VI-Grade Case Study - COMPLETE - Rev02

© by VI-grade. All rights reserved. 2007-2008

VI-gradeCase Studies


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Case Study: Audi Achieve best ranking against competitors Ranking based on iso lane-change

manouver, real and virtual

Use VI-SportsCar to model high performance car

Derive simplified model from system identification for fast approximate results

Utilize special VI-grade routines for trajectory planning and cone hit detection

Tight integration of VI-Sportscar and modeFrontier to find optimal vehicle configuration

A simulation-based fast procedure was established to accelerate the development process

The ranking based on this procedure matches the ranking vs. on road evaluation, thus allowing enormous time saving from real testing

Challenge

Solution

Outcome

P8P7

P6P5P4

P3P2

Download full story from www.vi-grade.com


Case Study: Opel Reduce cost and increase reliability of the

durability process Increase result quality by avoiding errors

related to manual file manipulation High number of maneuvers and vehicle

configurations require high degree of automation

VI-grade Service team developed a custom environment based on VI-SportsCar:

• Test rig for static load prediction• Standardized full vehicle dynamic events• Utilization of VI-Road for driver line prediction

virtual Road Load Data Acquisition (vRLDA) is now part of the GM vehicle development process

Post-processing tools for result checks, comparisons, automated plot and report generation embedded in the tool

Challenge

Solution

Outcome

Dynamic Load Prediction

Static Load Prediction

vRLDA

Data Maturity

Hardware build and test

Virtual Engineering



Case Study: Porsche Establish development process to assure

and improve comfort performance High fidelity component models are required

for accurate comfort and durability assessment

VI-grade’s Service team developed a custom drum testrig for cleat crossing to investigate steering wheel vibrations

VI-NeuralNetwork technology is used for high fidelity component models such as a damper

VI-SportsCar is first choice to capture transient behavior

Engineers at Porsche are now able to support their design teams utilizing solutions implemented by VI-grade

Improved bi-directional communication with test and design teams

Challenge

Solution

Outcome



Case Study: ESTECO

Intensive use of simulation techniques for understanding dynamics, improving comfort and predicting vehicle road loads

Correlate the detailed and the simplified model simulation results

Use modeFrontier together with VI-grade products to better understand parameters influence on overall performances

The complexity of the virtual model makes it impossible to estimate parameters interactions with using traditional methods

Multisimulation technology strongly helps to drive the entire engineering activity to the final goal: improve vehicle performance

Successful collaboration between ESTECO and VI-grade

Challenge

Solution

Outcome



Case Study: Multimatic Provide Vehicle Dynamics simulation to motorsport

industry in a timely manner Provide accurate results Be able to run DOE campaigns in a reduced amount

of time

Use VI-SportsCar to model race cars Validate the model against telemetry data from Pi

system Use VI-CarRealTime to speed up simulation process

without losing accuracy

Very good correlation between VI-SportsCar model and telemetry data

Very good correlation between VI-SportsCar model and VI-CarRealTime model

6 times speed-up factor by switching toVI-CarRealTime model

Possibility to run sensitivity analyses to vary important parameters

Challenge

Solution

Outcome



Case Study: NewmanHaasLanigan Racing Reliability: ensure cars are the most reliable (‘To

finish first, first you must finish’ - GT). Knowledge: study and understand the vehicle better

than any other competitor Optimize: armed with the best understanding,

configure the vehicle to best achieve our goals Efficiency: prepare and service the cars faster than

anyone else (office/shop/track/pit stops) Strategy: apply the smartest race-strategy

Use VI-SportsCar to gain knowledge on loads for durability assessment

Run battery of regression simulations to refine input data (see publication on virtual wheel force transducer)

Use validated models in VI-SportsCar to prepare the racecar

Eight-time Champ Car World Series Champions (’84,’91,’93,’02,’04-07*)

Rim

WFTHub

Slip-ring Spider Slip-ring /Cable

virtual wheel force transducer used to refine tire data

Challenge

Solution

Outcome


Case Study: Audi Sport AG In late 90’s Audi Sport decided to re-enter

Le Mans 24hours race.

Use VI-SportsCar to build Virtual Race Car + Track.

Use simulation for rapid design iteration to find best set-up

1999 : 3rd 2000 : 1st, 2nd, & 3rd

2001 : 1st & 2nd 2002 : 1st, 2nd, & 3rd 2003 : 1st, 2nd (Bentley) 2004 : 1st (private team) 2005 : 1st (private team)2006: 1st

2007: 1st

2008: 1st

Challenge

Solution

Outcome

“…procedures to optimize vertical dynamics, aerodynamic, mechanical setup and differential setup at the same time simulating a high dynamic kerb crossing have been investigated… simulation helps to understand how to improve performance of a complex race vehicle...“

--Dr. Martin MühlmeierVehicle DynamicsAUDI Sport AG Ingolstadt


Case Study: TREngineering Working in the motorsport competitions (A1GP, F3,

DTM) the heve to shorten development cycle while improving the over all performance.

Use VI-SportsCar to gain knowledge on how different subsystems asnd the entire full-vehicle work in all different race conditions

Perform several different type of analyses (suspension, 4post testrig, ADAMS/Insight, Aerolap, Close loop track simulations)

Top A1GP Team

Challenge

Solution

Outcome

trackrod adj.pushrod adj.

“Using different types of simulations available within VI-SportsCar, and combining them properly with in-house tools, it’s possible to determine and optimise vehicle performance”

-- Marcello Di FinaHead of Calculation Dept.


Case Study: Politecnico di Torino

Model Three Tilting Wheels (TTW) Vehicles and understand their stability and dynamic behaviour

Validate model tests vs. experimental results Develop a design tool for TTW vehicles.

Use VI-Motorcycle to model the TTW vehicle Take into account frame flexibility to capture correct

lateral dynamics Comparison between an equivalent 2-wheels vehicle

and TTW Sensitivity studies for stability

Very good correlation with test results Possibility to use VI-Motorcycle to predict TTW

behaviour

Challenge

Solution

Outcome



Case Study: APPH (part of BBA Aviation Group)

High quality supplier for complete landing gear system for civil, military, regional aircrafts and helicopters

Develop a complex design process that involves several different disciplines: CAD, FEM, MBS and physical testing

Use VI-Aircraft to model the landing gear subsystem and, taking into account:

• Structural flexibility

• Non-linear force components

• Stick-slip friction

• Hydraulic systems

• Tyre effects

Virtual approach allows to run multiple analyses in a reduced amount of time

Possibility to understand the influence of every parameters

Challenge

Solution

Outcome



Case Study: FIREMA Reduction of time to market for new rolling stock

leads to shorter design time Increase confidence in design Front load the design cycle for virtual homologation

VI-Rail is used for many standard analysis:• Modal• Stability• Comfort• Lateral Dynamics• Souplesse• Security vs. derailment

VI-Rail is used for advanced analysis:• Dead end impact• Dynamic cornering for clearance and buffer studies• Wheel set/bogie dynamics

VI-Rail is used to simulate a wide range of events, not only vehicle dynamics applications

Upfront analysis drives design decisions at Firema and leads to changes of vehicle parameters

Challenge

Solution

Outcome



Case Study: MMU Develop tools and methods to investigate innovative

new slab track designs for the European INNOTRACK project

• Pan-European project bringing IM and industry suppliers together

• Aiming at doubling passenger traffic & triple freight while reducing LCC by 30%

VI-grade and MMU engineers jointly developed a new Flexible Track System Model embedded inVI-Rail

The model combines a wheel rail contact algorithm with a beam or flexible body track model

Special flextrack post-processing GUI for stress calculation

Automatic track generation GUI allows for fast creation of new designs including support conditions

Easy-to-use set of tools in VI-Rail is used for the European INNOTRACK project by MMU and Corus

Challenge

Solution

Outcome

Max +σ (between bogie axles)

Max -σ (under axles)

Δ

σ

∆φ

PAD

FASTENING

Effect of Rail Roll on:

•Contact location

•Contact patch

•Number of contacts



Case Study: Reduce cost and time to market Gain and demonstrate engineering

competence to clients Confidence in design decisions for best

possible running behavior

VI-Rail is used to study the influence of several key design features of low-floor trams on the wheel profile wear

Design variations and concepts for:• Pivoting and non-pivoting bogies• Grooved and non-grooved rails• Wheels sets and independent wheels

Running dynamics event it is possible to determine wheel wear and to compare the influence of the different design parameters

VUKV is able to improve existing designs and to create new designs quickly with high confidence utilizing the simulation capabilities of VI-Rail

Challenge

Solution

Outcome

Front Outer-Curve-Side Wheel

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Rear Outer-Curve-Side Wheel

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Simulations – results, profile wear



Case Study: xxx

xxx

xx

Challenge

Solution

Outcome



Case Study: Aprilia Racing Searching for Max performance of a

racing bike• Reduce lap time• Increase maneuverability

Reduce simulation time

Use VI-BikeRealTime together with MATLAB and modeFrontier.

Simulation time reduced by 90% Reliable results

Challenge

Solution

Outcome



Case Study: KTM Load prediction for durability

analysis Co-simulate control systems (ABS) Handling and Stability analysis

Use VI-Motorcycle to model the entire system including virtual testrig and virtual roads.

Analyze the model in all different working conditions

Co-simulate VI-Motorcycle and MATLAB Simulink

Precise identification of hot spots for life prediction.

Detailed ABS modeling

Challenge

Solution

Outcome



Case Study: Piaggio Develop a new scooter with a

revolutionary configuration (MP3) Make an extensive usage of

numerical simulations in order to anticipate problems

Use VI-Motorcycle to model the new vehicle and to run several different tests.

VI-Motorcycle results have been compared with experimental results

Good agreement between VI-Motorcycle and experimental results.

Simulation had an important role in the MP3 design process.

Challenge

Solution

Outcome



Case Study: Ducati Replicate a track event on a virtual

environment Investigate the influence of suspensions

and steering damping on motorcycle stability under acceleration

Use VI-Motorcycle to model the bike, the circuit and the rider.

Verify the importance of taking into account grip loss.

Investigate the influence of steering and suspension damping for the motorcycle stability.

Easy to perfom sensitivity studies because of the fully parametric model in VI-Motorcycle

Seamless integration between VI-Motorcycle and MATLAB Simulink

Challenge

Solution

Outcome



Case Study: Ducati Corse Be the fastest motoGP racing bike

Use VI-Motorcycle and VI-Rider to investigate complex transient dynamics

Sensitivity studies for stability

Very good correlation with test results Virtual model used to understand reality and test

alternatives quickly Real-time model used as support tool for track

engineer

Challenge

Solution

Outcome



Case Study: NewmanHaasLanigan Racing

Ride optimization with 2 major objectives:• Modal control of sprung/unsgrung mass

systems• Aerodynamic Platform control

Solve conflicts between objectives requiring softer springs and others requiring harder springs.

Find an alternative to rig testing Define a method to model PSD

irregularities from measured elevation Use VI-Road to model roads with PSD

disturbances Perform VI-CarRealTime analyses on

different circuits

Eight-time Champ Car World Series Champions (’84,’91,’93,’02,’04-07*)

Challenge

Solution

Outcome



Case Study: ABARTH Develop simulation methodologies for

improving performance of a rally car

Use VI-SportsCar to gain knowledge on how different subsystems and the entire full-vehicle work in all different race conditions

Use VI-CarRealTime to run fast simulations and explore several different design variables

Perform several different type of analyses with 2WD and 4WD full vehicle models for best tuning (suspensions, engine, driveline, etc.)

Top Tourism Sport and Rally Car Manufacturer

Challenge

Solution

Outcome



Case Study: MIRA Development of a retro-fit hybrid

conversion which slashes fuel costs & lowers tailpipe emissions whilst retaining performance

To use VI-CarRealTime in order to have a fast and reliable vehicle model to connect with the control systems developed in the MATLAB/Simulink environment, and demonstrate novel vehicle dynamics features by using the rear mounted electric motors for All-Wheel-Drive (eAWD) and torque vectoring (eTV).

Advanced control system for vehicle dynamics developed and tested virtually

Challenge

Solution

Outcome



Case Study: Italdesign Giugiaro Develop an high performance hybrid

vehicle Being able to predict max performances

given by electric propulsion

To use VI-CarRealTime in order to model vehicle and to simulate max perfomance on Monza Track

Namir prototype has been set up with VI-CarRealTime in a such a way to accomplish performances similar to a GT car

Challenge

Solution

Outcome


Case Study: Audi Integrate VI-CarRealTime in the

Chassis Simulation Environment Being able to simulate interactions

between different control systems

To use VI-CarRealTime in conjunction with Adams/Car and Matlab.

The model gets created from Adams/Car

VI-CarRealTime model includes control systems modeled in MATLAB Simulink

Very good correlation between Adams model and VI-CarRealTime model

Design of control algorithms supported by VI-CarRealTime

Streamlined Chassis Simulation environment

Challenge

Solution

Outcome


Active DifferentialAudi Dynamic SteeringSemi-active DamperAirspringPowertrain controlESP incl. ABS, EBV, ASR, MSR


Case Study: Lockheed Martin Assess safe release of weapons (and

stores) for JSF multi-role fighter through a simulation procedure that will provide the basis for store certification

Use of a custom VI-AirCraft environment to compute store trajectories at the various conditions in the aircraft flight envelope

Model included aircraft structural responses and other physical models to obtain the most flight representative store trajectory

Model included pre-flight uncertainty analysis with MonteCarlo methods

Higher fidelity models Fewer required flight tests Program cost savings

Challenge

Solution

Outcome


Case Study: Alenia Aeronautica Realize a fully integrated procedure for

CAE aerospace simulation Improve efficiency of computational

process

Development of an integrated environment based on VI-AirCraft and MSC SimXpert for calculation of ground external loads according to aviation regulations and/or company policy and to pinpoint the critical conditions for sizing purpose

Coupling of VI-Aircraft with Nastran

Ability to perform comparative studies between flexible and rigid aircraft in order to evaluate the hypothesis of the flexibility and/or rigidity on the external loads prediction

More efficient simulation process

Challenge

Solution

Outcome


Case Study: British Aerospace Perform landing gear loads analysis of

the Short Take-Off and Vertical Landing (STOVL) variant of the F-35:

• Design an optimized ski-jump ramp profile • Develop the Shipborne Rolling Vertical

Landing (SRVL) maneuver

VI-Aircraft used to produce the loads used as primary design driver to optimize the ramp profile

VI-Aircraft used to forecast the effects on aircraft operations due to build and in-service variations from the nominal design profile

VI-Aircraft proved to be critical to the integration of the F-35B onto the UK CVF through;

• Providing data to drive decisions on an optimized ski jump ramp profile,

• Fixing take-off performance

Challenge

Solution

Outcome


Case Study: Lockheed Martin Correlate laboratory drop testing with

analysis predictions, with the purpose of :

• Qualifying the gear• Verifying and refining the model

VI-grade Landing Gear Drop Testrig corresponding to SAE 6053

Landing Gear Drop Test Assembly Validated subsystems used in full

airplane assembly

Very good correlation with test data Significant features uncovered by

correlation:• Freeplay• Tire friction modeling• Variable discharge coefficient• Airspring modeling

Challenge

Solution

Outcome

Documents

VI-Grade Case Study - COMPLETE - Rev02