Accelerated Load Data Analysis with LMS TecWare

(1)

Accelerated Load Data Analysis with LMS TecWare

(2)

Agenda

2

The durability engineering process

1

Durability challenges

3

LMS TecWare value proposition

4

LMS TecWare tips and tricks

(3)

(4)

Industry Challenges

! Shorten design cycles

! Test-based fatigue takes too long

! Increase productivity of product development

! Gain full insight into durability ! Improve relationship

OEM / supplier ! Innovative designs

!Light weight materials ! Compact structures ! More variants

!On fewer platforms ! Avoid product recall

!Superior quality ! But not over designed

!Lower price

! Enormous variety of choices

While competition requires rethinking processes… Resulting in…

Challenging market requirements…

(5)

The durability

(6)

Durability engineering process – “As-is” process

Build – test – redesign –

no longer practical

Time consuming -> overdesign

Very late in the development process Costly

Strength only ! Unrealistic loading

(7)

LMS TecWare

(8)

LMS durability engineering process – “To be” process

Optimizing for durability performance

VALUE 1 Assess durability performance earlier VALUE 2 Realistic simulation through representative loading conditions VALUE 3 Accelerate durability testing

(9)

The durability engineering process

LMS’ durability solutions – products and services

CATIA V5

The Durability Alliance

Performance simulation

Test

Load data processing

Refinement engineering Refinement engineering Detailed engineering Detailed engineering Upfront engineering Upfront engineering

Design

LMS Virtual.Lab Durability LMS TecWare LMS Virtual.Lab Designer Fatigue LMS Test Mobile

(10)

LMS durability solution value proposition - Value 1

Assess durability performance earlier in development

!

Extends stress analysis by taking into account damage accumulation

!

Identify and fix fatigue problems in a few days vs several weeks of physical testing

!

Enables what-if studies and results in a refined analysis

!

Delivers clear recommendations for guiding major design choices

!

Results in fewer iteration studies in testing

“LMS Lifetime prediction software identifies and fixes fatigue problems in a few days versus several weeks of physical testing.“

BMW Group

“LMS durability simulation enabled Fiat

Research Center to save an estimated 200,000 dollars on the durability development of a Case New Holland tractor and to compress the

development time with at least six months.”

Dr. Kamel Bel Knani, Head of the Structural Durability Team at FIAT-CRF

(11)

LMS durability solution value proposition – Value 2

Representative loading conditions – real-life simulation

“Collaborative web-based solution manages durability-specific test workflows and knowledge base.”

Volkswagen

“Using LMS TecWare the measurement data processing has been

completely automated. The graphical interface allows to easily create and debug the different steps in the process.”

DaimlerChrysler

Efficiently process huge amounts of data

Manage durability load data

Predict loads earlier in development

“To assess the durability performance of our designs in the early development stages, we require accurate loading information. Through the implementation of LMS Virtual.Lab Motion, our engineering teams generate system loads even before they can be measured on physical prototypes of new vehicles. “ Bruno Hazet, PSA

(12)

LMS durability solution value proposition – Value 3

Accelerate durability testing

!

Design and optimize durability test scenarios

!

More accurate and more efficient rig testing

“Through more accurate and efficient rig testing, LMS solutions contribute to higher product quality and lower engineering and component costs.” ZF Lemforder

Fahrwerktechnik

“The resulting proving ground and rig testing scenarios accurately replicated the excitation of the actual road in one-hundredth of the time that would have been required for road testing.”

Ford Otosan “LMS will help Ford cut

months from our

development cycle and save hundreds of thousands of dollars.”

Dr. Weiss, Ford Cologne.

6 7 8 9 60 1 10 100 75% 80% 85% 90% 95% 100%

rel. damage sum

tes t ti me [d ay s] _{From 60 to 10 days !}

(13)

Intelligent load data processing using LMS TecWare

To correlate data from test track, test rig, CAE

To efficiently manage durability data To efficiently process raw data

To design representative durability test schedules

(14)

LMS TecWare

To efficiently process huge amounts of data

!

Processing of raw data into loads for virtual and physical tests

! Automatic detection of :

! Measurement failures, outliners, etc.

! Test track segments

!

Streamlines the process from

!

data import,

!

consolidation,

!

reduction,

!

documenting,

!

comparison

Successful durability engineering requires intelligent load data processing.

“Using LMS TecWare the measurement data processing has been completely automated and the resulting reports deliver a maximum of engineering insight. The graphical

interface allows to easily create and debug the different steps in the process”

• Fast load data processing • Easy for non-experts

• Customizable to your process

(15)

LMS TecWare

To correlate data from test track, test rig, CAE

Correlation of results

Predict loads earlier in development

“To assess the durability performance of our designs in the early development stages, we require accurate loading information. Through the implementation of LMS Virtual.Lab Motion, our

engineering teams generate system loads even before they can be measured on physical prototypes of new vehicles. “

(16)

Loads cascading

! “Numerically measure” interface

component forces using a virtual test rig model

! Adapt existing ride and handling multi-body models for durability loads

cascading

! Use of LMS TecWare for correlating test and simulation

! Avoid physical prototyping

! Earlier in the design process

Application case

BMW using virtual test rigs for loads cascading

“Having used LMS durability technologies for load data analysis and numerical fatigue life predictions for several years, we are able to improve our durability engineering process substantially (...) and reduce the time and costs of the development process.”

Dr. Martin Brune, Manager Predevelopment, Methods, Calculation,

Dr. Martin Brune, Manager Predevelopment, Methods, Calculation, BMW GroupBMW Group

BMW axle test rig for non-driven front-suspensions

BMW Virtual Axle test rig model

(17)

LMS TecWare

To efficiently manage durability data

Durability Data Management

! Web-enabled

! Data annotation

! Process management (instrumentation, test rig preparation, ...)

! Data search and download (“Google”)

! Durability data displays

! Durability engineering data drivers

! Remote launching of batch jobs

The Durability Data Management system controls the different steps in the testing process. It allows efficient organization and creation of tasks and allows us to find back any data from any measurement campaign in a very efficient manner.

Efficiently search and retrieve durability data across departments

(18)

LMS TecWare

To design representative scenarios

Accelerated durability testing cycles

! Meeting 1.2 million km durability requirement

! Real tests would take 3 years

! Large-scale customer data collection

! 5000 km Turkish public road data

! Ford Lommel proving ground

! Development of accelerated rig test

! Target setting

! Test schedule definition

! Resulting test schedule 8 weeks

! Test acceleration of factor 100

LMS engineers performed dedicated data collection, applied extensive load data processing techniques and developed a 6- to 8-week test track sequence and 4-week accelerated rig test scenario that matched the fatigue damage generated by 1.2 million km of road driving.

• Condensed test schedules

• Design customer correlated test schedules

1

(19)

Reduce transmission time by 85%

! Reduced testing time

! Customer correlated

! No loose of fatigue content

! Dedicated data reduction methods

! Process integration

LMS TecWare

To accelerate durability test scenarios

Using hybrid engineering technologies of the LMS durability products we were able to improve durability testing procedures for gearboxes and transmission system drastically. Certain subsystem tests could be shortened from previously several weeks to now less than one day.”

Dr. Wolfram Weiß, Powertrain development, Ford Köln

Load data reduction for rotating components ! Multi-axial time at level

! Rotating moment histogram

(20)

LMS TecWare

Tips and Tricks

(21)

Durability load data processing

using LMS TecWare – Tips and Tricks

Consolidate Load data

Test

Performance

simulation

Design

Load data processing

Interpret Document Compare

Streamline Test schedule definition Load data Load data

(22)

LMS Tec.Manager

Tip 1. Organize data.

Intuitive search

!

Similar to Altavista® or Google®

!

Template-based search

Analyze search results using

!

Tree navigation

!

Excel style view on attributes

Full text search

!

Support of all common ‘Office’ files

!

Support of all text files

Facilitate use of data throughout

the entire development process

(23)

LMS TecWare Tips and Tricks

Tip 2. Standardize processes

(24)

Tip 2. Standardize processes

!

A drastical reduction in the time required to process time data

!

Automating tasks - less errors, reduces

user dependency

!

Easier for non-experts to master - no programming skills required

!

Faster creation of sequences of load data processing tasks

!

Quicker process flow debugging

!

Helps to standardize on corporate procedures

!

Protects investments - supports all LMS TecWare methods

(25)

Tip 3 - Reduce vast amount of data

! Benefits

!Open to most common file formats • Read and write

• On PC and UNIX platforms

!No file conversion, hence no time nor disk space wasted as data is directly accessed

ASCII " " LMS TecWare Kernel

LMS TecWare IF " " LMS TecWare Kernel

IST LabSite " " LMS TecWare Kernel

IST RigSys " " LMS TecWare Kernel

LMS CADA-X TDF " " LMS TecWare Kernel

LMS Test.Lab TDF " " LMS TecWare Kernel

LMS Roadrunner (SKALAR 20) " LMS TecWare Kernel

LMS Pimento (SKALAR 20) " _{LMS TecWare Kernel}

LMS Virtual.Lab Time series interface " " LMS TecWare Kernel

MH E.D.A.S. " _{LMS TecWare MH EDAS File Interface}

MH E.D.A.S.WIN " LMS TecWare MH EDAS File Interface

MSC.ADAMS (/Car) Durability interface " " _{LMS TecWare MTS RPC III File Interface}

MTS RPC-III " " LMS TecWare MTS RPC III File Interface

nCode DAC " LMS TecWare nCode DAC File Interface

NI DIAdem " " LMS TecWare NI DIAdem File Interface

IMC µMUSYCS FAMOS " LMS TecWare IMC µMusycs FAMOS File Interface

Aditec EDT " LMS TecWare Universal Binary File Interface

Aditec PBK/PK2 " LMS TecWare Universal Binary File Interface

HEAD acoustics " LMS TecWare Universal Binary File Interface

I-DEAS BUF (binary universal file) " LMS TecWare Universal Binary File Interface

Inhouse data formats via LMS Universal Binary " LMS TecWare Universal Binary File Interface

LMS TecWare File interfaces Part of Produc t Write R ead

(26)

from load level to load level 1 0 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 1 0 1 2 3 4 5 6 7 8 9 10 Classification into bins Load history Rainflow Matrix:

at any from-to cell: entry for the numbers of cycles

Durability load data processing

Why rainflow counting ?

Interpret Interpret

• Basic damage event : closed hysteresis loop

• Rainflow counting = counting of closed hysteresis loops in time signal

(Pseudo-) Damage Rainflow counting Damage calculation from to constant am plitude cons tant mea n standing hystereses hanging hystereses

Lines of constant mean and constant amplitude in a rainflow matrix

Closed hysteresis loop

(27)

!

Features

!Rainflow counting taking residue into account

!Multi-axial rainflow counting

!Rotating rainflow matrix

!CombiTrack : partial

optimization to design correlated test schedule

LMS TecWare

Accurate Load Data Processing

!

Increased accuracy

!Increased accuracy for :

• extrapolation of rainflow matrices,

• reconstruction to time signals, especially for shorter events

!Increased accuracy for multi-axial loading

!Increased accuracy for rotating components

!Increased accuracy : closer match between durability target and actual test schedule

(28)

LMS TecWare Reporting

!

Benefit

!Efficiently publish, share and compare load data

!

Features

!Creation of template-based reports

•MS Word

•MS Excel

•HTML

•ASCII csv

!Multi-page reports

!Fit for massive amounts of data

!Full axis labeling

!Automatic table of contents and page numbering

(29)

Accelerate physical and virtual testing

Tip 4 – Optimize existing test schedules

!

Different methods included for creating damage equivalent reduced-length tests

!

Pre-configured batch programs encapsulating input signal definition, parameter setting, processing and report generation

!

Methods working in time or rainflow domain, uni-axial or multi-axial

(30)

(31)

Streamlining load data processing

in all stages of the development process

Durability load data processing

LMS TecWare

!

Processing of raw data into loading histories for virtual and physical tests

!

Streamlines the process from data import, over consolidation, reduction, documenting, reporting and comparison

!

Optimizing existing test schedules for physical and virtual tests

!

Define customer correlated test schedules

!

Integrated load data management (via LMS Tec.Manager)

Everything you need for durability load data processing.

Successful durability engineering requires intelligent load

data processing.

Accelerated Load Data Analysis with LMS TecWare