1 www.penso.co.uk Optimised Engineering Design at Penso Consulting Chris Morrow BEng(Hons) BA Lead Engineer (Composites Group) Penso Consulting Ltd.
1 www.penso.co.uk
Optimised Engineering Design
at Penso Consulting
Chris Morrow BEng(Hons) BA Lead Engineer (Composites Group)
Penso Consulting Ltd.
2 www.penso.co.uk
Presentation Structure
Introduction to Penso Consulting 1
Penso Design Process Overview 2
Project Feasibility Phase Optimisation 3
Concept Definition Phase Optimisation 4
Virtual Series Phase Optimisation 5
Future Aspirations for Optimisation 6
Summary 7
3 www.penso.co.uk
Company Overview
Accreditation
TS16949 : 2009
ISO9001 : 2008
Core Competencies
Consulting
Composite Technologies
Special Operations
Clients
Strategic Alliances
Cytec (Oct 2015)
Pricol Technologies (Jan 2015)
ENGINEERING CENTRE
Coventry, UK
ENGINEERING OFFICE
Brentwood, UK
Pune, India
SALES AGENTS
Italy
Germany
4 www.penso.co.uk
Integrated Supply Chain
CHEMICALS
COMPOSITE MATERIALS
COMPONENT AND VEHICLE MANUFACTURE
In December 2015 Solvay acquired Cytec
Industries and simultaneously Cytec invested
in an equity stake in Penso.
This created a secure and integrated supply chain
with both CFRP pre-preg production and
part manufacturing [Coventry] centred in the UK
Midlands.
Turnover
Solvay €11bn
Cytec $2bn
Penso £30m
5 www.penso.co.uk
Company Overview
Consulting
Composite
Technologies
Project Management
Body Engineering
FEA Simulation / Crash
Lightweighting
EV Design
High Volume Composites
Cost Effective
Tooling & Machining
Integrated Composite Systems
Trim Development
Electrics & Electronics
Prototype build
Niche System Production
Series Production
Special Operations
6 www.penso.co.uk
History
2005
Management
buy out of P+Z,
Rebranded
Penso
Consulting
2006
Complete
interior design,
manufacture &
production
supply Brink
Carver ‘One’
2007
Fiat Professional
Specialist turnkey
vehicle programme
– engineer and
manufacture taxis
for UK public hire
sector
2008
Engineer and
manufacture
London Specific
Vito Taxi for
Mercedes Benz -
Full European Type
2 approval and
homologation
2009
Spyker C8 Aileron
complete vehicle
engineering,
interior trim and
convertible roof
system for Spyker
derivative.
2010
ISO9001 and
TS16949
accreditation
2011
Tier-1 supplier into JLR L538C Evoque Convertible
L405 LWB
CX75 engineering &
Composite Body
Structures
X152X Prototype, Tonneau
ETO engineering support.
Project Donington
engineering and build.
VARCITY Megacity.
2012
Supply of Production,
Interior Trim for
Morgan 3 Wheeler
2013
Re-Accreditation
of ISO9001 and
TS16949
Support Product
Launch L405 LWB
2014
L538C
L538C ADV
CDRM Models
P231
SP1 L322
SP2 L405
X261
SP = Special Project
2015
Bimini Hood
X590
X760 LCN
CF Train Door
7 www.penso.co.uk
Specialist Services
Penso Capabilities
Design & Development Prototyping & Testing
Composites
Body in W
hite
Sty
ling &
Surf
acin
g
Engin
eering F
easib
ility
Ele
ctr
ics &
Ele
ctr
onic
s
Mechatr
onic
s
Vehic
le P
ackagin
g
Sim
ula
tion &
CA
E
Tole
rance M
anagem
ent
Rapid
Technolo
gie
s
Rapid
Toolin
g
Rapid
Pro
toty
pin
g
Technolo
gy D
em
onstr
ato
r
Toolin
g D
evelo
pm
ent
Co
mp
osite P
rod
uctio
n
Qualit
y M
anagem
ent
Toolin
g &
Fix
ture
s
Pro
ject
Managem
ent
Launch S
upport
Toolin
g &
Machin
ing
Body-in-B
lack
Data
Managem
ent
Model M
akin
g
Build
Nic
he V
ehic
les
Ho
mo
log
atio
n
Type A
ppro
val
Toolin
g M
anufa
ctu
re
8 www.penso.co.uk
Design Process Overview
Iterative Process: CAD, CAE and Manufacturing Loops, underpinned at all
stages by Optimisation
Penso Design Phases
Project
Feasibility Package Exploration
Target Feasibility
Component Splits
Material Usage Estimates
Concept
Definition Load Path Development
Joint Development
Concept Generation and
Selection
Tradeoff Evaluation
Virtual
Series Component Development
Mass Reduction
Performance
Improvement / Target
Catchback
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
Penso
Design
Process
9 www.penso.co.uk
Project Feasibility Phase Optimisation
Deriving a basic load management strategy
- Key load paths
- Primary, secondary and tertiary joint classification
- Problematic areas
- Part splits
- Manufacturing techniques
Project Scoping: Package Exploration
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
10 www.penso.co.uk
Project Feasibility Phase Optimisation
Target feasibility: are cost, performance, mass and package constraints
compatible?
- Using a donor architecture, or a package volume, rapid assessment of feasibility
of proposed targets is possible.
- What are the limits of the structural performance of the design / concept and are
these consistent with manufacturing assumptions? What opportunities exist if
project assumptions are modified?
Project Scoping: Design Space Characterisation
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
11 www.penso.co.uk
Project Feasibility Phase Optimisation
Initial material selection and usage estimates: more resolution for project
quotation.
- Evaluation of various materials, and trade-off comparisons in terms of mass and
package.
- Identification of areas that require inserts, or additional reinforcement.
Project Scoping: Added Resolution
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
12 www.penso.co.uk
Project Feasibility Phase Optimisation
Preliminary load management strategy.
Initial panel splits, reinforcement regions and problematic areas.
Identified potential manufacturing techniques.
Material usage estimates and trade-offs.
Confidence in the feasibility of the project in terms of cost, mass, package
and performance.
This information kick starts the rapid generation of concepts in the next
design phase.
Key Phase Outcomes
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
13 www.penso.co.uk
Concept Definition Phase Optimisation
Genesis facilitates the rapid generation and evolution of design concepts.
Concept Generation
Preliminary Package Exploration:
Concept Creation (RDM/Topology)
Interpreted Concept:
Concept Development
(Sizing / Topometry)
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
14 www.penso.co.uk
Concept Definition Phase Optimisation
Load path and joint development: incorporating the most efficient design
from the beginning of the project.
Concept Generation
Sub Model Package Exploration: Primary Loadcases
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
15 www.penso.co.uk
Concept Definition Phase Optimisation
Concept evaluation: How much mass is required to make a proposed
architecture achieve performance targets and how does it compare to other
competing concepts?
- Rapid method of establishing relative efficiency of concepts
- Mass deltas are meaningful, absolute mass may not be.
- Identifies areas that are driving mass into the design.
Concept Selection
Thickness (mm) Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
16 www.penso.co.uk
Concept Definition Phase Optimisation
A number of potential design concepts, which have been rapidly matured.
Increased resolution on load management strategy and design of primary
load paths.
Preliminary joint design for key interfaces.
Selection of a concept which is subsequently matured through the virtual
series phase.
Key Phase Outcomes
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
17 www.penso.co.uk
Virtual Series Phase Optimisation
Productionisation of design, while incorporating manufacturing and cost
constraints.
fibre types, and mixed laminates.
- Counter Intuitive result.
Design Refinement: Composites
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
- Optimisation undertaken
comprehensive suite of load cases,
including linearised crash
loadcases, modal, stiffness and
durability.
- Multi material optimisation with a
cost objective, allowing comparison
of different fibre types, and mixed
laminates.
- Counter intuitive result in this
example: CFRP Dominant Solution
Cheaper than GFRP.
Thickness (mm)
18 www.penso.co.uk
Virtual Series Phase Optimisation
Maturation of castings, pressings and extrusions: General geometry and
reinforcement, wall thickness, lightening features.
Design Refinement: Metallics
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
- Continuation of conceptual work, driving the
design through to prototypes and
production.
- Multiple loops of topology and RDM
followed by topometry and sizing.
- Regularly used on production projects,
delivering significant mass, cost and time
savings.
19 www.penso.co.uk
Sensitivity studies: Which components / areas are critical for performance
metrics?
- RDM, Sizing and Topometry allow rapid identification of critical regions.
- Evaluation of performance ‘ceiling’ of current design, with incorporation of
manufacturing constraints – Max panel thickness, panel stack-ups, adhesive use.
- Removal of redundant mass.
- Tweaking of panels to eliminate NVH issues (Topography)
Virtual Series Phase Optimisation
Design Refinement: Performance Improvement
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
20 www.penso.co.uk
Production ready design
Efficient structure that achieves all performance and mass targets.
Inherent manufacturability incorporated in the design.
Minimal amount of design loops, reducing project costs and time.
Tried and tested process that has been used on many production vehicles.
Virtual Series Phase Optimisation
Key Phase Outcomes
Project
Feasibility
Concept
Definition
Virtual
Series Prototype Launch
21 www.penso.co.uk
Future Aspirations for Optimisation
Increased automation during laminate development process: reduction in
manual ply rationalisation. This could be achieved by adding topometry
parameters:
- Minimum ply area.
- Maximum number of disconnected regions.
- Maximum number of unique thicknesses per panel.
Robust, automated method for fixing placement and sizing.
Interface with design software.
Enhancing Efficiency and Creativity Moving Forwards
22 www.penso.co.uk
Summary
Optimisation is used extensively to drive design at all stages of the design
process at Penso.
Facilitate rapid characterisation of the project design space, allowing for
more accurate quotation.
Allows generation, evaluation and evolution of design concepts, progressing
from a package space to a mature design in the shortest possible time
frame.
Thanks to Martin, Oliver and the team for their continued support.
VRAND Genesis + GRM Plugins
23 www.penso.co.uk
Chris Morrow
Lead Engineer – Composites Group
Penso Consulting Ltd
Woodhams Road
Coventry
Warwickshire
CV3 4FX
United Kingdom
T: +44 (0)2476 217760
www.penso.co.uk
www.linkedin.com/company/penso
www.twitter.com/PensoGroup
Contact