Accelerated Load Data Analysis with LMS TecWare Launching LMS TecWare Rev 3 LMS User Conference 2006 Dominiek Coppens Product Line Manager
Agenda 1 Durability challenges 2 The durability engineering process 3 LMS TecWare value proposition 4 LMS TecWare tips and tricks 5 Conclusions 2 LMS User Conference 2006
3 LMS User Conference 2006 Durability challenges
Industry Challenges Challenging market requirements Resulting in While competition requires rethinking processes! Avoid product recall! Superior quality! But not over designed! Lower price! Enormous variety of choices! Innovative designs! Light weight materials! Compact structures! More variants! On fewer platforms! Shorten design cycles! Test-based fatigue takes too long! Increase productivity of product development! Gain full insight into durability! Improve relationship OEM / supplier 4 LMS User Conference 2006
The durability engineering process 5 LMS User Conference 2006
Durability engineering process As-is process Build test redesign no longer practical Strength only! Unrealistic loading Time consuming -> overdesign Very late in the development process Costly 6 LMS User Conference 2006
LMS TecWare value proposition 7 LMS User Conference 2006
LMS durability engineering process To be process Optimizing for durability performance VALUE 2 Realistic simulation through representative loading conditions VALUE 1 Assess durability performance earlier VALUE 3 Accelerate durability testing 8 LMS User Conference 2006
The durability engineering process LMS durability solutions products and services Upfront engineering Detailed engineering Refinement engineering Design Performance simulation Test CATIA V5 LMS Test Mobile LMS Virtual.Lab Designer Fatigue LMS Virtual.Lab Durability The Durability Alliance LMS TecWare Load data processing 9 LMS User Conference 2006
LMS durability solution value proposition - Value 1 Assess durability performance earlier in development LMS Lifetime prediction software identifies and fixes fatigue problems in a few days versus several weeks of physical testing. BMW Group LMS durability simulation enabled Fiat Research Center to save an estimated 200,000 dollars on the durability development of a Case New Holland tractor and to compress the development time with at least six months. 10 LMS User Conference 2006! Extends stress analysis by taking into account damage accumulation! Identify and fix fatigue problems in a few days vs several weeks of physical testing! Enables what-if studies and results in a refined analysis! Delivers clear recommendations for guiding major design choices! Results in fewer iteration studies in testing Dr. Kamel Bel Knani, Head of the Structural Durability Team at FIAT-CRF
LMS durability solution value proposition Value 2 Representative loading conditions real-life simulation Efficiently process huge amounts of data Using LMS TecWare the measurement data processing has been completely automated. The graphical interface allows to easily create and debug the different steps in the process. DaimlerChrysler Manage durability load data Collaborative web-based solution manages durability-specific test workflows and knowledge base. Volkswagen Predict loads earlier in development To assess the durability performance of our designs in the early development stages, we require accurate loading information. Through the implementation of LMS Virtual.Lab Motion, our engineering teams generate system loads even before they can be measured on physical prototypes of new vehicles. Bruno Hazet, PSA 11 LMS User Conference 2006
LMS durability solution value proposition Value 3 Accelerate durability testing! Design and optimize durability test scenarios! More accurate and more efficient rig testing LMS will help Ford cut months from our development cycle and save hundreds of thousands of dollars. Dr. Weiss, Ford Cologne. 100 Through more accurate and efficient rig testing, LMS solutions contribute to higher product quality and lower engineering and component costs. ZF Lemforder Fahrwerktechnik test time [days] 10 60 9 1 100% From 60 to 10 days! 8 7 6 95% 90% 85% 80% 75% The resulting proving ground and rig testing scenarios accurately replicated the excitation of the actual road in one-hundredth of the time that would have been required for road testing. Ford Otosan rel. damage sum 12 LMS User Conference 2006
Intelligent load data processing using LMS TecWare To design representative durability test schedules To efficiently process raw data To accelerate test scenarios To correlate data from test track, test rig, CAE To efficiently manage durability data 13 LMS User Conference 2006
LMS TecWare To efficiently process huge amounts of data Successful durability engineering requires intelligent load data processing.! Processing of raw data into loads for virtual and physical tests! Automatic detection of :! Measurement failures, outliners, etc.! Test track segments! Streamlines the process from! data import,! consolidation,! reduction,! documenting,! comparison Fast load data processing Easy for non-experts Customizable to your process Helps to standardize on corporate proced Using LMS TecWare the measurement data processing has been completely automated and the resulting reports deliver a maximum of engineering insight. The graphical interface allows to easily create and debug the different steps in the process 14 LMS User Conference 2006
LMS TecWare To correlate data from test track, test rig, CAE Correlation of results Predict loads earlier in development To assess the durability performance of our designs in the early development stages, we require accurate loading information. Through the implementation of LMS Virtual.Lab Motion, our engineering teams generate system loads even before they can be measured on physical prototypes of new vehicles. Bruno Hazet, PSA 15 LMS User Conference 2006
Application case BMW using virtual test rigs for loads cascading BMW axle test rig for non-driven front-suspensions BMW Virtual Axle test rig model Measurement Initial MBS model Optimized MBS model Loads cascading! Numerically measure interface component forces using a virtual test rig model! Adapt existing ride and handling multibody models for durability loads cascading! Use of LMS TecWare for correlating test and simulation! Avoid physical prototyping! Earlier in the design process Having used LMS durability technologies for load data analysis and numerical fatigue life predictions for several years, we are able to improve our durability engineering process substantially (...) and reduce the time and costs of the development process. Dr. Martin Brune, Manager Predevelopment, Methods, Calculation, BMW Group 16 LMS User Conference 2006
LMS TecWare To efficiently manage durability data Efficiently search and retrieve durability data across departments Durability Data Management! Web-enabled! Data annotation! Process management (instrumentation, test rig preparation,...)! Data search and download ( Google )! Durability data displays! Durability engineering data drivers! Remote launching of batch jobs The Durability Data Management system controls the different steps in the testing process. It allows efficient organization and creation of tasks and allows us to find back any data from any measurement campaign in a very efficient manner. 17 LMS User Conference 2006
LMS TecWare To design representative scenarios Damage based on strain gage signals, full truck 1 Condensed test schedules Design customer correlated test schedules Accelerated durability testing cycles! Meeting 1.2 million km durability requirement! Real tests would take 3 years! Large-scale customer data collection! 5000 km Turkish public road data! Ford Lommel proving ground! Development of accelerated rig test! Target setting! Test schedule definition! Resulting test schedule 8 weeks! Test acceleration of factor 100 LMS engineers performed dedicated data collection, applied extensive load data processing techniques and developed a 6- to 8-week test track sequence and 4-week accelerated rig test scenario that matched the fatigue damage generated by 1.2 million km of road driving. 18 LMS User Conference 2006
LMS TecWare To accelerate durability test scenarios Reduce transmission time by 85%! Reduced testing time! Customer correlated! No loose of fatigue content! Dedicated data reduction methods! Process integration Load data reduction for rotating components! Multi-axial time at level! Rotating moment histogram! Rotating rainflow counting Using hybrid engineering technologies of the LMS durability products we were able to improve durability testing procedures for gearboxes and transmission system drastically. Certain subsystem tests could be shortened from previously several weeks to now less than one day. Dr. Wolfram Weiß, Powertrain development, Ford Köln 19 LMS User Conference 2006
LMS TecWare Tips and Tricks 20 LMS User Conference 2006
Durability load data processing using LMS TecWare Tips and Tricks Design Performance simulation Test Load data processing Durability data management Streamline Load data Consolidate Interpret Document Compare Load data Test schedule definition Load data 21 LMS User Conference 2006
LMS Tec.Manager Tip 1. Organize data. Rev 3 Intuitive search! Similar to Altavista or Google! Template-based search Analyze search results using! Tree navigation! Excel style view on attributes Full text search! Support of all common Office files! Support of all text files Facilitate use of data throughout the entire development process 22 LMS User Conference 2006
LMS TecWare Tips and Tricks Tip 2. Standardize processes 23 LMS User Conference 2006
LMS TecWare Tips and Tricks Tip 2. Standardize processes Rev 3! A drastical reduction in the time required to process time data! Automating tasks - less errors, reduces user dependency! Easier for non-experts to master - no programming skills required! Faster creation of sequences of load data processing tasks! Quicker process flow debugging! Helps to standardize on corporate procedures! Protects investments - supports all LMS TecWare methods 24 LMS User Conference 2006
LMS TecWare Tips and Tricks Tip 3 - Reduce vast amount of data! Benefits! Open to most common file formats Can be used for Part of Read and write On PC and UNIX platforms! No file conversion, hence no time nor disk space wasted as data is directly accessed LMS TecWare File interfaces Read Write Product ASCII " " LMS TecWare Kernel LMS TecWare IF " " LMS TecWare Kernel IST LabSite " " LMS TecWare Kernel IST RigSys " " LMS TecWare Kernel LMS CADA-X TDF " " LMS TecWare Kernel LMS Test.Lab TDF " " LMS TecWare Kernel LMS Roadrunner (SKALAR 20) " LMS TecWare Kernel LMS Pimento (SKALAR 20) " LMS TecWare Kernel LMS Virtual.Lab Time series interface " " LMS TecWare Kernel MH E.D.A.S. " LMS TecWare MH EDAS File Interface MH E.D.A.S.WIN " LMS TecWare MH EDAS File Interface MSC.ADAMS (/Car) Durability interface " " LMS TecWare MTS RPC III File Interface MTS RPC-III " " LMS TecWare MTS RPC III File Interface ncode DAC " LMS TecWare ncode DAC File Interface NI DIAdem " " LMS TecWare NI DIAdem File Interface IMC µmusycs FAMOS " LMS TecWare IMC µmusycs FAMOS File Interface Aditec EDT " LMS TecWare Universal Binary File Interface Aditec PBK/PK2 " LMS TecWare Universal Binary File Interface HEAD acoustics " LMS TecWare Universal Binary File Interface I-DEAS BUF(binary universal file) " LMS TecWare Universal Binary File Interface Inhouse data formats via LMS Universal Binary " LMS TecWare Universal Binary File Interface 25 LMS User Conference 2006
Durability load data processing Why rainflow counting? Basic damage event : closed hysteresis loop Interpret Rainflow counting = counting of closed hysteresis loops in time signal Rainflow counting 1 0 9 8 7 6 5 4 3 2 1 Load history from load level 1 2 3 4 5 6 7 8 9 1 0 to load level 1 2 3 4 5 6 7 8 9 10 Damage calculation Closed hysteresis loop Classification into bins Rainflow Matrix: at any from-to cell: entry for the numbers of cycles to (Pseudo-) Damage from constant amplitude constant mean Lines of constant mean and constant amplitude in a rainflow matrix standing hystereses hanging hystereses 26 LMS User Conference 2006
LMS TecWare Accurate Load Data Processing Accuracy! Features! Rainflow counting taking residue into account! Increased accuracy! Increased accuracy for : extrapolation of rainflow matrices, reconstruction to time signals, especially for shorter events! Multi-axial rainflow counting! Increased accuracy for multi-axial loading! Rotating rainflow matrix! Increased accuracy for rotating components! CombiTrack : partial optimization to design correlated test schedule! Increased accuracy : closer match between durability target and actual test schedule 27 LMS User Conference 2006
LMS TecWare Reporting! Benefit! Efficiently publish, share and compare load data! Features! Creation of template-based reports MS Word MS Excel HTML ASCII csv! Multi-page reports!fit for massive amounts of data! Full axis labeling!automatic table of contents and page numbering 28 LMS User Conference 2006
LMS TecWare Tips and Tricks Tip 4 Optimize existing test schedules Optimized existing test schedules! Different methods included for creating damage equivalent reduced-length tests! Pre-configured batch programs encapsulating input signal definition, parameter setting, processing and report generation! Methods working in time or rainflow domain, uni-axial or multi-axial Accelerate physical and virtual testing 29 LMS User Conference 2006
30 LMS User Conference 2006 Conclusion
Durability load data processing LMS TecWare Streamline Everything you need for durability load data processing. Successful durability engineering requires intelligent load data processing. Document! Processing of raw data into loading histories for virtual and physical tests! Streamlines the process from data import, over consolidation, reduction, documenting, reporting and comparison! Optimizing existing test schedules for physical and virtual tests! Define customer correlated test schedules! Integrated load data management (via LMS Tec.Manager) Streamlining load data processing in all stages of the development process Consolidate 31 LMS User Conference 2006