Vehicle system integration guidelines for component suppliers Where today meets tomorrow. . Unrestricted © Siemens 2020
Vehicle system integration
guidelines for component suppliers
Where today meets tomorrow.
.
Unrestricted © Siemens 2020
Unrestricted © Siemens 2020
Page 2 Siemens Digital Industries Software
Introduction
Automotive industry trends and needs
Body Component
• Increasing testing effort
• Prototype availability?
• Impact of modification?
• …
How to ensure system performance while keeping
development time and cost under control?
Powertrain
Need vehicle-level
component
evaluation
Throughout the development# of vehicle variantsICE
PHEV
EV
Unrestricted © Siemens 2020
Page 3 Siemens Digital Industries Software
Introduction
Challenges for suppliers
More pressure from OEM to work on
integration
• How to evaluate component
behavior at full vehicle level?
• How to cascade targets from full
vehicle to component?
• How to solve vehicle integration
issues earlier?
Unrestricted © Siemens 2020
Page 4 Siemens Digital Industries Software
How to keep control of the NVH Performance
at any stage of the development cycle?
Can we provide methods that
addresses all these challenges?
YES, WE CAN!
Electrification
# of variants
No proto’s
Global use of
components Platform strategy
Unrestricted © Siemens 2020
Page 5 Siemens Digital Industries Software
Content
Full vehicle testing
and TPA
Component-based
TPA
Model-based
development
Model-based system
testing
Unrestricted © Siemens 2020
Page 6 Siemens Digital Industries Software
Bench marking &
Target setting
Concept Design
Component Verification
Bench Validation
Troubleshooting
What-if games &
optimization
Detailed Engineering
Ensure vehicle-level component NVH evaluation
Throughout the development cycle
Target Setting Concept validation Detailed Engineering Validation/Refinement
Full Vehicle Testing and TPA
Unrestricted © Siemens 2020
Page 7 Siemens Digital Industries Software
Full vehicle testing and TPA
Testing the component in full vehicle
Driving Condition:
How the vehicle is controlled
by the driver
Operating Condition
How the vehicle reacts to the
driver input (vehicle status)
Sub-system Behavior
How the subsystem behaves
in that operation
Subjective perception
How the driver perceives the
vehicle response
Many potential test scenarios:
• Vehicle Variants
• Markets
• Operating modes (SoC,
torque, rpm, temperature, …)
Unrestricted © Siemens 2020
Page 8 Siemens Digital Industries Software
Full vehicle testing and TPA
Transfer Path Analysis
P
a
X =Source (Fi,Qj) Transfer (NTF) Receiver (yk)
Engine
Exhaust
Tyres
EPS
(H)EV
Drive lineTransmission
HVACWiper System
Measure
d..
Tota
l
be_f:18:X
..
be_f:18:Y
..
be_f:18:Z
..
be_f:5018:X
..
be_f:5018:Y
..
be_f:5018:Z
..
be_r:
9:X
..
be_r:
9:Y
..
be_r:
9:Z
..
be_r:
5009:X
..
be_r:
5009:Y
..
be_r:
5009:Z
..
sh_f:30:X
..
sh_f:30:Y
..
sh_f:30:Z
..
sh_f:5030:X
..
sh_f:5030:Y
..
sh_f:5030:Z
..
sh_r:
32:X
..
sh_r:
32:Y
..
sh_r:
32:Z
..
sh_r:
5032:X
..
sh_r:
5032:Y
..
sh_r:
5032:Z
..
subf:20:X
..
subf:20:Y
..
subf:20:Z
..
subf:5020:X
..
subf:5020:Y
..
subf:5020:Z
..
10.00
60.00
dB
(A)
Pa
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
Contribution at path or group (case vs. rpm or frequency) A
Understand Critical
Transfer Paths
Cascade Targets
Unrestricted © Siemens 2020
Page 9 Siemens Digital Industries Software
9 copyright LMS International – 2010
Full vehicle testing and TPA
Transfer Path Analysis – HVAC TPA
Compressor
Engine mounts
Condenser mounts
Driveline surfaces
Structure borneAirborne Fluid borne
Pipe mounts
Target
Structure borne Airborne
Evaporator surfaces
Ac
tive
Pa
ss
ive
or
tran
sfe
rR
eceiv
er
Classical TPA
Body interface source id
Complexity of HVAC sub-system
• Multiple potential noise & vibration
sources: Compressor, Condenser,
Tubing, HVAC Module with Blower &
Motor, Ducts & vents
• Multiple potential transfer paths &
mechanisms
• Need For Detailed TPA assessment
Unrestricted © Siemens 2020
Page 10 Siemens Digital Industries Software
Full vehicle testing and TPA
Evaluate the sub-system
in full vehicle
Cascade targets from
system to components
Unrestricted © Siemens 2020
Page 11 Siemens Digital Industries Software
Bench marking &
Target setting
Concept Design
Component Verification
Bench Validation
Troubleshooting
What-if games &
optimization
Detailed Engineering
Component-based TPA
Ensure vehicle-level component NVH evaluation
Throughout the development cycle
Target Setting Concept validation Detailed Engineering Validation/Refinement
Unrestricted © Siemens 2020
Page 12 Siemens Digital Industries Software
Component-based TPA
Improving OEM – Supplier cooperation
Invariant load description
Realistic NVH design targets
Supplier OEM
Several ISO initiatives to standardize invariant
structure borne source characterization
Compressor
Motor
Steering rackEngine
HVAC
Undercarriage
Integration
Reduction
gearbox
shorter design cycles / reduced prototype availability / more variants / frontloading of engineering / …
Unrestricted © Siemens 2020
Page 16 Siemens Digital Industries Software
Component-based TPA
Example applications
Source MechanismInvariant
Source Synth. Model
Sub-Receiver
Connection ElementsReceiver
Steering
System
Blocked
Forces &
Impedances
Mount Pos.
SubframeFEM/TEST
FRF
BodyFEM/TEST
FRF
Tire
Road
Noise
Blocked
Forces &
Impedances
Wheel Center.
SuspensionFEM/TEST
FRF
BodyFEM/TEST
FRF
HVAC
Compressor
Blocked
Forces &
Impedances
Connection.
VehicleFEM/TEST
FRF
Wiper
System
Blocked
Forces &
Impedances
Connection
MountsTEST
Stiffness
BodyFEM/TEST
FRF
Gearbox
Actuator
Blocked Forces or
Free Accelerations
& Volume Velocities
Impedances
VehicleFEM/TEST
FRF
Y targetNTF Test bench load
Unrestricted © Siemens 2020
Page 17 Siemens Digital Industries Software
Simcenter Engineering project – Tire supplier
Road noise – Wheel center blocked forces
Identification of blocked forces on test rig
→ Source in operation: 20 / 40 / 60 / 80 / 100 kph.
→ Blocked forces calculated using in-situ TPA: matrix inversion
using multiple integral shakers for FRF
→ Blocked forces direct measured on rigid test rig using force cell
(usable up to 300 Hz)
On board validation of target response
on test rig
→ On-board validation
→ Identification of path contribution
→ Input for realistic target setting & prediction
→ Independent of test rig
Hz
dBN X
Hz
dBN Y
Hz
dBN Z
Hz
dB
Nm MZ
Hz
dB
Nm MX
Blo
cked
Fo
rces a
nd
Mo
men
tsHz
dBg
Measured
Predicted
Hz
dB g
AutoPower RIG:TARGET_1:+Z
AutoPower RIG:TARGET_1:+Z<RIG:TARGET_1:Z
AutoPower RIG:TARGET_1:+Z<TIRE:RIM_CR:RX
AutoPower RIG:TARGET_1:+Z<TIRE:RIM_CR:RZ
AutoPower RIG:TARGET_1:+Z<TIRE:RIM_CR:X
AutoPower RIG:TARGET_1:+Z<TIRE:RIM_CR:Y
AutoPower RIG:TARGET_1:+Z<TIRE:RIM_CR:Z
Measured Vibration
Predicted Vibration
Target
Wheel
contribution
Unrestricted © Siemens 2020
Page 18 Siemens Digital Industries Software
ZF TRW
Positioning steering systems NVH at the front of the development cycle
Development of the world’s first NVH steering system bench
• Reduced overall resources to solve
NVH-related issues
• Accurately estimated resources for
NVH resolution upfront
• Received positive feedback from
customers, who appreciate the
output data as well as the approach
used to gather it
“We can establish exactly how much force we are allowed to introduce to a
particular car to stay below a given NVH target, and we find that our customers
appreciate this approach a lot.”
Christian Landsberg, Global Chief Engineer NVH
• Translate NVH recommendations into real and objective requirements and targets
Integrate test and simulation to determine and resolve the root causes of problems
Developing a powerful partnership
Unrestricted © Siemens 2020
Page 19 Siemens Digital Industries Software
Component-based TPA
Improve OEM cooperation
by setting realistic targets
on invariant loads
Enhance usage of bench
data to create virtual
prototype assembly
Unrestricted © Siemens 2020
Page 20 Siemens Digital Industries Software
Bench marking &
Target setting
Concept Design
Component Verification
Bench Validation
Troubleshooting
What-if games &
optimization
Detailed Engineering
Model-Based Development
Ensure vehicle-level component NVH evaluation
Throughout the development cycle
Target Setting Concept validation Detailed Engineering Validation/Refinement
Unrestricted © Siemens 2020
Page 21 Siemens Digital Industries Software
Rp
m
Model-based development
Process deployment for system engineering
Scalable model complexity
f(accuracy, information)
Component – system tests
Vehicle tests
Update & Validate
Complement
Diagnose
Insights
25001000 rpm
dB
180
-180
Phase
°
Powertrain
Suspension
Sensitivity studies Modification studiesDesign exploration
Change impact
Model provides insight in rotational dynamics
& coupling driveline and suspension dynamics
Measured
..
Tota
l
be_f:18:X
..
be_f:18:Y
..
be_f:18:Z
..
be_f:5018:X
..
be_f:5018:Y
..
be_f:5018:Z
..
be_r:9
:X..
be_r:9
:Y..
be_r:9
:Z..
be_r:5
009:X
..
be_r:5
009:Y
..
be_r:5
009:Z
..
sh_f:30:X
..
sh_f:30:Y
..
sh_f:30:Z
..
sh_f:5030:X
..
sh_f:5030:Y
..
sh_f:5030:Z
..
sh_r:3
2:X
..
sh_r:3
2:Y
..
sh_r:3
2:Z
..
sh_r:5
032:X
..
sh_r:5
032:Y
..
sh_r:5
032:Z
..
subf:20:X
..
subf:20:Y
..
subf:20:Z
..
subf:5020:X
..
subf:5020:Y
..
subf:5020:Z
..
10.00
60.00
dB
(A
)
Pa
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
Contribution at path or group (case vs. rpm or frequency) A
Full vehicle model
including engine,
motor, ECU control,
driveline, suspension
and vehicle model
Unrestricted © Siemens 2020
Page 22 Siemens Digital Industries Software
Model-based development
Full vehicle reverse engineering
Unrestricted © Siemens 2020
Page 23 Siemens Digital Industries Software
Simcenter Engineering project – Automotive supplier
EV full vehicle modeling for component design evaluation
Target: be able to develop full vehicle system simulation models for early design studies of
components such as active suspensions, electro-motors, braking systems.
TESLA MODEL X 75D
• Electric vehicle with dual motor all-wheel drive
• Focus for evaluation : Chassis, Body, Powertrain
Model for Tip-in / Tip-out
E-Motor Control
Jerk is mitigated by tuning the torque filtering
Tau=0.001
Tau=0.1
Tau=0.5
Unrestricted © Siemens 2020
Page 24 Siemens Digital Industries Software
Accurate component modelsPublish component data in
standardized component libraries
Virtual prototype assemblyMaximized data usage for a wide range of performance predictions
Available for all Maximize accessibility of component
data
Performance evaluation Access models by large group for wide
range of performance predictions
1D
Vehicle
architecture
Unrestricted © Siemens 2020
Page 25 Siemens Digital Industries Software
Virtual prototype assemblyMaximized data usage for a wide range of performance predictions
Unrestricted © Siemens 2020
Page 26 Siemens Digital Industries Software
Model-based development
Enable component
concept design with
system simulation
Quick assessment of
many design variants
Unrestricted © Siemens 2020
Page 27 Siemens Digital Industries Software
Bench marking &
Target setting
Concept Design
Component Verification
Bench Validation
Troubleshooting
What-if games &
optimization
Detailed Engineering
Ensure vehicle-level component NVH evaluation
Throughout the development cycle
Target Setting Concept validation Detailed Engineering Validation/Refinement
Model-Based System Testing
Unrestricted © Siemens 2020
Page 28 Siemens Digital Industries Software
Model-based system testing
Overview
D
One testing framework ranging from virtual testing to field testing
Providing consistent validation & verification throughout the development
A
C
Simulation based
cascaded design
Test based cascaded
verification
Increased productivity, Testing cost
reduction and improved engineering insights
throughout the development cycle
INT
ER
FA
CE
INT
ER
FA
CE
INT
ER
FA
CE
INT
ER
FA
CE
B
Unrestricted © Siemens 2020
Page 29 Siemens Digital Industries Software
Benefit
Challenge
Solution
Validate transmission design targets for
multiple attributes: Life-time, quietness,
weight reduction, low friction
Model of motorcycle engine and chassis
providing real-life test conditions
• Validate transmission design before full
vehicle prototype is available
Simcenter Engineering project - Transmission supplier
Motorcycle e-CVT bench
Unrestricted © Siemens 2020
Page 30 Siemens Digital Industries Software
Benefit
Challenge
Solution
Ensure correct bench operations for
component validation tests. Testing
conditions may be limited due to bench
design (torsional resonances, power)
Deploy a Digital twin of the bench +
component to set requirements (motor size,
inertia, stiffness) and ensure the correct
loading in all scenarios
• Easily evaluate broad range of variants
and combinations
• Study feasibility of test scenarios during
concept phase
Simcenter Engineering project - Auto OEM
Torsional bench mechanical design
Torsional Mode
Motor Torque
Bench Model
Unrestricted © Siemens 2020
Page 31 Siemens Digital Industries Software
Model-based system testing
Enable component
testing in the lab in real-
life conditions
Solve integration issues
upfront
Unrestricted © Siemens 2020
Page 32 Siemens Digital Industries Software
Ensure vehicle-level component NVH evaluation
Throughout the development cycle
Evaluate the sub-system in Full
Vehicle with test and system
simulation technologies
Cascade Targets from System
to Components with TPA
Improve OEM cooperation by
using invariant loads from
Component based TPA
Enable component concept
design with Model based
Development
Solve integration issues upfront
with Model Based System
Testing
Questions?