© 2007, ProSTEP iViP e.V. ·07-12-06

ProSTEP iViP e. V. / VDA

Integration of Simulation and

Computation in a PDM-

Environment (SimPDM)

Introduction

15-16 November, 2007

5th Technology Workshop Bilbao

AutoSim

© 2007, ProSTEP iViP e.V. ·07-12-06

Agenda

1. SimPDM Members

2. Integration problems of CAE into PDM

3. Objectives

4. Use Cases

5. SimPDM Data Model

6. Benefits through SimPDM

7. Summary

© 2007, ProSTEP iViP e.V. ·07-12-06

Members of Project Group SimPDM

OEMs:

Audi AG

BMW AG

Behr GmbH & Co. KG

Daimler AG

Dr.Ing.h.c.F.Porsche AG

MAN Turbomaschinen AG

Robert Bosch GmbH

Schaeffler KG

MagnaSteyr AG & Co KG

Volkswagen AG

System vendors:

:em engineering methods AG

Agile Software Corporation

Altair Engineering GmbH

CADFEM GmbH

FE Design GmbH

IBM Deutschland GmbH

MSC.Software GmbH

MDTVision GmbH

PDTec GmbH

PROSTEP AG

Parametric Technology GmbH

Siemens PLM Software

T-Systems International GmbH

Universities & Research Institutes:

The Virtual Vehicle Competence

Center

IWP, TU Chemnitz

DiK, TU Darmstadt

IMI, TU Karlsruhe

© 2007, ProSTEP iViP e.V. ·07-12-06

Product Structure vs. Model Structure

PDM - Product Structure

§Structure usually CAD Model

conform

§Nodes represent parts with

unique ID

§Oriented on Manufacturing

BOM

§ Structure orients on specific

simulation task

§Node represents abstract

elements of model

§Bases on simulation domain

specific elements

Simulation Model Structure

Swivel joint

MBS model “Front axle”

Spring

Damper

Wheel pillar

Wheel

Suspension arm

. . .

Front axle

Spring

Damper

Suspension arm

Wheel pillar

Wheel bearing

Brake caliper

Suspension strut

. . .

Source: DiK, TU-Darmstadt, Feasibility study

© 2007, ProSTEP iViP e.V. ·07-12-06

Quantifying Time within Simulation

Information acquisition*

Data preparation

Model creation

Computation / Simulation

Reporting

StartStart

GoalGoal

51%51%

49%49%

Share of total time(Average over all respondent)

* On new computation, no variant computation

Source: DiK, TU-Darmstadt, Feasibility study

© 2007, ProSTEP iViP e.V. ·07-12-06

Problems of Integration

Time line t0 t1 > t0

DM

U

PDMSystem

Product structure (Bill of material)

CAD

synchronous Product development

asynchronous

• Asynchronous (manual data request)

ð Time delayð Possibly wrong versions/variantsð Computation results do not fit with

current development status

vir

tua

l p

roto

typ

e

CAE

Concept validation

• Synchronous (automated parameter synchronization)

ð Change management and version control

ð Acceleration of processesð Simulation always takes place on

current development status

Connection to PDM

synchronous Concept validation

© 2007, ProSTEP iViP e.V. ·07-12-06

Challeges and Goals in General

• Challenges (from user’s point of view)– Massively raising number of simulation for virtual product

verification requires increasingly the introduction of Simulation Data Management

– Simulation and computation data usually are not managed within the PDM system

– Time for gathering data and information for the model creation takes approx. 50 % of the time. This is rather long.

• Project goals (from user’s point of view)– Reduction of wrong data sets / versions within computation

– Reduction of the portion of time for gathering data and information for the model creation

– Reduction of the time amount needed for simulation model changes when design changes occur

© 2007, ProSTEP iViP e.V. ·07-12-06

NativeFormat

STEP

NativeFormat

STEP

Simulation-SystemPDM-System

Model structure

Check-Out

Check-In

Productstructure

Simulation-System

mass:

inertial:

structure

nr.:

version:

Activity Recommendation

Po

stp

rocesso

rP

rep

roces

so

r

Po

stp

rocesso

rP

rep

roces

so

r

1

3

2

3

1. Development of CAE model structures parallel to the product structure in the

PDM-systems due to different version cycles.

2. Definition of necessary extensions in the CAE-systems.

3. Specification of mapping between PDM- and CAE-systems model structures.

4. Specification of requirements for necessary interfaces software.

5. Prototypical implementation and validation in pilot operation.

4 5 4 5

Source: DiK, TU-Darmstadt, Feasibility study

© 2007, ProSTEP iViP e.V. ·07-12-06

SimPDM Objectives

SimPDM „Integration of Simulation and Computation in a PDM Environment “

à Development of a specification in order to integrate CAE-Systems into a PDM-Environment.

Objectives:– Definition of use cases for the development of a specification for

the integration – Using synergetic effects through experience exchange and

knowledge transfer of SimPDM members– Definition of communication processes between a xDM system and

SDM systems within the PDM environment– Definition of a meta data model for simulation and computation data– Definition of an industrial standard for integration

Non objectives:Does not define an interchange data format between different CAEapplications

© 2007, ProSTEP iViP e.V. ·07-12-06

PDM

xDM 2

CAE xDM 1

Parameter

synchronization

between product

structure and CAE

model structure

Connection of

CAE application and

xDM system

CAE-

SystemConnection

PDM Functionality tailor-

made for CAE data

management

SimPDM - Approach

• Process analysis – potential

identification for SimPDM

• Development data model –

structuring data and information

• PDM functionality tailor-made for

CAE data management (e.g. own

version management, own

configuration management)

• Parameter synchronization –

functionality for the interdisciplinary

communication

• VDA / ProSTEP iViP

recommendation – towards an open

standard

• Allows a matching granularity of

stored data (ranging from managed

files to accessible parameters)

ABC

DB

X

© 2007, ProSTEP iViP e.V. ·07-12-06

SimPDM Use Cases

1. SimPDM process „Crash simulation of complete vehicles (FEA)“

• Configuration of modules and complete product models

• Process has different starting points

• Data handling

2. SimPDM process „ Analysis of operation loads on a virtual test track (usually MBS)“

• Simulation has lead within development

• Working with “abstract” data, few geometry

• Working with templates

3. SimPDM process „Design evaluation of charge air cooler (CFD)“

• “Simple” validation of a defined product

• No complex product configuration

© 2007, ProSTEP iViP e.V. ·07-12-06

Use Case 1

Crash simulation of complete vehicles

1. PDM-Backbone

2. Definition of configuration

3. Data extraction

4. Data conversation

5. Geometry meshing

6. Create input deck

7. Computation

8. Evaluation

9. Documentation

Image Source: Daimler AG

© 2007, ProSTEP iViP e.V. ·07-12-06

Use Case 2

Analysis of operation loads on a virtual test track

1. Data collection

2. Model generation (topology, parametric design)

3. Definition of analysis

• Definition of driver model

• Definition of virtual test track

• Configuration of simulation

4. Simulation run

5. Evaluation of simulation results

Image Source: Dr.Ing.h.c.F.Porsche AG

© 2007, ProSTEP iViP e.V. ·07-12-06

Use Case 3

Design evaluation of charge air cooler1. Import of CAD geometry (e.g. via STEP)

2. Geometry preparation: adjusting details, surfaces

3. Geometry meshing

4. System data acquisition (pressure loss and heat carriage functions) from data base à computation of porosity coefficient

5. Assembly of meshes (3), definition of border constraints, material data, coefficients within the pre-processor à creation of solver input data

6. Start of computation and cluster segmentation as the case may be

7. Post processing: identification of integrated result data like pressure loss, temperature differences, homogenity coefficients, creation of sections and plots with temperature, pressure and air distribution

8. Documentation

Image Source: Behr GmbH & Co. KG

© 2007, ProSTEP iViP e.V. ·07-12-06

Processes within SimPDM Context1) Process analysis

2) Clustering to Use Cases

4a) Referencing of Use Cases to Data Model using SimPDM Services

ABC

DB

X

4b) Definition of to-be-process

5) Documentation in the VDA-Recommendation and Recommended Practices

ABC

DB

X

3) Detailed data flow analysis within Use Cases

© 2007, ProSTEP iViP e.V. ·07-12-06

Base information (BASE)• Analysis definition• Model assembly• Analysis result• External file references• Versioning

CAD-PDM-Data (CAD)• Reference to CAD-PDM data• BOM, connection element list, CAD data

Properties (PROP)• General properties• Properties based on

• Parameters• Characteristic diagrams• Functions• Elements

• Material properties• Property sets

• Versioning

Topology (PROP)• Cross domain definition• Generic• Expandable

• Defined by properties

Setting (SETT)• Solver settings• General settings

Loads (LOAD)• Load cases• Start conditions• Boundary conditions

Configuration (CONF)• Abstract product structure• Configuration

Parameter synchronization (SYNC)• Reference on parameter in other databases• Mapping specification definition

Modular Structure of SimPDM Data Model

© 2007, ProSTEP iViP e.V. ·07-12-06

Packages SimPDM Data ModelReasonable combinations of used packages:

• Only BASE: Management of– Analysis control– Model and model assemblies (optionally)– Analysis results and reports

• BASE, CONF: Additional Management of– Model variants

• BASE, TOPO, PROP: Additional detailed Management of– Model topologies– Topological element properties

• BASE, TOPO, PROP, CONF: Additional Management of– Model variants

• BASE, TOPO, PROP, SETT/LOAD: Additional detailed Management of– Solver settings– Load cases with relations to topological elements and their properties (Start and

boundary conditions)

• BASE, TOPO, PROP, SETT/LOAD, CONF: Additional Management of– Model variants and load cases

The package CAD can be used optionally with all reasonable combination. It allows the additional management of function model information coming from CAD-PDM environment (BoM, Connection element list, geometry)

The package SYNC allows parameter synchronization and mapping specification definition between CAE-xDM and CAD-PDM environment.

© 2007, ProSTEP iViP e.V. ·07-12-06

Benefits of SimPDM

• Benefits Simulation Data Management:Reproducibility (of results), standardized processes and data management, Authorization concept, ideal case: own versioning and own configuration within CAE environment

• Benefits SimPDM (as an open standard):common understanding, well defined language and terminologies for requirements, broad acceptance, generic solution, less effort for application customizing, therefore market extension, availability of interfaces

• Benefits SimPDM (on technical issues compared to today’s simulation data management systems):management of items up to parameters, parameter synchronization CAD PDM – CAE xDM and other DB’s, e.g. CAT, generic connection of xDM system and CAE application

© 2007, ProSTEP iViP e.V. ·07-12-06

Summary

• Due to increasing virtual product validation the CAE data management is a great challenge

• Simulation models and results and its relations to the design data must be managed

• Version and configuration management for simulation data, reproducible input and result data

• SimPDM provides simulation data management for an integrated product development environment

• SimPDM avoids proprietary solutions based on enterprise specific requirements

• SimPDM is the common approach developed with end users, CAE and PDM system vendors and research institutes

© 2007, ProSTEP iViP e.V. ·07-12-06

Thank you for your attention

Contact:

Dr. Marcus Krastel, SimPDM project coordinator

:em engineering methods AG

Lise-Meitner-Str. 10

64293 Darmstadt

Phone: +49 (61 51)/39 77 88 - 5

Mail: marcus.krastel@em.ag