Simulation %%%%

Category: Simulation

04 Nov 2019

Optimizing NVH for EVs

This article first appeared in Automotive Engineering – October 2019.

Unique acoustic and harmonic challenges require an integrated approach to simulation and analysis. An expert at Adaptive Corp. explains.

Despite global sales market share stuck at single-digit levels, electric vehicles (EVs) are steadily filling the development pipelines at major OEMs. And as engineers are acutely aware, EVs bring a paradigm shift in the noise, vibration and harshness (NVG) arena. Their harmonic spectra are dramatically different than those of even the smoothest, most refined combustion-engine vehicles and hybrids.

EVs are anything but silent, however. They’ve got their own acoustic challenges, experts assert. Traction motors can be relatively quiet (in terms of tonal harmonic noise) in the low and mid frequencies, but unmasked gear whine and various sounds in the propulsion system are far more noticeable and potentially annoying. There’s also the relative cacophony of the tire noise, HVAC fans and compressor cycling. Even electrical switching and the muffled gurgle of battery coolant can be heard in some EVs while at rest. 

While the industry is likely years away from customers complaining of EV cabin noise, leading practitioners in the NVH-reduction field are already working on up-front solutions. One of them is Adaptive Corp., a specialist in simulation, structural analysis and product lifecycle management for automotive, aerospace and other industries. Optimizing designs for improved performance (including NVH, weight, cost, durability) is Adaptive’s specialty, according to customers with whom Automotive Engineering spoke. The NVH science behind EVs and hybrids is increasingly a focus of Adaptive’s services, explained Wayne Tanner, the company’s chief operating officer. 

“It’s true that we have to ‘up our game’ with EVs,” Tanner told AE. “We’re hearing this from all our customers who are in the EV supply chain, such as those who make tires and suppliers of motors. We’re looking at components and subsystems that were never before considered to make the vehicle quieter.”

Easing the development crunch

The industry’s move to electric propulsion is driving new business across the engineering-solutions sector. Tanner, who is responsible for all his company’s activities related to simulation and analysis, notes that the industry trend is toward clean-sheet vehicle platforms dedicated to battery-electric propulsion. OEMs such as Tesla and Volkswagen – the latter’s dedicated and modular MEB platform to be shared by Ford on some models – are committed to this strategy that optimizes structural stiffness (with its related NVH benefits) and other attributes. 

“The time-to-market is increasingly short, which is why product-development teams need simulation to do their fast, quick iterations,” Tanner said, “and to make accurate predictions before they build prototypes and test vehicles.”

The aim is to avoid the dramatic and often eleventh-hour ‘band-aiding’ of vehicle structures. Such activities include costly material replacements and noise-path mitigation by adding heavy NVH countermeasures, in order to meet production deadlines. “That’s certainly something that we can help with if we’re brought into the development process sooner, farther upstream,” Tanner noted. Engineers sometimes don’t think of components and subsystems as a system until they’re actually put together, he observed. 

“Some customers, because they’re moving so fast, can’t find time to do a simulation upfront – then they discover the need for add-on countermeasures at a late hour,” he said. 

vibroacoustics
Vibroacoustics and flow-noise-full-spectrum analysis methods in Dassault’s Wave6 software.

 

Tanner has worked in simulation for over 20 years in various disciplines including design optimization, load development, weld fatigue and dynamics. He and other NVH experts assert that the sooner system-level and full-vehicle models can be developed in any vehicle program, the more effectively predictions can actually improve those designs to reduce NVH, rather than being band-aids in the end.

Inside the toolbox

For its simulation platform, Adaptive partners with Dassault Systèmes, whose 3DEXPERIENCE is rated by users as state of the art in comprehensive NVH simulation toolsets. “The advantage of (3DEXPERIENCE) is, it gives us a single data model that can contain CAD and simulation data,” Tanner said. “We connect that to systems engineering to drive requirements all the way from start to finish, to manage the workflow. Some of the tools we have at our disposal aren’t fully integrated into the platform, but we’re able to put everything together and manage that data. This allows our customers to access a single data source.”

Tanner offered a peek inside Adaptive’s extensive sim toolbox. On the aerodynamics /CFD side is PowerFLOW; on the acoustics side is another Dassault tool called Wave6 that’s used to project an acoustic signature. On the mechanical side, Adaptive engineers use Simpack, which helps them develop all the mechanical vibrations needed for a given analysis. There are also electromagnetic tools. 

“We connect all these tools into a single workflow – to drive mechanical and/or aerodynamic vibrations into the acoustic field, for example – on the 3DEXPERIENCE platform,” he said. Once an OEM is ready to begin road and/or dynamometer testing, they employ Adaptive to validate and correlate from the company’s virtual model into production models.

Another weapon in the arsenal is True-Load from Wolfstar Technologies. It leverages finite-element models to determine the optimum location for strain gauges on unmodified physical parts then generates load-scaling functions. The company claims typical strain correlation within 2% of measured values. Output feeds directly into True-QSE events, described by Tanner as “a powerful post-processing tool” that supports rapid virtual iteration.

“It allows us to take that test mule and put information-gathering tools on it, whether it be strain gauges or accelerometers, capture real-time load and vibration data from that system, and correlate it to our FE models,” Tanner explained. “We use that to drive our simulation – and to predict more that may happen.”

NVH simulation and analysis is “at the beginning of the power of what we can do,” Tanner said. “The tools are becoming more inter-connected and fully integrated, allowing us to run seamlessly from CAD to simulation to structural analysis to acoustics to vibration. The workflow is increasingly faster, enabling us to run multiple simulations in a single day. It used to take weeks.”

 

 

 

14 Nov 2019
Product lifecycle management

Be Part of the “Industry Renaissance” with Dassault’s 3DEXPERIENCE PLM Platform

Challenge and opportunity can be said to be different sides of the same coin. Certainly that’s true for industry these days—especially for those in the product development and manufacturing space. The recent cover story in Compass Magazine, “Industry Renaissance transforms invention, learning, production and trade,” makes the case that the change going on in the current era is so profound that it rivals the invention of the printing press for how it reshapes society.

Welcome to the era of the “experience.” Gone are the days of manufacturing a simple, physical product. Today it’s all about solutions, services, and experiences—sometimes that’s a physical product plus an experience, sometimes that’s simply a service or experience with no tangible goods. Manufacturers—big and small, traditional and not—all scramble to meet what the Compass Magazine piece calls consumers’ “insatiable appetite for faster, slicker, personalized services.”

What makes the difference in this new market paradigm is the ability to virtualize and collaborate digitally, and to do that—to stay in the game—you’ve got to have the right tools.

What tools do you need?

To respond to customers and the market quickly, to adapt and personalize products, and to integrate physical products with services and experiences, manufacturers can’t rely on traditional habits, processes, and systems.

  • Everything must be digital. Siloed information in filing cabinets isn’t going to cut it in the digital age, so the first key is you need all of your product information, from customer requests and preliminary designs to simulation and test data to marketing and supplier information, in digital form.
  • Everything must be accessible to everyone. You also need all of that information in a single location, where it can be accessed by everyone who needs it. Customer input, marketing material, design files, manufacturing drawings, manufacturing workflows, and more should be co-located in a product file—a single source of truth for critical enterprise data.
  • You’ve got to be able to collaborate. Everyone, everywhere access for corporate data is critical, but so is the ability for team members—and members of different cross-functional teams—to collaborate and share knowledge and know-how. As Shunqun Yang, from Yellow River Engineering Consulting, an international architectural engineering firm based in Zhengzhou, China, explains, “In traditional design, multiple layers of human reviews are required to avoid errors, omissions and collisions. However, with the single data source and real-time collaboration possible on our experience platform, a [single] review can identify and resolve problems early and avoid repeated modifications.” (Quoted in Compass Magazine.)

Be Part of the Renaissance with 3DEXPERIENCE

Dassault Systèmes’ product lifecycle management (PLM) platform, 3DEXPERIENCE ensures you have no more silos and no more islands of information. As one of the premier PLM platforms, it helps manufacturers manage a product from initial idea or request through to service after manufacturing, offering virtualization, collaboration support, and digital efficiency at every step along the way.

It starts with a centralized database, a single repository or vault where all product data is stored, accessible by everyone in—and even out of—the company who needs to participate. As members of the platform, individuals can view shared data, be part of collaborative tasks, and participate in virtual communities around project work. They can collaborate on design, simulation, virtual testing, manufacturing planning and simulation, and other tasks, communicating and saving all notes, changes, versions, and even automated approval routes through the centralized platform.

3DEXPERIENCE can help your organization transform your processes to ensure you take part in the Industry Renaissance. For more information, contact Adaptive.

30 Sep 2019

Catch 3DEXPERIENCE Simulation on Wheels in the Midwest

Check out SIMULIA on Wheels with the 3DEXPERIENCE tour coming to a location in the Midwest.  Mark your calendar to check out the mobile playground which is touring from September – November 2019.

On the tour, you will find a playground of interactive experiences that showcases the power of simulation through a virtual replication of the real world, the “3DEXPERIENCE twin.” As your single source of truth, this enables simulation to be fully integrated throughout concept, design, engineering and manufacturing.

View the Tour Dates:

Anyone is welcome to attend the events marked “Open House”.  Technology Days are private events held at a specific organization.

 

 

 

 

05 Sep 2019

Driving Innovation in a 5G World

Every new advance in technology means a boon for consumers—and a challenge for manufacturers. One of the latest challenges is 5G technology, which looks to provide fast communication, reliable low-latency data links, and support for vast quantities of connected devices. 5G promises new ways of doing business across a variety of industries, from smart manufacturing to safe autonomous driving and remote surgery.

Of course, our devices need to be designed to make use of it—and quickly—and that’s where manufacturers face a bumpy road. They have to deliver high-performance designs in a short time frame with no compromise to compliance, reliability, and safety. Fortunately, just as consumer technology advances by leaps and bounds, so does the technology they need to be competitive.

Digital Simulation is Critical for Innovation

Like many manufacturers designing and producing physical consumer goods, device manufacturers can improve the efficiency, speed, and reliability of their designs by making use of simulation technology. By employing virtual simulation throughout the design process, from early concept exploration to virtual compliance testing, they can save time and money by only making and testing physical prototypes when the digital simulations are error-free.

Fully integrated platforms, such as Dassault Systèmes’ 3DEXPERIENCE, which combines simulation, modeling, manufacturing, collaboration, and intelligence apps in a single package, make the virtual simulation effort seamless.

In addition to the basic capacity in 3DEXPERIENCE for managing complex data and design variations, it’s SIMULIA solution includes CST software for electromagnetics which provides a number of advanced benefits:

  • The ability to simulate full 5G systems in their environment, including the human body.
  • Electromagnetic simulation speeds of up to ten times that of other simulation approaches.
  • High performance computing (HPC) capabilities to explore alternate designs in parallel and meet short product timelines.
  • A library of designable antenna models for rapid synthesis, modeling, and simulation.
  • A complete multiphysics portfolio including structural, thermal, and fluids for co-simulation.
  • High-fidelity design exploration via Design of Experiments capabilities.
  • The ability to create key performance indicators (KPIs) and regulatory results with automated post-processing.

For enterprises looking to develop new products that utilize 5G technology on time and in budget, an integrated platform such as 3DEXPERIENCE can be the answer. For more information on how to maximize your installation and configuration, contact Adaptive.

Be sure to watch our on-demand webinar: Electromagnetic Simulation for Design & Analysis of Antennas & MW/RF Components

Download one of our other resources:

Simulation Enabled Design of Microwave Filters and Multiplexers

Optimal 5G Design with Virtual Prototyping

High Fidelity Simulation for 5G Communication

12 Aug 2019
Electromagnetic Simulation

Webinar: Electromagnetic Simulation for Design & Analysis of Antennas & MW/RF Components

Join Adaptive’s own Wayne Tanner, Chief Operations Officer and Narayana Balu, Simulation Solution Consultant, Dassault Systèmes for our latest webinar.

In the 5G era, antennas and arrays form the basis of connected devices and vehicles. Antenna design, simulation and placement on platforms form one of the largest and strongest application areas of CST Studio Suite. Users design and optimize components ranging from miniaturized antennas printed on densely populated PCBs to electrically large arrays and reflector antennas. Antenna Magus – a unique antenna design tool compliments the design workflow by enabling users to quickly choose antenna models based on a range of specifications.

RF components such as filters, multiplexers, and transducers are also essential with the proliferation and sub-division of frequency bands. It is important to mitigate interference between increasingly crowded systems of transceivers and hence filters with high dynamic range and sensitivity are crucial, but challenging to design and optimize. In this webinar, we will look at how CST Studio Suite helps design and simulate antennas and RF components across a diverse set of industries.

Key Takeaways

  • Learn the fundamentals of antenna design and simulation in a 5G era
  • Design and optimization of antennas and components ranging from miniaturized antennas on PCBs to large arrays and reflector antennas
  • How to mitigate interference between crowded systems of transceivers and filters with high dynamic range
  • How using a comprehensive design and simulation platform provides benefits to cross functional teams to shorten design cycles and bring products to market faster

Watch the Replay.