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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
Brazil 134
São Paulo - Betim
Curitiba - Tatuí
China 201
Shanghai - Beijing
Changchun - Chongqing
Guangzhou - Liuzhou
Qingdao - Shenzhen
Zhaoyuan
Czech Republic 236
Hradec Králové - Brno
Liberec - Mlada Boleslav
Germany 129
Ingolstadt - Frankfurt
Munich - Stuttgart
Wolfsburg
India 168
Pune - Chennai
New Dehli
UK 45
Cambridge - Nuneaton
USA 30
Detroit - Los Angeles
Spain 1.411
Barcelona - Headquarters &
Main Technical Center
Granada - Madrid
Mojácar - Pamplona
Vigo
Total: 2.495 people
Branch offices 141 people
• Aichi
• Bangkok
• Bologna
• Brussels
• Erbusco
• Gothenburg
• Istanbul
• Jakarta
• Košice
• Kuala Lumpur
• Leini
• Lukang
• Nizhny Novgorod
• Paris
• Penang
• Poznan
• Pretoria
• Puebla
• Riyadh
• Seoul
• Togliatti
• Tokyo
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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