VIRTUAL TEST-BED-INSTALLATION ( TEST-BED-DMU )

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1 ProSTEP ivip Symposium 2009 VIRTUAL TEST-BED-INSTALLATION ( TEST-BED-DMU ) K. Zamazal, K. Klöckl, W. Faustmann, H. Sorger AVL List GmbH B. Gruhn FOCUSON Business Consulting Gmbh

2 AVL COVERS ALL CUSTOMER SEGMENTS Engineering Passenger Cars 2-Wheelers Racing Simulation Construction Agriculture Commercial Vehicle Testing Locomotive Marine Power Plants 2

3 AVL TECHNICAL CENTERS POWERTRAIN Ann Arbor,MI UK Haninge Sweden Södertalje Headquarters Graz Moscow Plymouth, MI Tokio Nagoya Korea Lake Forest, CA China Sao Paulo France Germany India Neuenstadt München Regensburg Stuttgart Ingolstadt Remscheid Turkey 3

4 Content AVL s Development Challenges Virtual Test-Bed-Installation Development Process Improvement Project Benefits and Project Results Summary and Conclusion 4

5 AVL s Development Challenges Broad variety of projects virtual and physical 1000 Power / Cylinder [kw] Displacement / Cylinder [L] 5

6 AVL s Development Challenges Increasing number of projects in short time 1000 Number of projects Passenger Cars 1 Commercial Vehicles 10 Large Vehicles

7 Project kickoff meeting Basic concept selection Concept FMEA Concept design Concept design update Engine Development Process (EDP) (standardized and continuously improved since 1998) 42 Concept study Thermodynamic calculation Mechanical calculation Concept definition and choice of major suppliers Thermodynamic layout EMS specification Release of concept design Mechanical calculation Detail design Acoustic calculation 36 CAD data transfer Procurement engine generation 1 Engine build / first engine run Gen. 1 FIE rig tests EMS preparation Component development Design Thermodynamics EMS-Calibration Mechanics Acoustics Target costing Development support 30 Baseline performance & emission development Baseline engine mapping & ECU calibration Cold start development 24 Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Functional development (test bed & vehicle) Durability development (test bed) Baseline acoustic development (test cell) Pass-by noise & vehicle interior noise development Specification engine Gen. 2 Hot & cold climate tests Mechanical calculation engine generation 2 Vehicle endurance testing: mileage accumulation Release of concept for preproduction development Design update for engine generation 2 Procurement engine generation 2 First engine run generation 2 Performance & emission verification Release of casting pattern and forging die procurement OBD software development (if required) 18 Prototype development Tolerance investigations Component development & fatigue tests Functional development EMS optimization (steady state and dynamic test beds) Durability development (test bed) Engine & vehicle acoustic verification Update of engine documentation Driveability & emission optimization in vehicles EMC tests & OBD calibration Functional development in vehicles; hot & cold climate tests Vehicle endurance testing Production validation 12 Preproduction development Mileage accumulation Release procedures for supplier developed systems Analysis of acoustic vehicle conformity Design freeze MLI Design freeze SLI ECU data release for validation tests Engines & vehicles from production tooling Start of pilot production 6 Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests EMC validation Durability validation (test bed) Homologation Acoustic validation Vehicle endurance validation Months before SOP EMS data release Quality assurance tests Start of production 0 7

8 Content AVL s Development Challenges Virtual Test-Bed-Installation Optimization Approach Technical Results of the Test-Bed-DMU Development Process Improvement Project Benefits and Project Results Summary and Conclusion 8

9 Engine Test Process 14 Test Tasks Description of Results for each tasks? Optimisation for all engine development projects 9

10 Improve AVL s Frontloading by Virtual Test Bed Installation Concept study First engine enabling fully relevant performance emission and also durability targets Virtual Powertrain Prototype development Product maturity Preproduction development Effort Product validation Frontloading Start of production Development time 10

11 Virtual Test-Bed-Installation Optimization Approach 11

12 Virtual Test-Bed-Installation Activities to make an optimization come true Define concept Design all sensors, weldingrings, adapter, Adapt / convert existing test rigs Create a library for component administration Consider different CAD-Systems Allow automatic adjusting of fixtures Define collision free mounting Define Standard ETS Adapt files to make available with PARTSolution 12

13 Virtual Test-Bed-Installation Technical Results 13

14 Content AVL s Development Challenges Virtual Test-Bed-Installation Development Process Improvement Project Challenges and Gains The General Model Analysis of Processes Affected Process Improvement Tools Applied Project Results Benefits and Project Results Summary and Conclusion 14

15 Design Process Improvement Project Process Challenges and Gains with Development Process Redesign Challenges Surgery on the Living Body Workflow and Interface Changes Data Structures in Complex Environments have to be Changed Carefully Impact on the Organisation and the People within Quantification of the Improvement (Costs, Time) Gains Process Costs: Reduction around 20% for the Processes Improved Development Time: Benchmark with Competition shows 30% shorter Time Secondary additional Effects: Quality 15

16 Design Process Improvement Project The General Model Personnel Layer Organization Layer Advanced development Process Layer 16

17 Project kickoff meeting Basic concept selection Concept FMEA Concept design Concept design update Design Process Improvement Project Analysis of Processes affected 42 Advanced Concept study Thermodynamic calculation Mechanical calculation Concept definition and choice of major suppliers Thermodynamic layout EMS specification Release of concept design Mechanical calculation Detail design Acoustic calculation 36 CAD data transfer Procurement engine generation 1 Engine build / first engine run Gen. 1 FIE rig tests EMS preparation Component development Design Thermodynamics EMS-Calibration Mechanics Acoustics Target costing Development support 30 Baseline performance & emission development Baseline engine mapping & ECU calibration Cold start development 24 Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Functional development (test bed & vehicle) Durability development (test bed) Baseline acoustic development (test cell) Pass-by noise & vehicle interior noise development Specification engine Gen. 2 Hot & cold climate tests Mechanical calculation engine generation 2 Vehicle endurance testing: mileage accumulation Release of concept for preproduction development Design update for engine generation 2 Procurement engine generation 2 First engine run generation 2 Performance & emission verification Release of casting pattern and forging die procurement OBD software development (if required) 18 Advanced Prototype development Tolerance investigations Component development & fatigue tests Functional development EMS optimization (steady state and dynamic test beds) Durability development (test bed) Engine & vehicle acoustic verification Update of engine documentation Driveability & emission optimization in vehicles EMC tests & OBD calibration Functional development in vehicles; hot & cold climate tests Vehicle endurance testing Advanced Production development validation 12 Advanced Preproduction development development Mileage accumulation Release procedures for supplier developed systems Analysis of acoustic vehicle conformity Design freeze MLI Design freeze SLI ECU data release for validation tests Engines & vehicles from production tooling Start of pilot production 6 Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests EMC validation Durability validation (test bed) Homologation Acoustic validation Vehicle endurance validation Months before SOP EMS data release Quality assurance tests Start of production 0 17

18 Project kickoff meeting Basic concept selection Concept FMEA Concept design Concept design update Design Process Improvement Project Analysis of Processes affected 42 Advanced Concept study Thermodynamic calculation Mechanical calculation Concept definition and choice of major suppliers Thermodynamic layout EMS specification Release of concept design Mechanical calculation Detail design Acoustic calculation 36 CAD data transfer Procurement engine generation 1 Engine build / first engine run Gen. 1 FIE rig tests EMS preparation Component development Design Thermodynamics EMS-Calibration Mechanics Acoustics Target costing Development support 30 Baseline performance & emission development Baseline engine mapping & ECU calibration Cold start development 24 Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Functional development (test bed & vehicle) Durability development (test bed) Baseline acoustic development (test cell) Pass-by noise & vehicle interior noise development Specification engine Gen. 2 Hot & cold climate tests Mechanical calculation engine generation 2 Vehicle endurance testing: mileage accumulation Release of concept for preproduction development Design update for engine generation 2 Procurement engine generation 2 First engine run generation 2 Performance & emission verification Release of casting pattern and forging die procurement OBD software development (if required) 18 Advanced Prototype development Tolerance investigations Component development & fatigue tests Functional development EMS optimization (steady state and dynamic test beds) Durability development (test bed) Engine & vehicle acoustic verification Update of engine documentation Driveability & emission optimization in vehicles EMC tests & OBD calibration Functional development in vehicles; hot & cold climate tests Vehicle endurance testing Advanced Production development validation 12 Advanced Preproduction development development Mileage accumulation Release procedures for supplier developed systems Analysis of acoustic vehicle conformity Design freeze MLI Design freeze SLI ECU data release for validation tests Engines & vehicles from production tooling Start of pilot production 6 Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests EMC validation Durability validation (test bed) Homologation Acoustic validation Vehicle endurance validation Months before SOP EMS data release Quality assurance tests Start of production 0 18

19 1,0,0 Kunde 0,0,1 0,0,2 0,0,3 SP 1 2;0;0 Beauftragung 1,2,1 0,0,2 4,1,0 0;0;0 SP 2 Vorbereitung 1,2,0 1,0,0 1;1;0 u. Aufbau 1,3,0 0;0;0 Vorprüfung SP 3 2,2,0 0;0;0 Vorprüfung 1,1,2 2;0;0 SP 4 Prüflauf und 3,1,0 Datenerfassung 0,5,0 SP 5 Technischer 4,0,0 Abschluss 2,1,0 SP 6 Administrativer Abschluss SP 7 Lieferanten -sicht Kundensicht Auftragsankündigung trifft ein Auftrag + Erstellung Prüfprogramm Anlieferung & Aufbau Prüfling Prüflauf (inkl. Kontrolle, Teilauswertung, ggf. Neulauf) Abbau Lieferung von Prüfling und Ergebnissen an Kunden Auslieferung ist erfolgt 2,0,0 3,0,0 1,1,0 Kunde SP 8 Design Process Improvement Project Process Improvement Tools Applied Method Target of Method Applied Übergreifender Entwicklungsprozess Prüflings-Beschaffung (Prototypen-Erstellung Prüflings-Entsorgung inkl. Logistik Prüfablauf Techn. Techn. Technischer Nachbereitung& Prüf- Vorbereitung Prüflauf Ergebnis- Ergebnis-Lieferung Auftrag Lieferung Prüf-Planung und Administration Inkl. Rechnungsstellung Instandhaltung Prüffeld Technische Langfristplanung Prüffeld Organisatorische Langfristplanung Maturity Models Process Map Customers readiness is an indicator for volume and scope of the resulting project Overview of relevant business processes, their relations and implementation in the complete R&D resp. test field process Personal-Planung und Administration Legende: Primärer Geschäftsprozess Sekundärer Geschäftsprozess Supplier Input Anforderung an Versuchsingenieur Messprozess (Dauer, (A&G) Start, Art und weitere Entwicklungsingenieur Spezifikationen) (A&G) Prüfling? Prüfprogramm (Ist, Soll zu klären) Standard-Prozesse Process Output Customer Versuchsingenieur Prüfling (A&G) Prüfergebnisse Entwicklungsingenieur (Messdaten, Zwischen- (A&G) auswertungen, Entwicklungsingenieur elektronisch online Fahrzeug (Kunden des oder auf Datenträger) Kunden) Betriebsdaten Teamleiter (Laufzeit, Stillstands- Abteilungsleiter zeiten und -ursachen Bereichsleiter Finanzdaten, ) Virtueller Leitstand Kontrolldaten, wie z.b. (zukünftig) nötiger Ölwechsel Techn. Controlling (z.b. Rechnungsdaten) SIPOC Process model with respect to: Supplier Input Prozess Output Customer. This is a first rough picture of the value-chain process, helping to identify all parties involved A A (Eigen-) Leistung Prüfauftrag prüfen PCAT for Development IAM Process Cost Analysis Tool is a prerequisite to give a quantitative picture of possible process improvments in the development process The interface-analysis-matrix shows to which extend the organization is living the processes resp. has a process understanding. Furthermore starting points for improvements will be detected. 19

20 Content AVL s Development Challenges Virtual Test-Bed-Installation Design Process Improvement Project Benefits and Project Results Direct Benefits in Time and Costs Indirect and Following Benefits Summary and Conclusion 20

21 Benefits Direct Benefits in Time and Costs Hours for each Project Advanced development Virtual Time fix h/engine Project h P1 P2 P3 P4 P7 P14 P26 21

22 Benefits Direct Benefits in Time and Costs Hours per project with/without Quality Processes (QP) h Break Even Advanced development P1 P5 P9 P13 P17 P21 P25 P29 P33 P37 P41 with QP P45 P49 P53 P57 without QP P61 P65 P69 P73 P77 P81 P85 P89 P93 P97 22

23 Benefits Indirect Benefits in Time Quality and Reproducability Test Equipment Planning (TFMS) Standardization of Tests Prototype Oriented Purchasing Advanced development Common Understanding in the Design and Mechanic Department 23

24 Content AVL s Development Challenges Virtual Test-Bed-Installation Design Process Improvement Project Benefits and Project Results Summary and Conclusion 24

25 Summary / Conclusion /Next Steps Implementation Project in Budget on Time Technical Aspects Time for DMU Effort is becoming shorter Enlarge Library with Tools, etc. Availability for all designers via PARTSolutions Derive 3D sensor mounting model from ETS circuit Process Aspects Process implemented and accepted 3-Layer Model was vital for the success of the quick implementation Future process optimizations along the EDP will be established acc. to this approach 25

26 Thank you to the audience Combustion Engine Transmission Battery System Electric Engine Control Strategy 26

27 Abstract Virtueller Motorenversuchsaufbau Der PrüfstandsDMU Als qualitätsunterstützendes Entwicklungswerkzeug zur Komponentenfreigabe sowie für Abstands- und Einbauuntersuchungen im Fahrzeug sind die Nutzung des DMU (Digital Mock Up) und die entsprechenden Softwarepakete etabliert und prozessgestützt in Verwendung. Ebenso unumstritten sind die Prototypentests am Prüfstand, alle bei AVL List GmbH entwickelten Motoren werden im Motorenversuch komplett aufgebaut, mit Messstellen bestückt und hinsichtlich ihrer Funktion getestet. Der Prüfstandsaufbau ist sehr hardwarelastig, das Rüsten des Motors für den Prüfstand aufwendig und erst bei Vorliegen aller Motorenteile möglich. Dieser Prozess wurde im Sinne eines konsequenten Frontloading in die virtuelle Welt übergeführt und in den Freigabeprozess aufgenommen. Der Vortrag beleuchtet die Vorteile und Hindernisse sowie die Wirtschaftlichkeit dieses zukünftig als Standard eingesetzten Optimierungsschrittes. K. Zamazal, K. Klöckl, W. Faustmann, H. Sorger AVL List GmbH 27

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