Conference Dynamic Simulation in Vehicle Engineering Realtime Simulation of Vehicles Containing Detailed Components

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Thomasine Lorena Robertson
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2 SIMPACK Introduction Agenda SIMPACK AG Company, History and Customers Focus of MBS (Multi-Body Simulation) Automotive Examples SIMPACK Realtime History Functionality Applications Conclusion Page 2

3 SIMPACK Worldwide SIMPACK UK Ltd. Leicester SIMPACK AG (Headquarters) Munich SIMPACK Japan K.K. Tokyo SIMPACK US Inc. Detroit Associates SIMPACK France S.A.S Lyon Partners Wind General Rail Automotive, Engine, Land machinery SIMPACK business growth in automotive and engine sector = 28% Page 3

4 Some SIMPACK History MAN Technology 2013 Jaguar Land Rover switches to SIMPACK for all MBS 2011 Ford starts using SIMPACK for Powertrain 2011 SIMPACK v9.0 release 2007 FVA chooses SIMPACK 2007 Vestas, Winergy, Hansen choose SIMPACK 2005 Daimler and BMW switch to SIMPACK Engine 2002 SIMPACK Rail became worldwide market leader 1996 BMW and Land Rover start using SIMPACK 1993 SIEMENS and Bosch start using SIMPACK 1993 INTEC (now SIMPACK AG) a DLR spin-off launches SIMPACK 1987 German Aerospace Research Centre (DLR) and MAN Technology start developing SIMPACK (more than 20 years prior MBS experience) Page 4

5 System Behavior Coupled Effects Single Pendulum Triple Pendulum Page 5

6 Focus of MBS System Behavior Coupled effects Internal and external excitations System behavior Page 6

7 Automotive Application 2003 Daimler SIMPACK User Meeting Presentation ( Page 7

Acceleration (m/s^2) Z displacement (m) Automotive Applications 2004 Land Rover / Jaguar Sine wave ridges Reduced recession to 500N/mm Complete vehicle simulation Ride / Passenger comfort Flexible

8 Acceleration (m/s^2) Z displacement (m) Automotive Applications 2004 Land Rover / Jaguar Sine wave ridges Reduced recession to 500N/mm Complete vehicle simulation Ride / Passenger comfort Flexible Chassis and Subframes Hydromounts X displacement (m) Seat rail Z Simpack Predicted CP1-4 TPA Measured Frequency (HZ) Model validation on 4 Post Test Rig SIMPACK User Meeting Presentation ( Page 8

9 Automotive Applications Final developed ride betters the original target by some margin. SIMPACK User Meeting Presentation ( Page 9

10 Interfaces and Versatility Realtime dspace Concurrent ETAS MathWorks xpc etc. Aerodynamics AeroDyn AeroModule Flex5 vsaero Flower Etc. CAD-Programs CATIA Pro/ENGINEER Optimisation ModeFrontier Engenious MATLAB Response Surface Modelling CACE-Programs MATLAB, Simulink AmeSim ItiSIM (SimulationX) FMI FEA / Durability ANSYS Nastran ABAQUS PERMAS FEMFAT FAT4FEM Page 10

template models Model Fidelity Attainable Goals DoF Other Solutions Look-up table model Basic component model Low frequency model testing

11 Realtime Model Fidelity SIMPACK Realtime Many other software solutions have limited Degrees-of-Freedom (DoF) SIMPACK enables more degrees of freedom with higher frequency dynamics Permits use of non-linear frequency dependent bushings and mounts Not restricted to predefined template models Model Fidelity Attainable Goals DoF Other Solutions Look-up table model Basic component model Low frequency model testing (static suspension) <20 High fidelity component model Model correlation up to high frequencies. Virtual component analysis and testing >100 Page 11

12 Realtime Application 2009 High-Dynamic Engine Test Bench, Realtime Hardware-in-the-Loop (HIL) testing Exported SIMPACK model (> 100 DOFs) Longitudinal accelerations up to 20 Hz SIMPACK News article ( Page 12

13 Passenger Comfort Application Page 13

14 Realtime Application 2010 Man-in-the-loop for Testing Electronic Stability Program (ESP) Exported SIMPACK Model 7 DOF simulator SIMPACK News article ( Page 14

15 Real-time Application Man-in-the-loop - Handling - Sales Tool Page 15

16 Realtime Application 2011 Musculoskeletal Multi-Body Modeling used for HiL Simulations SIMPACK News article ( Page 16

SIMPACK Realtime Versions Model Reduction (Reduced) SIMPACK Online

UDP / Shared Memory Realtime Environment SIMPACK Classic Realtime via

Realtime Model reduction and compilation not required, direct use of

OS (and combination thereof) Supports all SIMPACK elements Parallel

expensive realtime hardware not required Already successfully

17 SIMPACK Realtime Versions Model Reduction (Reduced) SIMPACK Online Model Code Export Compilation SIMPACK RT-LIB SIMPACK Offline Model UDP / Shared Memory Realtime Environment SIMPACK Classic Realtime via Code Export SIMPACK 9 Realtime Real-Time Hardware 2013 SIMPACK 9 Realtime Model reduction and compilation not required, direct use of SIMPACK models No RT-LIBs, different for each realtime hardware and OS (and combination thereof) Supports all SIMPACK elements Parallel computation with latest solver developments available Specialized expensive realtime hardware not required Already successfully deployed at major international OEMs for driving simulators and engine test benches Page 17

turnaround times Runs on standard Linux realtime enabled OS Runs on standard INTEL

18 SIMPACK Realtime Functionality Realtime SOLVER Realtime ANIMATION Realtime LOGGING SIMPACK Realtime Functionality Overview Compilation free process for fast turnaround times Runs on standard Linux realtime enabled OS Runs on standard INTEL x86 hardware Realtime logger used for animations, live and playback, and post-processing Page 18

19 System Setup SIMPACK Realtime, unified multicore Linux RT environment Animation runs on same or different CPU as solver and receives data via UDP (network) communication SIMPACK Realtime Animation Page 19

different CPU as solver and receives data via UDP (network)

20 System Setup SIMPACK Realtime, separate multicore simulation engine: SIMPACK Realtime Animation Animation runs on same or different CPU as solver and receives data via UDP (network) communication Predefined targets: dspace, Concurrent, etc. Page 20

highdynamic engine test bench Real-time simulation system SIMPACK Offline

21 Workflow: Workflow from SIMPACK Offline to Online (Realtime Model) SIMPACK Offline = SIMPACK Online! Model Database SIMPACK Online application: e.g. highdynamic engine test bench Real-time simulation system SIMPACK Offline Application: e.g. hydropulse test rig, bad road simulation, etc. SIMPACK News article ( Page 21

22 Validation / Customer Application 2014 Model Validation Clemson 7.5 and 13.5 MW test bench Gearbox and loading mechanism from RENK Detailed SIMPACK models Focus on real-time simulation which enables a customer plant to be initially tested Page 22

23 Application Example 2013 Driving Simulator at Fraunhofer ITWM: SIMPACK News article ( Page 23

Conclusion SIMPACK Realtime Easy process for using high fidelity MBS models within a realtime environment Same models and model database for offline and online simulations Use of component based

24 Conclusion SIMPACK Realtime Easy process for using high fidelity MBS models within a realtime environment Same models and model database for offline and online simulations Use of component based models with high frequency content Easy parametric studies Not restricted to predefined template models Applicable within any industrial sector Predefined targets: dspace, Concurrent, etc. Visit our stand and try it out yourself! Page 24

25 Website Conference and User Meeting Presentations Newsletter articles Videos, Navigation Select industrial sector for All Relevant Links Click here Page 25

Further Developments and Applications of SIMPACK Code Export

Further Developments and Applications of SIMPACK Code Export Frank Kohlschmied, Intec GmbH Introduction New Developments in SIMPACK Code Export C-Code Export Code Export-Executable usable as partner in