iteration of Structural Strains with SIMPACK (Daimler, SIMPACK User Meeting 2011)


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- Vehicle Model incl. flex. Components and Dynamic Bushing Element

- Deterministic Single Road Obstacles and Comfort Tire Model

--> Ride and NVH Optimisation,Load Data Calculation

Chassis Dynamics

Complete Vehicle Simulation on Deterministic Road (Single Bump/Pothole)


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Estimation of Reliable Design Loads During Extreme Strength and DurabilityEvents at Jaguar Land Rover (Jaguar Land Rover, SIMPACK User Meeting 2011)


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Internal EngineDynamicsInternal Engine Dynamics

Gear Drive

Clutch and Flywheel

Drive LineExhaustSystem


Suspension Design

Chassis Dynamics

Steering System





- …

SIMPACK Valve Train Simulation:- valve longitudinal and lateral dynamics- contact forces/contact loss, hla and valve spring analysis- forces/stress/durability of all valve train components- complete valve train - camshaft torsional/bending behaviour- camshaft bearing design (EHD)- stress analysis and durability prediction


Internal Engine Dynamicswww.pro-sim.com



SIMPACK Crank Train Simulation:- crankshaft/flywheel/damper torsional design- crankshaft/flywheel/damper bending analysis- crankshaft bearing forces and design (EHD)- connecting rod bearing forces and design (EHD)- stress analysis and durability prediction

- …

Internal Engine Dynamics


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SIMPACK Usage in Automotive IndustryInternal Engine Dynamics

SIMPACK Chain Drive:

- avoiding and optimisation of resonances- dynamic loads and stress/durability calculation- friction optimisation- acoustics prediction

- …


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SIMPACK Belt Drive:

- avoiding and optimisation of resonances- dynamic loads and slip behaviour

- …


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SIMPACK Gear Drive:

- avoiding and optimisation of resonances- dynamic loads calculation- gear rattle and whine

- …


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Application of SIMPACK for Simulating Valve Trains and Timing Mechanisms at Mercedes- Benz Automotive Engines (Daimler, SIMPACK User Meeting 2006)


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Gear Drive

Clutch and Flywheel

Drive Line


Isolated or Dynamically Coupled Effects up to High Frequency NVH

ExhaustSystem


Suspension Design

Chassis Dynamics

Steering System





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