Modern Seat Development Process in Faurecia Modern Seat Development Process in Faurecia supported...

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Technical perfection, automotive passion.

Marcin Debniak, Faurecia Poland R&D

European HyperWorks Technology ConferenceBerlin, GermanyOctober 23-24, 2007

Modern Seat Development Process in Faurecia supported

by Hyper Works products

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Technical perfection, automotive passion.

Door panel / Modules

Instrument panel / Cockpit

Front endSeating

Exhaust system

Acoustic package Door panel / Modules

Instrument panel / Cockpit

Front endSeating

Exhaust system

Acoustic package

Faurecia is an expert in 6 major modules

What is Faurecia

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Technical perfection, automotive passion.

Auburn Hills

Toledo

Troy

USA

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Pune

Shin-Yokohama

India

JapanShanghai

China

KoreaShihwa

MagnyMéruMouzonNogent/Ver.Seloncourt

AudincourtBrièresBavansBeaulieuFlers

Quart de Poblet

Torsas

Spain

Sweden

Germany

France

FürthHagenbach Ingolstadt MunichPeine SassenburgScheuerfeldStadthagen

Poland

Grojec

• Sales: Over 11.6 billion €

• R&D 5,2% of sales (610M€)

• Over 4000 engineers

• Over 65,000 employees world wide

• 28 R&D centers

• Listed on the Euronext Paris - Eurolist

Faurecia basic key figures 2006

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Technical perfection, automotive passion.

Car Seats

• One of six modules produced by Faurecia• Very complex structure• Up to 99 parts and 16 electrics engines • Seat design takes into account numerous factors,

including safety, comfort, and the standardization of parts that are not visible and an extreme customization of appearance

• More and more customers requirements as well as legal requirements

• Year by year number of seat features is permanently increasing

• Up to 80% of design given by safety issues• Comfort becomes more and more important• Around 100 test before being assemble in vehicle

• New ideas and permanent innovation

What Grojec is focus on

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Technical perfection, automotive passion.

Why CAE Department in Grojec (Poland)?

• Biggest production plant in Poland (over 1500 employees)

• Good location, close to main strategic customers (France and Germany) – mobility

• Great potential – good educated young staff

• Fast growing market

• Low Cost Country

GRÓJEC

Faurecia R&D GROJEC

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Technical perfection, automotive passion.

• 28 Simulation Engineers

• Work on complete seats projects as well on single parts modifications and optimization on following levels:

• Meshing• Static and quasi-static calculations• Dynamic calculations • Optimization

• Used software: HyperWorks, ABAQUS and PAM-CRASH

• Support for Faurecia offices in Germany, France, China and USA

CAE GROJEC activity

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Technical perfection, automotive passion.

Altair Software used in Grojec:

HyperWorks

HyperMesh – pre-processing (meshing and model preparation)

HyperCrash – pre-processing (model preparation)

HyperGraph – pre-processing + post-processing

HyperView – post-processing (model evaluation and results …)

RADIOSS – explicit solver

CAE GROJEC

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Technical perfection, automotive passion.

Single parts (wires, tubes, metal parts etc.)

Complete seats

Car environment

Assemblies

Mechanisms (solid meshing)

Meshing – HypeMesh

CAE GROJEC – HyperMesh support

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Technical perfection, automotive passion.

Single parts

Complete seats

Car environment

Assemblies

Mechanisms

CAE GROJEC – HyperMesh support

• Welding and spot welds definition (up to 200 points)• Pivots, screws , rivets• Property definition (thickness, type of elements, materials, etc) • Contact definition

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Technical perfection, automotive passion.

Single parts

Complete seats

Car environment

Assemblies

Mechanisms

CAE GROJEC – HyperMesh support

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Technical perfection, automotive passion.

Single parts

Complete seats

Car environment

Assemblies

Mechanisms

CAE GROJEC – HyperMesh support

• Include files creations• Contact managements• Occupants• Boundary conditions and loads

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Technical perfection, automotive passion.

Why HyperMesh?

• Simple and friendly user interface

• User defined applications – macros

• BOM (Bill Of Material)

• Compatible with most of CAD and FEA software• CAD (Catia V5, Catia V4, Unigraphics)• FEA (RADIOSS, ABAQUS, PAMCRASH, Ls-Dyna)

• Smart and powerful algorithm for shell and solid meshing (Batchmesher, HyperMorph)

• Very efficient in daily work, stable (especially ver. 7)

• Easy managing of big models (include manager, groups etc. )

• Good technical support (customization, trainings)

CAE GROJEC – HyperMesh support

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Technical perfection, automotive passion.

Why HyperCrash?

• Software available only for RADIOSS (well suited)

• Visually clear, smart and simple functions:

• Foam compression tool

• Easy and fast dummy positioning

• Seat belts generator

• Contact interfaces manager

• Penetrations and intersections checker

• Quality manager

CAE GROJEC – HyperCrash support

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Technical perfection, automotive passion.

Why HyperView?

• One post processing tool for all codes

• Simple and user friendly interface

• Easy graph creation

• Possibility to compare crash- with calculation results

• Simple and intuitive results visualization

• Macros and user defined functions

CAE GROJEC – Hyper View support

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Technical perfection, automotive passion.

FEA explicit calculations using Altair Software - Radioss

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

- Better part of:

-Dynamic tests

-Static and quasi-static testsECE R21Test of the minimum radius

During the test, it is determined whether partswithin the impact zone used for reinforcementmay be displaced or protrude so as to increasethe hazards to passengers or the severity ofinjuries.

ECE R14Dynamic Test95th percentil dummyPulse ECE R 1650km/h

Airbag deactivated

E CE R 17H eadrestraint M om ent T est

M om ents:

M om ent about H-Point = 373 NmHeadrest = 373 Nm

Dyna m ic Test(Fron tal- and rear im pact)

Test without Dumm ySpeed = ca. 4 5 km /hDeceleratio n = 20 g for 30 ms

E CE R17

E CE R17Load Test (H -Po int)

Mo men t = 530 Nm

Headrestraint Im pact Test

Impact Speed = 24,1km /hReduced m asse = 6,8 kgmax. deceleration = 80 gmax. decelerations time = 3m s

ECE R17ECE R25

ECE R16Dynamic Test

Test with dummy (50%)Speed = 50km/hdeceleration = 26g - 32g

0

5

10

15

20

2530

35

0 20 40 60 80

AB

C

F

ED

G H

I

Ver

zöge

rung

in g

Zeit in ms

ECE R95Dynamic Test(Lateral collision)

Test with EUROSID Dummy(50% Dummy)Speed = 50 km/hDeceleration = according to the mobile barrier

ECE R94 Dynamic Test(Protection of the occupants in the event of a frontal collision into a 40% barrier)

Test with dummy (50%)Speed = 56km/h

Belt anchorage 3 Point

Loads:

Pelvic = 13500NTorso body block = 13500NAditional: 20 x seat weight (if at least 1 Anchorage is at the seat)

ECE R14

ECE R17Dynamic Test

(Luggage Load Protection)

Two Types of Test BodiesWeight = 18kg and 10kgSpeed = ca. 50km/hDeceleration: acc. to crash corr.

0

10

20

30

0 20 40 60 80 100 120

28

50 65Zeit in ms

Ver

zög

eru

ng

in g

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

Dynamic tests:

- Frontal Collison

- Rear Collision

- Luggage Load Protection

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

Static (quasi static) tests:

- Seat Belt Anchorage ECE R 14

- ISOFIX testECE R 14

-Static (quasi static) and dynamic customer defined tests, with all requested configurations.

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

Acceptable results compared to reality. Convergence 75-90%

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

Test – calculation convergence: 92%

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

Why RADIOSS?

• Included in HyperWorks package

• Code very stabile regarding unexpected issues

• Work very well with big models (include structure, transform cards, C-Nodes, etc.)

• Proper material definitions for most of materials (i.e.. Foam)

• Able to work in DMP mode

• Efficient – calculation time

• Convergence with real test (75-92%)

• Used by our customers (Peugeot, Citroen, Ford, FIAT, etc.)

CAE GROJEC – Radioss solver support

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Technical perfection, automotive passion.

Conclusion!

Why we are using HyperWorks software?

• One package for pre-, post-processing and explicit solver:• Simple • User friendly• Well prepared user interface• User defined functions and macros• Ready to develop • Open to customers suggestions and customization• V7 release very stable

• HypeMesh – best tool in terms of meshing and model preparation (interface,tools and graphic visualization)

• HyperView – intuitive interface, powerful graphs , smart, fast, easy to customize, tpl• RAIDOSS – worldwide used by our customers, wide range of

posibilities (explicit, implicit), acceptable accuracy

CAE GROJEC

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Technical perfection, automotive passion.

Future view!

1. Strong collaboration is expected between Faurecia and Altair2. Radioss explicit evaluation – accuracy 90-95%3. Implementing Radioss as a main calculation code4. Dummy improvements (rigid, deformable)5. Sixth stars and Radioss calculation – whiplash methodology6. Implementing Radios implicit as a stabile solution for qusi-static calculation7. Implementation more and more of Optistruct in seat development8. BatchMesher evaluation9. Stabilization of Hyper Works v8 on Linux platform

CAE GROJEC

Technical perfection, automotive passion.

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Technical perfection, automotive passion.

European HyperWorks Technology Conference, Germany, Berlin 23-24 October

Thank You For attention !