vi-grade case study - complete - rev02
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© by VI-grade. All rights reserved. 2007-2008
VI-gradeCase Studies
© by VI-grade. All rights reserved. 2007-2008
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Zielgenauigkeit
Eigenlenkverhalten
Gierstabilität
Grenzbereichsverhalten stationär
Grenzbereichsverhalten dynamisch
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- Base Version
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Zielgenauigkeit
Eigenlenkverhalten
Gierstabilität
Grenzbereichsverhalten stationär
Grenzbereichsverhalten dynamisch
Agilität
Lastwechsel
Kurvenbremsen
Wanken
Aufstützen (bei Kreisfahrt)
Nicken - Antirollbar13.5/9
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Zielgenauigkeit
Eigenlenkverhalten
Gierstabilität
Grenzbereichsverhalten stationär
Grenzbereichsverhalten dynamisch
Agilität
Lastwechsel
Kurvenbremsen
Wanken
Aufstützen (bei Kreisfahrt)
Nicken
- Antirollbar12/12
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Zielgenauigkeit
Eigenlenkverhalten
Gierstabilität
Grenzbereichsverhalten stationär
Grenzbereichsverhalten dynamisch
Agilität
Lastwechsel
Kurvenbremsen
Wanken
Aufstützen (bei Kreisfahrt)
Nicken
- CG 20mm up
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Zielgenauigkeit
Eigenlenkverhalten
Gierstabilität
Grenzbereichsverhalten stationär
Grenzbereichsverhalten dynamisch
Agilität
Lastwechsel
Kurvenbremsen
Wanken
Aufstützen (bei Kreisfahrt)
Nicken
- Tire 2450.2
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Case Study: Audi Achieve best ranking against competitors Ranking based on iso lane-change
manouver, real and virtual
Use VI-SportsCar to model high performance car
Derive simplified model from system identification for fast approximate results
Utilize special VI-grade routines for trajectory planning and cone hit detection
Tight integration of VI-Sportscar and modeFrontier to find optimal vehicle configuration
A simulation-based fast procedure was established to accelerate the development process
The ranking based on this procedure matches the ranking vs. on road evaluation, thus allowing enormous time saving from real testing
Challenge
Solution
Outcome
P8P7
P6P5P4
P3P2
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Opel Reduce cost and increase reliability of the
durability process Increase result quality by avoiding errors
related to manual file manipulation High number of maneuvers and vehicle
configurations require high degree of automation
VI-grade Service team developed a custom environment based on VI-SportsCar:
• Test rig for static load prediction• Standardized full vehicle dynamic events• Utilization of VI-Road for driver line prediction
virtual Road Load Data Acquisition (vRLDA) is now part of the GM vehicle development process
Post-processing tools for result checks, comparisons, automated plot and report generation embedded in the tool
Challenge
Solution
Outcome
Dynamic Load Prediction
Static Load Prediction
vRLDA
Data Maturity
Hardware build and test
Virtual Engineering
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Porsche Establish development process to assure
and improve comfort performance High fidelity component models are required
for accurate comfort and durability assessment
VI-grade’s Service team developed a custom drum testrig for cleat crossing to investigate steering wheel vibrations
VI-NeuralNetwork technology is used for high fidelity component models such as a damper
VI-SportsCar is first choice to capture transient behavior
Engineers at Porsche are now able to support their design teams utilizing solutions implemented by VI-grade
Improved bi-directional communication with test and design teams
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: ESTECO
Intensive use of simulation techniques for understanding dynamics, improving comfort and predicting vehicle road loads
Correlate the detailed and the simplified model simulation results
Use modeFrontier together with VI-grade products to better understand parameters influence on overall performances
The complexity of the virtual model makes it impossible to estimate parameters interactions with using traditional methods
Multisimulation technology strongly helps to drive the entire engineering activity to the final goal: improve vehicle performance
Successful collaboration between ESTECO and VI-grade
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Multimatic Provide Vehicle Dynamics simulation to motorsport
industry in a timely manner Provide accurate results Be able to run DOE campaigns in a reduced amount
of time
Use VI-SportsCar to model race cars Validate the model against telemetry data from Pi
system Use VI-CarRealTime to speed up simulation process
without losing accuracy
Very good correlation between VI-SportsCar model and telemetry data
Very good correlation between VI-SportsCar model and VI-CarRealTime model
6 times speed-up factor by switching toVI-CarRealTime model
Possibility to run sensitivity analyses to vary important parameters
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: NewmanHaasLanigan Racing Reliability: ensure cars are the most reliable (‘To
finish first, first you must finish’ - GT). Knowledge: study and understand the vehicle better
than any other competitor Optimize: armed with the best understanding,
configure the vehicle to best achieve our goals Efficiency: prepare and service the cars faster than
anyone else (office/shop/track/pit stops) Strategy: apply the smartest race-strategy
Use VI-SportsCar to gain knowledge on loads for durability assessment
Run battery of regression simulations to refine input data (see publication on virtual wheel force transducer)
Use validated models in VI-SportsCar to prepare the racecar
Eight-time Champ Car World Series Champions (’84,’91,’93,’02,’04-07*)
Rim
WFTHub
Slip-ring Spider Slip-ring /Cable
virtual wheel force transducer used to refine tire data
Challenge
Solution
Outcome
© by VI-grade. All rights reserved. 2007-2008
Case Study: Audi Sport AG In late 90’s Audi Sport decided to re-enter
Le Mans 24hours race.
Use VI-SportsCar to build Virtual Race Car + Track.
Use simulation for rapid design iteration to find best set-up
1999 : 3rd 2000 : 1st, 2nd, & 3rd
2001 : 1st & 2nd 2002 : 1st, 2nd, & 3rd 2003 : 1st, 2nd (Bentley) 2004 : 1st (private team) 2005 : 1st (private team)2006: 1st
2007: 1st
2008: 1st
Challenge
Solution
Outcome
“…procedures to optimize vertical dynamics, aerodynamic, mechanical setup and differential setup at the same time simulating a high dynamic kerb crossing have been investigated… simulation helps to understand how to improve performance of a complex race vehicle...“
--Dr. Martin MühlmeierVehicle DynamicsAUDI Sport AG Ingolstadt
© by VI-grade. All rights reserved. 2007-2008
Case Study: TREngineering Working in the motorsport competitions (A1GP, F3,
DTM) the heve to shorten development cycle while improving the over all performance.
Use VI-SportsCar to gain knowledge on how different subsystems asnd the entire full-vehicle work in all different race conditions
Perform several different type of analyses (suspension, 4post testrig, ADAMS/Insight, Aerolap, Close loop track simulations)
Top A1GP Team
Challenge
Solution
Outcome
trackrod adj.pushrod adj.
“Using different types of simulations available within VI-SportsCar, and combining them properly with in-house tools, it’s possible to determine and optimise vehicle performance”
-- Marcello Di FinaHead of Calculation Dept.
© by VI-grade. All rights reserved. 2007-2008
Case Study: Politecnico di Torino
Model Three Tilting Wheels (TTW) Vehicles and understand their stability and dynamic behaviour
Validate model tests vs. experimental results Develop a design tool for TTW vehicles.
Use VI-Motorcycle to model the TTW vehicle Take into account frame flexibility to capture correct
lateral dynamics Comparison between an equivalent 2-wheels vehicle
and TTW Sensitivity studies for stability
Very good correlation with test results Possibility to use VI-Motorcycle to predict TTW
behaviour
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: APPH (part of BBA Aviation Group)
High quality supplier for complete landing gear system for civil, military, regional aircrafts and helicopters
Develop a complex design process that involves several different disciplines: CAD, FEM, MBS and physical testing
Use VI-Aircraft to model the landing gear subsystem and, taking into account:
• Structural flexibility
• Non-linear force components
• Stick-slip friction
• Hydraulic systems
• Tyre effects
Virtual approach allows to run multiple analyses in a reduced amount of time
Possibility to understand the influence of every parameters
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: FIREMA Reduction of time to market for new rolling stock
leads to shorter design time Increase confidence in design Front load the design cycle for virtual homologation
VI-Rail is used for many standard analysis:• Modal• Stability• Comfort• Lateral Dynamics• Souplesse• Security vs. derailment
VI-Rail is used for advanced analysis:• Dead end impact• Dynamic cornering for clearance and buffer studies• Wheel set/bogie dynamics
VI-Rail is used to simulate a wide range of events, not only vehicle dynamics applications
Upfront analysis drives design decisions at Firema and leads to changes of vehicle parameters
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: MMU Develop tools and methods to investigate innovative
new slab track designs for the European INNOTRACK project
• Pan-European project bringing IM and industry suppliers together
• Aiming at doubling passenger traffic & triple freight while reducing LCC by 30%
VI-grade and MMU engineers jointly developed a new Flexible Track System Model embedded inVI-Rail
The model combines a wheel rail contact algorithm with a beam or flexible body track model
Special flextrack post-processing GUI for stress calculation
Automatic track generation GUI allows for fast creation of new designs including support conditions
Easy-to-use set of tools in VI-Rail is used for the European INNOTRACK project by MMU and Corus
Challenge
Solution
Outcome
Max +σ (between bogie axles)
Max -σ (under axles)
Δ
σ
∆φ
PAD
FASTENING
Effect of Rail Roll on:
•Contact location
•Contact patch
•Number of contacts
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Reduce cost and time to market Gain and demonstrate engineering
competence to clients Confidence in design decisions for best
possible running behavior
VI-Rail is used to study the influence of several key design features of low-floor trams on the wheel profile wear
Design variations and concepts for:• Pivoting and non-pivoting bogies• Grooved and non-grooved rails• Wheels sets and independent wheels
Running dynamics event it is possible to determine wheel wear and to compare the influence of the different design parameters
VUKV is able to improve existing designs and to create new designs quickly with high confidence utilizing the simulation capabilities of VI-Rail
Challenge
Solution
Outcome
Front Outer-Curve-Side Wheel
0.00E+00
2.00E+04
4.00E+04
6.00E+04
8.00E+04
1.00E+05
1.20E+05
Wea
r In
dex
[N
.m]
Front Inner-Curve-Side Wheel
0.00E+00
2.00E+04
4.00E+04
6.00E+04
8.00E+04
1.00E+05
1.20E+05
Wea
r In
dex
[N
.m]
Rear Outer-Curve-Side Wheel
0.00E+00
2.00E+04
4.00E+04
6.00E+04
8.00E+04
1.00E+05
1.20E+05
Wea
r In
dex
[N
.m]
Rear Inner-Curve-Side Wheel
0.00E+00
2.00E+04
4.00E+04
6.00E+04
8.00E+04
1.00E+05
1.20E+05
Wea
r In
dex
[N
.m]
Simulations – results, profile wear
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© by VI-grade. All rights reserved. 2007-2008
Case Study: xxx
xxx
xx
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Aprilia Racing Searching for Max performance of a
racing bike• Reduce lap time• Increase maneuverability
Reduce simulation time
Use VI-BikeRealTime together with MATLAB and modeFrontier.
Simulation time reduced by 90% Reliable results
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: KTM Load prediction for durability
analysis Co-simulate control systems (ABS) Handling and Stability analysis
Use VI-Motorcycle to model the entire system including virtual testrig and virtual roads.
Analyze the model in all different working conditions
Co-simulate VI-Motorcycle and MATLAB Simulink
Precise identification of hot spots for life prediction.
Detailed ABS modeling
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Piaggio Develop a new scooter with a
revolutionary configuration (MP3) Make an extensive usage of
numerical simulations in order to anticipate problems
Use VI-Motorcycle to model the new vehicle and to run several different tests.
VI-Motorcycle results have been compared with experimental results
Good agreement between VI-Motorcycle and experimental results.
Simulation had an important role in the MP3 design process.
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Ducati Replicate a track event on a virtual
environment Investigate the influence of suspensions
and steering damping on motorcycle stability under acceleration
Use VI-Motorcycle to model the bike, the circuit and the rider.
Verify the importance of taking into account grip loss.
Investigate the influence of steering and suspension damping for the motorcycle stability.
Easy to perfom sensitivity studies because of the fully parametric model in VI-Motorcycle
Seamless integration between VI-Motorcycle and MATLAB Simulink
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Ducati Corse Be the fastest motoGP racing bike
Use VI-Motorcycle and VI-Rider to investigate complex transient dynamics
Sensitivity studies for stability
Very good correlation with test results Virtual model used to understand reality and test
alternatives quickly Real-time model used as support tool for track
engineer
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: NewmanHaasLanigan Racing
Ride optimization with 2 major objectives:• Modal control of sprung/unsgrung mass
systems• Aerodynamic Platform control
Solve conflicts between objectives requiring softer springs and others requiring harder springs.
Find an alternative to rig testing Define a method to model PSD
irregularities from measured elevation Use VI-Road to model roads with PSD
disturbances Perform VI-CarRealTime analyses on
different circuits
Eight-time Champ Car World Series Champions (’84,’91,’93,’02,’04-07*)
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: ABARTH Develop simulation methodologies for
improving performance of a rally car
Use VI-SportsCar to gain knowledge on how different subsystems and the entire full-vehicle work in all different race conditions
Use VI-CarRealTime to run fast simulations and explore several different design variables
Perform several different type of analyses with 2WD and 4WD full vehicle models for best tuning (suspensions, engine, driveline, etc.)
Top Tourism Sport and Rally Car Manufacturer
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: MIRA Development of a retro-fit hybrid
conversion which slashes fuel costs & lowers tailpipe emissions whilst retaining performance
To use VI-CarRealTime in order to have a fast and reliable vehicle model to connect with the control systems developed in the MATLAB/Simulink environment, and demonstrate novel vehicle dynamics features by using the rear mounted electric motors for All-Wheel-Drive (eAWD) and torque vectoring (eTV).
Advanced control system for vehicle dynamics developed and tested virtually
Challenge
Solution
Outcome
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© by VI-grade. All rights reserved. 2007-2008
Case Study: Italdesign Giugiaro Develop an high performance hybrid
vehicle Being able to predict max performances
given by electric propulsion
To use VI-CarRealTime in order to model vehicle and to simulate max perfomance on Monza Track
Namir prototype has been set up with VI-CarRealTime in a such a way to accomplish performances similar to a GT car
Challenge
Solution
Outcome
© by VI-grade. All rights reserved. 2007-2008
Case Study: Audi Integrate VI-CarRealTime in the
Chassis Simulation Environment Being able to simulate interactions
between different control systems
To use VI-CarRealTime in conjunction with Adams/Car and Matlab.
The model gets created from Adams/Car
VI-CarRealTime model includes control systems modeled in MATLAB Simulink
Very good correlation between Adams model and VI-CarRealTime model
Design of control algorithms supported by VI-CarRealTime
Streamlined Chassis Simulation environment
Challenge
Solution
Outcome
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Active DifferentialAudi Dynamic SteeringSemi-active DamperAirspringPowertrain controlESP incl. ABS, EBV, ASR, MSR
© by VI-grade. All rights reserved. 2007-2008
Case Study: Lockheed Martin Assess safe release of weapons (and
stores) for JSF multi-role fighter through a simulation procedure that will provide the basis for store certification
Use of a custom VI-AirCraft environment to compute store trajectories at the various conditions in the aircraft flight envelope
Model included aircraft structural responses and other physical models to obtain the most flight representative store trajectory
Model included pre-flight uncertainty analysis with MonteCarlo methods
Higher fidelity models Fewer required flight tests Program cost savings
Challenge
Solution
Outcome
© by VI-grade. All rights reserved. 2007-2008
Case Study: Alenia Aeronautica Realize a fully integrated procedure for
CAE aerospace simulation Improve efficiency of computational
process
Development of an integrated environment based on VI-AirCraft and MSC SimXpert for calculation of ground external loads according to aviation regulations and/or company policy and to pinpoint the critical conditions for sizing purpose
Coupling of VI-Aircraft with Nastran
Ability to perform comparative studies between flexible and rigid aircraft in order to evaluate the hypothesis of the flexibility and/or rigidity on the external loads prediction
More efficient simulation process
Challenge
Solution
Outcome
© by VI-grade. All rights reserved. 2007-2008
Case Study: British Aerospace Perform landing gear loads analysis of
the Short Take-Off and Vertical Landing (STOVL) variant of the F-35:
• Design an optimized ski-jump ramp profile • Develop the Shipborne Rolling Vertical
Landing (SRVL) maneuver
VI-Aircraft used to produce the loads used as primary design driver to optimize the ramp profile
VI-Aircraft used to forecast the effects on aircraft operations due to build and in-service variations from the nominal design profile
VI-Aircraft proved to be critical to the integration of the F-35B onto the UK CVF through;
• Providing data to drive decisions on an optimized ski jump ramp profile,
• Fixing take-off performance
Challenge
Solution
Outcome
© by VI-grade. All rights reserved. 2007-2008
Case Study: Lockheed Martin Correlate laboratory drop testing with
analysis predictions, with the purpose of :
• Qualifying the gear• Verifying and refining the model
VI-grade Landing Gear Drop Testrig corresponding to SAE 6053
Landing Gear Drop Test Assembly Validated subsystems used in full
airplane assembly
Very good correlation with test data Significant features uncovered by
correlation:• Freeplay• Tire friction modeling• Variable discharge coefficient• Airspring modeling
Challenge
Solution
Outcome