presentación de powerpoint - simpack.com filedefine a different simulation mbs code (simpack),...

SIMPACK Usage for Handling, Comfort and Durability simulations on virtual Proving Ground

October 2018

Ivan Mula Vivero – Project Manager, Chassis Simulation (Vehicle Dynamics)

Content

01_ BACKGROUND

02_ OBJECTIVES

03_ ACTIVITIES

04_ RESULTS

05_ CONCLUSIONS

06_ FUTURE WORK

Content

01_ BACKGROUND 02_ OBJECTIVES

03_ ACTIVITIES

04_ RESULTS

05_ CONCLUSIONS

06_ FUTURE WORK

Applus IDIADA: Who we are and what we do

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Main Technical Center

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• Aichi

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Applus IDIADA is an engineering partner to the automotive industry providing complete solutions for product development

projects worldwide. International presence (as of 10th July, 2018)

Main Centres for Engineering, Testing and Homologation

Applus IDIADA: Who we are and what we do SUSPENSION AND VEHICLE DYNAMICS TEAM

Multi-disciplinary international team supporting customers in the development and validation of the Vehicle Dynamics performance.

Tyre testing

& modelling

Chassis

Test rigs

Subjective

tuning &

evaluation

R&H objective

testing

Suspension

Design

VD CAE

Development

Concept Prototype Series

Vehicle dynamics simulation

Chassis functional development

Suspension design support

15+ YEARS OF EXPERIENCE

Background

Vehicle Dynamics Ride / Comfort simulations:

IDIADA has gathered significant experience in the field of handling, comfort and

durability simulations in Virtual Proving Ground (VPG).

Require a HiFi MBS model including:

• Flexible bodies

• Ride tire models (e.g. FTire, CD-Tire)

• Dynamics properties of rubber elements

(e.g. bushes, engine mounts)

• Friction modelling (e.g. Ball joints, steering

column and rack)

• High Resolution road (e.g. CRG road)

Background

Main problem:

Simulation time is too high! • Best scenario: x150 real time

• Worst scenario: x600 real time

Key factors for this performance:

• Number of DoF is very high due to Flexible bodies.

• Model stability is low due to high dynamics states.

• Definition of solver settings (tolerances, step size, etc.).

• Complex dynamic components and frequency dependent

elements.

• Driver model struggle to follow a path in the uneven road.

Durability cycle: 5 km

25 hours

Comfort tracks: 2 km

10 hours

Content

01_ BACKGROUND

02_ OBJECTIVES 03_ ACTIVITIES

04_ RESULTS

05_ CONCLUSIONS

06_ FUTURE WORK

Objectives

Define a different simulation MBS code (SIMPACK),

potentially better for VPG simulations:

Same level of correlation as current IDIADA´s MBS code.

Reduced simulation times.

Potential advantages of SIMPACK:

• Many OEMs are using SIMPACK already.

• New OEMs are open to adopt new solutions if they are more efficient.

• Friendliness of the GUI and Wizard environment.

• More structured and customizable single Database concept.

• Faster and more stable solver.

• Efficient to run complex DOEs or automatic optimization.

• More appropriate for development of active systems in SiL / MiL.

• RealTime capable solver available.

• Potentially ready to be use in a full-scale Driving Simulator.

Content

01_ BACKGROUND

02_ OBJECTIVES

03_ ACTIVITIES 04_ RESULTS

05_ CONCLUSIONS

06_ FUTURE WORK

Activities

A project is structured to evaluate this

new simulation setup, based in 3 main

activities:

1 engineer with

Simpack expertise

1 Simpack demo

license 1 validated

MBS model

Simulation model build

(Generate corresponding Simpack model

and validate it using the same tyres)

Analysis of results

• Effort required for model generation

• Effort required to set up each simulation scenario

• Level of correlation with respect to the validated MBS model.

• Simulation stability

• Simulation times

SIMPACK database development

(Generate missing info from an already

validated MBS model)

Project requirements:

Activity 1: SIMPACK database development

Simulation model build

SIMPACK database development Generation into the SIMPACK automotive

database of all the missing information

needed to model the validated MBS model

SIMPACK Wizard

Development of templates for SIMPACK Wizard interface:

• Validated MBS vehicle model

• Validated MBS loadcases / scenarios

Components Submodels

Model

Loadcase

Scenario

Activity 1: SIMPACK database development

Simulation model build

SIMPACK database development

Templates developed for the vehicle model to be correlated:

SIMPACK

Wizard

Validated

MBS model

Damper Strut

for

McPherson

Steering non-linear friction and compliance elements

Flexible Control blade attachments

Complete EPAS

system (CEPAS /

REPAS)

Activity 1: SIMPACK database development

Simulation model build

SIMPACK database development

Templates developed for the loadcases to be correlate with validated MBS scenarios:

SIMPACK

Wizard

Validated MBS

scenario

Full KnC LC Handling SDNA Open Loop LC

(custom profiles for Steering / Velocity)

Ride / Durability LC

(custom profiles *.crg/*.rdf)

Activity 2: Simulation model build

Simulation model build

Analysis of results

Generate SIMPACK

model in Wizard

using validated data

Set the same conditions for the scenarios

Run simulations

Content

01_ BACKGROUND

02_ OBJECTIVES

03_ ACTIVITIES

04_ RESULTS 05_ CONCLUSIONS

06_ FUTURE WORK

Activity 3: Analysis of results

• Effort required for model generation

• Effort required to set up each simulation scenario

• Level of correlation with respect to the validated MBS model

• Simulation stability

• Simulation times

Once the templates are created, the effort required for model generation and simulation scenario setup is

similar in both softwares, but SIMPACK Wizard seems more organized and structured for non-expert

MBS users and the GUI is more friendly to use with customized comments and documentation pages.

Easy to use GUI for SIMPACK Wizard

Structured organization is more clear in SIMPACK

Custom comments and documentation

Activity 3: Analysis of results

• Effort required for model generation

• Effort required to set up each simulation scenario

• Level of correlation with respect to the validated MBS model

• Simulation stability

• Simulation times

The level of correlation between both models was satisfactory, showing a close match in the results from KnC

FRONT AXLE REAR AXLE

Activity 3: Analysis of results

• Effort required for model generation

• Effort required to set up each simulation scenario

• Level of correlation with respect to the validated MBS model

• Simulation stability

• Simulation times

Ride / Comfort and Durability simulations were used to compare simulation times and stability, in this case,

the correlation was accurate enough with respect to the validated MBS model and the SIMPACK model.

Activity 3: Analysis of results

• Effort required for model generation

• Effort required to set up each simulation scenario

• Level of correlation with respect to the validated MBS model

• Simulation stability

• Simulation times

Solver times comparison (2 CPU´s threads): ** SIMPACK was not able to solve a 120mm KERB using FTire.

RealTime factors (Elapsed Time) SIMPACK Other MBS code

U_Shape (Ftire) x106 x147

Badly Maintain Road (Ftire) x76 x154

Belgian blocks (Ftire) x90 *N/A

Kerb strike 100mm (Ftire) x86 x109

Kerb strike 120mm (Ftire) **N/A x112

Kerb strike 150mm (MF) x43 x88

* It was not possible to simulate PAVE on the other MBS code.

Results: Some remarks

o FTire mass was not removed from the “wheel” mass when running the simulation with this type of

tire in 110/210 components.

o It was not an option to run a non-rotating driveline, so the driveshafts were missing in SIMPACK.

o The last element of the “SIMBEAM ARB” was not modelled as “rigid massless” in SIMPACK.

o Aerodynamic forces for lift / downforce were missing in SIMPACK.

o Non-linearity stiffness of damper piston and rod guide was not modelled in SIMPACK.

o Non-linearity compliance of wheel hub bearing was not modelled in SIMPACK.

o For some KnC events, the equilibrium condition for the model was slightly different between the

validated MBS scenario and SIMPACK.

Some remarks have to be mention in the scope of this project:

• The time allocation was just enough for a basic correlation, leaving some elements to be modelled which

will improve the accuracy of the results:

• Also, due to this short time allocation, it was not possible to explore more solver settings for particular

loadcases in SIMPACK which leave some room for improvement. Also, it was not possible to study the

parallelization capability for both solvers.

Content

01_ BACKGROUND

02_ OBJECTIVES

03_ ACTIVITIES

04_ RESULTS

05_ CONCLUSIONS 06_ FUTURE WORK

Conclusions

• SIMPACK is highly customizable to the customer

and very powerful as long as high skill MBS engineers

are available to develop the automotive database.

• Its readiness for use is quite limited using the

“default” database in order to produce results since the

first day and it requires expert MBS engineers to make

it “ready for use”.

• Once the templates are created, the effort required for

model generation and simulation scenario setup is

similar in both softwares, but SIMPACK Wizard seems

more organized and structured for non-expert

users.

• SIMPACK GUI is more friendly to use with customized

comments and documentation pages, also the

SIMPACK Post-processor is easier to interact and

very powerful, make it more usable and effective for

the user.

Conclusions

• Accuracy of the results has to be fully correlated with

measurement data but it has been proven that it is at least at

the same level of accuracy as the other MBS code.

• SIMPACK is by average 60% faster to solve, ranging from

30% to more than 100% in some cases. Meaning a higher

efficiency for running complex simulations as Ride / Comfort

or Durability.

• SIMPACK solver stability seems higher than the other

MBS code, as it is able to solve very unstable models and it

only failed to solve one test due to FTire solver stability. The

solver from the other MBS code seems to struggle more if

the scenario is not perfectly set with the right initial

conditions.

• Finally, the availability of a RealTime solver in SIMPACK,

make it ideal for Driving Simulator applications, keeping the

high fidelity modelling of a MBS vehicle model and the

capacity of change parameters between tests easily.

Content

01_ BACKGROUND

02_ OBJECTIVES

03_ ACTIVITIES

04_ RESULTS

05_ CONCLUSIONS

06_ FUTURE WORK

Future work

Tyre models Tyre models are frequently limiting the simulation speed and also the stability of its

solver can compromise the results.

If SIMPACK can supply a CD-Tire / FTire Real Time (RT) capable version of the same

tyre model, it can be evaluated too.

SIMPACK Automotive Database Development of a comprehensive Automotive Database for customers, to be ready for

use with SIMPACK Wizard without the need of modifying the templates.

SIMPACK RealTime (RT) solver Study the robustness of the RT solver to be similar as the standard solver and evaluate

the performance of the RT model after simplifying some elements to reach a realtime

capability.

RT solver is a key feature for Driving Simulator and SiL / HiL applications.

Thank you for your kind attention

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