Best Practices of Innovative Engineering with Simcenter Realize innovation. Restricted © Siemens AG 2017
Best Practices ofInnovativeEngineering withSimcenter
Realize innovation.Restricted © Siemens AG 2017
Unrestricted © Siemens AG 20172017.MM.DDPage 2 Siemens PLM Software
Product development needs paradigm shiftFrom complicated to complex aircraft
• Model-based systems engineering needed• Enable department model exchange• Front-load integration verification
Complex
Complex aircraft
• Document-based systems engineering• Isolated departments• Integration verification at the end of
development
Complicated
Complicated aircraft
With aircraft ever-increasing complexity, it becomes offoremost importance assess earlier in the design cyclethe interactions among systems
Unrestricted © Siemens AG 20172017.MM.DDPage 3 Siemens PLM Software
Addressing the aerospace industry painsKey enabler to improve program performance
Improved concept processè -50% accumulated rework
Improved detailed designè -10% development cost
Improved verification processè -20% testing cost
Cost overruns
Schedule overruns
Missed requirements
Supplier alignment
Integration problems
Unforeseen complexity
Increasing model-based approach will be crucialSimulation of engineering physics and business processes
Unrestricted © Siemens AG 20172017.MM.DDPage 4 Siemens PLM Software
The aviation industry is on the verge of a major shift towardselectrified propulsion
2016 – 2020Hybrid Electric Systems Project• Hybrid Ground Demonstrator,
10 MW platform• <2 MW potential platform applications vertical
take off and landing (VTOL), door-to-door
2028Regional Aircraft100 passengers, 6-8 MW
2035+Short Range Aircraft150-200 passengers, 20MW
Maintenance,modific.,
insur., fees
Crew
15%14% 100%
TCOFuel
20%
Purchase
51%
1. Reduction of fuel consumption: main lever to reduce aircraft TCO(example 737-800)
2. Projected emission goals: can only be reached with disruptive concepts 1)
Industry: various hybrid electric propulsion roadmapdefined for demonstration (TRL‘s) and product developmentuntil 2035, e.g.
2005 205020402030202020102010 2030 2050
CO2 mn ton
3. Customer perspective: extension of potential operating hours through noisereduction
1) IATA technology roadmap, June 2013
Possible through innovation ofexisting technologies
EU agreement “Flight-path 2050”:75% CO2 emission reduction (per PK) 2)
Requires biofuels and/or disruptiveconcepts (e.g. eAircraft)
Unrestricted © Siemens AG 20172017.MM.DDPage 6 Siemens PLM Software
From work in silos…
ECSHydraulicsFlightcontrols Electric
Fuel LandinggearEngine
Unrestricted © Siemens AG 20172017.MM.DDPage 7 Siemens PLM Software
…To a collaborative approachsupported by virtual integrated aircraft
ECS
Hydraulics
Flightcontrols
Electric Fuel
Landinggear
Engine
Unrestricted © Siemens AG 20172017.MM.DDPage 8 Siemens PLM Software
Customer Process Today… Integrating System Behaviour @ Higher Level = Misery
ATA 24:ElectricalATA 24:Electrical
ATA 21, 24, 30, 36:Pneum. / ECSATA 21, 24, 30, 36:Pneum. / ECS
ATA 71+…Engine SystemsATA 71+…Engine Systems
ATA 27, 32:FCS, Landing GearATA 27, 32:FCS, Landing Gear
ATA 29:Hydraulics, FUEL,...ATA 29:Hydraulics, FUEL,...
+ Additional Coding for Thermal + Additional Coding for Thermal + Additional Coding for Thermal + Additional Coding for Thermal + Additional Coding for Thermal
?
Mechanism Simulation Tool A Fluids Simulation Tool B Engine Simulation Tool C Electrical Simulation Tool D Pneumatic Simulation Tool E
Unrestricted © Siemens AG 20172017.MM.DDPage 9 Siemens PLM Software
Integrated Aircraft Performance
Siemens PLM Systems Simulation… allowing Thermal Behavior Synthesis at Aircraft Level
ATA 24:ElectricalATA 24:Electrical
ATA 21, 24, 30, 36:Pneum. / ECSATA 21, 24, 30, 36:Pneum. / ECS
ATA 71+…Engine SystemsATA 71+…Engine Systems
ATA 27, 32:FCS, Landing GearATA 27, 32:FCS, Landing Gear
ATA 29:Hydraulics, FUEL,...ATA 29:Hydraulics, FUEL,...
ü + Thermal ü + Thermal ü + Thermal ü + Thermal ü + Thermal
TeamcenterSimcenter System Synthesis
Simcenter Amesim
ü
Unrestricted © Siemens AG 20172017.MM.DDPage 10 Siemens PLM Software
Supporting the entire supply chain
Aircraft OEMAirbus
Assembly and validation
TIER 1Safran Landing Systems
Landing gear
TIER 2Safran Landing Systems
Braking and steering
TIER 3Zodiac Hydraulics
Valves and pumps
Less energyconsumption
More efficientand lighter
Smaller pumpLow leakages
Simcenter
Unrestricted © Siemens AG 20172017.MM.DDPage 11 Siemens PLM Software
Airbus HelicoptersReducing prototype costs by a factor of 4
From component and system engineering to real-time simulation
• Shortened hydraulic systemoptimization cycle by a factor of 3
• Decreased prototype costs by afactor of 4
• Avoided late delivery penalties“Being able to anticipate a problem is a significant source of cost and riskreduction.”
Nicolas Damiani, Expert in Simulation and Operational Analysis
• Ensure accuracy of plant and real-time hydraulics models• Enhance flight simulators’ fidelity
Real-time models for full flight simulatorsDynamic analysis of hydraulic systems
Unrestricted © Siemens AG 20172017.MM.DDPage 12 Siemens PLM Software
IRKUT builds Virtual Integrated Aircraft using a secure and optimizedmodeling process
Business challenges:• Predict subsystem and system behavior once
integrated into aircraft• Consider design options without mobilizing
considerable financial and human resources• Minimize the number of errors discovered at the
verification phase• Obtain optimal design within the shortest timeline
Keys to success:• Perform thermal analysis of the avionic bay• Assess system interaction early and accurately• Apply the VIA processResults:• Reduced modeling time by a factor of 5• Established a secured and optimized modeling process• Enhanced model, architecture and configuration
management
“Compared to our previous solution, LMS Amesimallows us to reduce time spent in building our mostcomplex models by a factor of 5.”
Marina GrishinaEngineer Engineering and Simulation
IRKUT
Unrestricted © Siemens AG 20172017.MM.DDPage 14 Siemens PLM Software
Move quicker towards full electric aircraft
• Optimize your power budget andnetwork quality wrt. missionprofile
• Validate architecture choicebefore integration
• Ensure safety by optimizingthermal management strategies
Unrestricted © Siemens AG 20172017.MM.DDPage 15 Siemens PLM Software
Airbus FranceFlexible multi body simulation for estimation of A350 XWB main landingdoor actuator load
Cosimulation Simcenter Motion - Simcenter Amesim
• Simcenter Amesim accurate shockabsorber model created
• Simcenter Motion for rigid andflexible structure creation enablingparametric aero loads
• Improved numerical performancewith Simcenter Amesim compiled inSimcenter Motion
“Simcenter Amesim is used to create an accurate shock absorber model incomparison with experiments, giving physical insight. It takes around 2-3 min for adoor extension simulation.”
Boris Nahmias, Airbus France, 2015 LMS European Aerospace Engineering Conference
• Create multi body components with Simcenter Motion• Launch co-simulation between Simcenter Motion and Simcenter Amesim including
special DLL for aerodynamic loading on flexible bodies
Integration of Simcenter Amesim output andinput control block
Creation of multibody components withSimcenter Motion
Actuator
Sensor
Motion ModelSystem Model
Actuator
Sensor
Motion ModelSystem Model
Unrestricted © Siemens AG 20172017.MM.DDPage 17 Siemens PLM Software
Engineering ChallengesDevelopment cycles continue to grow; quality challenges
Example
Boeing KC-46 delays& cost overrun
Electro-mechanical co-design failure. Wiringbundles did not meetrequirements.
DefenseNewsOctober 2017
… the company has now had to cough upabout $2.9 billion in pretax fees as delaysand cost overruns mount …
Unrestricted © Siemens AG 20172017.MM.DDPage 18 Siemens PLM Software
Engineering ChallengesCritical Failure Under Operation
Uncertainty in certificationLoad Cases
Disconnected engineeringprocesses Missed targets
Design / ComponentEngineering
Test
Systems andControls
Weight
Strength
Weight
Strength
vs.
Unrestricted © Siemens AG 20172017.MM.DDPage 19 Siemens PLM Software
Simcenter 3D Solutions3D CAE for the Digital Twin
Broad range of physicssimulation solutions in a
single environment
§ Fast and accurate solvers§ Fully coupled multi-physics solutions§ Scalable performance on high performance
computing (HPC)§ Licensing flexibility : cloud, tokens§ Backed by Siemens industry expertise
Unrestricted © Siemens AG 20172017.MM.DDPage 20 Siemens PLM Software
Example: Simulate, optimize, build (Drop Test + Full / AC)
• Validate Landing Gearperformance with virtual test
• Gain full insight from co-Simulation with physics basedlibraries of Simcenter Amesim
• Correlate models withmeasurement data
Unrestricted © Siemens AG 20172017.MM.DDPage 21 Siemens PLM Software
Example: Simulate, optimize, build (Drop Test + Full / AC)
• Leverage optimized andvalidated models
• Perform analysis forassembled Aircraft
• Optimze aircraftlanding/maneuveringperformance
Unrestricted © Siemens AG 20172017.MM.DDPage 22 Siemens PLM Software
Challenging Requirements for the Engineering Teams
Delivering Cost Effective, Configurable,Smart & Attractive Vehicle Performance
Managing Complexity of requiredMechatronic System Innovations
Unrestricted © Siemens AG 20172017.MM.DDPage 24 Siemens PLM Software
Simcenter 3D Solutions for automotive industryMultiple physics working together for increased accuracy
ThermalAnalysis
Thermo-Mechanical
Analysis
Topologyoptimization
StructuralAnalysis
Fluid-MotionAnalysis
Heatexchanges
Motion Analysis
Thermal-Mechanical-
Flow Analysis
Thermal FlowSimulation
Flow Analysis
Motion withflexible bodies
Fluid-Structure interactionsMotion Control
Analysis
Unrestricted © Siemens AG 20172017.MM.DDPage 25 Siemens PLM Software
Simcenter 3D Solutions for automotive industryStructural analysis and more
Nonlinear Analysis : static,transient, contact, plasticity,
implicit, explicit
Linearizedconfigurations
Damage and fracture mechanics
Metallic and compositematerials
Condensationmethods (SE)
Durability and fatigueLinear Analysis :static, modal,
buckling
Thermal Analysis :conduction, convection,conjugated heat transfer,
radiation
Thermo-MechanicalAnalysis
Temperature dependentmaterials
Frequency andTransient response,
random
Unrestricted © Siemens AG 20172017.MM.DDPage 26 Siemens PLM Software
Durability PerformanceCombining Best of Simulation & Testing
UnderstandingOperational loads
Target setting & TestProcedures
Physical ProductOptimisation &
Validation
Design Optimisation VirtualProduct Validation
Final ProductValidation
Durability EngineeringØ A unique portfolio of services, products & technologies covering the full durability process
Ø Realistic design and validation through representative loading conditionsØ Assess durability performance in earlier in the design process
Ø Accelerate field and lab testing
Load data analysisRough road field dataacquisition Numerical simulation Rig testing Product sign-off
Unrestricted © Siemens AG 20172017.MM.DDPage 27 Siemens PLM Software
Vehicle NVH & AcousticsTransfer Path Analysis – a way to breakdown NVH issues
X =Source Transfer Receiver
Quantifying the structureborne sourcesTransfer Path Analysis
Engine
Road input
Transmission
Steering wheelvibrations
Seat vibrations
Noise issues
• Structured way of approaching noise issue instead of time consumingtry-and-error approaches
• Identification of weak panels and sensitive paths for noise issue• Deeper insights in load strength and noise transfer sensitivity• Reusability of identified loads for simulation
P aM
easu
red
..
Tota
l
be_f
:18:
X..
be_f
:18:
Y..
be_f
:18:
Z..
be_f
:501
8:X
..
be_f
:501
8:Y
..
be_f
:501
8:Z
.. be_r
:9:X
..
be_r
:9:Y
.. be_r
:9:Z
..
be_r
:500
9:X
..
be_r
:500
9:Y
..
be_r
:500
9:Z
..
sh_f
:30:
X..
sh_f
:30:
Y..
sh_f
:30:
Z..
sh_f
:503
0:X
..
sh_f
:503
0:Y
..
sh_f
:503
0:Z
..
sh_r
:32:
X..
sh_r
:32:
Y..
sh_r
:32:
Z..
sh_r
:503
2:X
..
sh_r
:503
2:Y
..
sh_r
:503
2:Z
..
subf
:20:
X..
subf
:20:
Y..
subf
:20:
Z..
subf
:502
0:X
..
subf
:502
0:Y
..
subf
:502
0:Z
..
10.00
60.00
dB(A
)P
a
sh_r:32:Z
0.00 350.00Hz
RMS Sum
Spectrum: PRCM:0001:S
Spectrum: PRCM:0002:S
Spectrum: PRCM:0004:S
Spectrum: PRCM:0003:S
Spectrum: PRCM:0006:S
Spectrum: PRCM:0005:S-40.00
50.00
dB(A
)
Pa
Contr ibution at path or group (case vs. rpm or f requency) A