Vehicle system integration guidelines for component suppliers · 2020. 11. 19. · Ensure vehicle-level component NVH evaluation Throughout the development cycle Evaluate the sub-system

Vehicle system integration

guidelines for component suppliers

Where today meets tomorrow.

.

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



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?



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



Content

Full vehicle testing

and TPA

Component-based

TPA

Model-based

development

Model-based system

testing



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



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, …)




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






-40.00

50.00

dB

(A)

Pa

Contribution at path or group (case vs. rpm or frequency) A

Understand Critical

Transfer Paths

Cascade Targets



9 copyright LMS International – 2010


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




Evaluate the sub-system

in full vehicle

Cascade targets from

system to components



Bench marking &

Target setting

Concept Design


Bench Validation

Troubleshooting

What-if games &

optimization


Component-based TPA






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 / …



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



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



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



Component-based TPA

Improve OEM cooperation

by setting realistic targets

on invariant loads

Enhance usage of bench

data to create virtual

prototype assembly



Bench marking &

Target setting

Concept Design


Bench Validation

Troubleshooting

What-if games &

optimization


Model-Based Development






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







-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




Full vehicle reverse engineering



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



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



Virtual prototype assemblyMaximized data usage for a wide range of performance predictions




Enable component

concept design with

system simulation

Quick assessment of

many design variants



Bench marking &

Target setting

Concept Design


Bench Validation

Troubleshooting

What-if games &

optimization





Model-Based System Testing



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



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



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



Model-based system testing

Enable component

testing in the lab in real-

life conditions

Solve integration issues

upfront





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?

Documents

Vehicle system integration guidelines for component suppliers · 2020. 11. 19. · Ensure vehicle-level component NVH evaluation Throughout the development cycle Evaluate the sub-system