Airbag Development Process Using HyperWorks Automation. Nirmal Narayan Jill Bentz Harry Park Terry Sella Russ Morris

Transcription

1 Airbag Development Process Using HyperWorks Automation Nirmal Narayan Jill Bentz Harry Park Terry Sella Russ Morris

2 Agenda About Autoliv Airbag Development Process Typical Airbag CAE Analysis Simulation Based Volume Analysis Demo- Automation of Volume Analysis using TCL/TK Future steps and Summary Q&A

3 Objective Understand the airbag development process. Demonstrate an example of the automation using Altair TCL/TK.

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5 Autoliv Vision & Mission The Worldwide leader in Automotive Safety Systems

6 Autoliv in Brief Sales By Region

7 Autoliv Products

8 Having an Impact - US Highway Fatality Rate Drops to 62 Year Low - For 2011, the highway fatality rate was 32,300 people.

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10 PAB Development Process Step 1: Start with vehicle data Centerline cross-section Occupant size and positions Pulse information

11 PAB Development Process Step 2: System or application engineer defines cushion profile or profiles: Incorporate best practices for different crash scenarios Select main panel shape or define 3D shape Try 1 Try 2

12 PAB Development Process Step 3: CAE analyst creates a cushion model Volume calculation at 1 psi. for inflator sizing Static deployment in environment for deployed shape 1psi. Static deployment Satisfied with cushion volume and shape?

13 PAB Development Process Step 4: Run system model with new PAB designs Belted AF05 (new NCAP), Unbelted AM50 Tune vent sizes, tether length, inflator output, adaptive vent, belt load Satisfied with cushion performance? No redesign Yes now we need cushions for testing

14 PAB Development Process Step 5: Kick off drawing to build prototype cushions Once we have a good candidate design CAE analyst unwraps 3D model to 2D flat panels Geometry based (mathematical scripts) Simulation based 2D line data becomes basis for cushion assembly drawing 3D model 2D flat pattern

15 PAB Development Process Step 6: Prototype cushions Prototype cushions for integrity testing Fold and tether confirmation If QA okay, then proceed with on to OOP or sled testing

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17 COMPLEXITY Typical Airbag CAE Analysis Airbag Volume Analysis Coverage Study Stress Analysis Linear Impactor Sled Systems Simulation Full Vehicle Crash Analysis

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19 3D to 2D Simulation Based Method 3D to 2D SIMULATION CAD DATA GENERATION

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21 Volume Analysis using Simulation Methods 3D CAD DATA GENERATE MESH FEA SOLVER VOLUME 2D CAD DATA GENERATE MESH AIRBAG STITCHING FEA SOLVER VOLUME

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23 Case Study: Automation of Airbag Stitching Performing volume analysis using 2D panels, involves stitching of panels together to create 3D enclosed volume. Automation achieved by Altair TCL/TK scripts. Manual stitching takes hours and is a tiresome process. With automation the stitching could be done in minutes. TCL/TK SCRIPTS

24 Automation Demo

25 Volume Analysis Report

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27 Future Steps Identity routine simple CAE analysis which can be easily automated. Develop a one click application to get the highest productivity For example, the volume analysis is performed routinely and sometimes can be time consuming. Develop a stand-alone application which reads CAD data and can create the volume report. Make the application simple enough, so that any non CAE persons in the organization can use it. CATIA CAD CREATE MESH SELECT MATERIAL APPLY PRESSURE GENERATE REPORT SUBMIT TO SOLVER STAND ALONE APPLICATION

28 Summary Airbag development is a multi step iterative process. CAE is extensively used in the airbag development in each of the steps. Automation can be used to effectively reduce the development time and increase productivity.