ME 457 Special Lecture: Introduction to Virtual Product Development Steve Rohde [e-mail]

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ME 457 Special Lecture Introduction to
Virtual Product DevelopmentSteve
Rohdesteve_at_quantumsignal.com

• Spring 2003

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Outline

• Math Models
• Virtual
• Math-Based Process
• Product Development Processes
• Benefits
• Examples
• History

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The Significance of Modeling Simulation
Modeling and simulation are emerging as key
technologies to support manufacturing in the 21st
century, and no other technology offers more
potential . . . for improving products,
perfecting processes, reducing design-to-manufactu
ring cycle time, and reducing product realization
costs.
Finding of Integrated Manufacturing Roadmapping
Initiative, May 21, 1999. Sponsored by NIST,
DOE, NSF, DARPA
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Examples of Models

• Clay, styrofoam or fiberglass models
• Plastic models
• Building/city models
• Artists models
• Clothing models
• Electric circuit analogies
• Analog computer models
• Math models

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What is a Math Model?
Mathematics - the scientific study of quantities,
including their relationships, operations, and
measurement, expressed by numbers and symbols. -
Academic Press Dictionary of Science Technology
Math Models - mathematical representations of
physical or abstract entities which capture their
form / their functional behavior / or other
aspects of their behavior.
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Examples of Math Models

• Economic/world models
• Enterprise models
• Marketing models
• Financial models
• Computer system models
• Chemical reaction models
• Human anatomy/physiology models
• Physics models
• Biometric models
• Product engineering models
• Manufacturing engineering models

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Examples of Math Model Use in GM
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Virtual reality

• Virtual - "of, relating to, or possessing a
  power of acting without the agency of matter
• - Webster's Third New International Dictionary

• Movies
• Total Recall
• Brainstorm

Virtual reality creation of an environment
which seems real in important respects usually
computer-based.
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Virtual Reality
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The Virtual Vehicle Paradigm
Extensive use of math-models to guide decisions

• Marketing
• Definition
• Form
• Fit
• Function
• Process
• Sales Service

• Virtual clinics
• Virtual studio
• Virtual mock-up
• Virtual test lab
• Virtual proving grounds
• Virtual tool-room
• Virtual factory

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Math-based Processes

• Process - a series of actions, changes, or
  functions that bring about an end or result.
• - The American Heritage Dictionary

Math-based process - a process based upon or
enabled by the use of mathematical models. A
math-based process is usually implemented using a
computer.
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A Product Development Process

• The set of all activities required to define,
  design, and engineer a product including its
  manufacturing and assembly processes.

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The Good Old Days. . .
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The Modern Automotive Vehicle
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Major Automotive Vehicle Subsystems

• Powertrain
• Accessories
• Brakes
• Steering
• Suspension
• Body

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Automotive Vehicle Subsystem Interactions
Body Linear Angular Motion, Heat Flow in/out
Fuel Consumption Emissions
Powertrain
Body
Brakes
Accessories
Suspension
Steering
Vehicle Configuration Loading Windows up/down

• Accelerator Pedal
• Shift Lever
• Clutch Pedal

Accessory Controls
Brake Pedal
Steering Wheel
Road
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Automotive Vehicle Subsystem Interactions
Body Linear Angular Motion, Heat Flow in/out
Fuel Consumption Emissions
Powertrain
Body
Brakes
Accessories
Suspension
Steering
Computer(s) Intelligence
Vehicle Configuration Loading Windows up/down

• Accelerator Pedal
• Shift Lever
• Clutch Pedal

Accessory Controls
Brake Pedal
Steering Wheel
Road
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Math-Based Engineering Process
Hour 2-3
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Traditional Product Development Process
Build
Fix
Test
Iteration
Form Function

• For Complex Products
• Cycle Time Too Long
• Facility Intensive
• Cost High
• Convergence Not Assured

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Math-Based Design Process

• Math-based design The process of designing and
  refining vehicles and components on
  sophisticated computer systems. Once approved,
  the designs are sent electronically to machines
  that cut tools and dies for the vehicle,
  minimizing the chance of errors. Computers can
  also simulate the performance of components and
  modules, as well as assembly line systems.
• --The Detroit News December 21, 1998

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1964 DC-9 Program Savings via Math
1. Increased reliability and maintainability of
product 2. Program cost decreased 50 3.
Increased quality and quantity of results 4.
Fewer drawing changes after initial release 5.
Improved competitive position
Bottomline Investment 300K Savings
2.5M Time Reduction gt50
from Use of Computer Programs in Aircraft
Design by Melvin Stone, Douglas Aircraft Co.,
SAE 1964 referring to DC-9 stucture
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Why move to math now?
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Advanced Technology Vehicles
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Benefits of Math-Based Technology

• 50 productivity improvement in last several
  years
• Over 109 savings
• VDP time reductions gt18 months
• CAE today is 7-10 times faster than hardware
  verification
• CAE costs are a fraction of test verification
  costs
• CAE will become the principle design verification
  direction methodology!
• Identified CAE as a critical element in product
  development
• Welcome the merger of the combined capabilities
  of visualization and supercomputers for Digital
  Prototyping total solution

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The Math Advantage

• Hardware test learnings are limited to what can
• be made visible
• Example
• For a durability test to be useful it must run to
  
• failure

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The Math Advantage

• In math tests we can see both causes and
  effects track things that we cant measure!
• Example
• We can see the flow of energy the final shape
  during a crash test

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Some Relative Costs
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How do we implement math based design?
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Answer Using Systems Engineering!

• Systems Engineering
• Top down vs. Bottoms up
• Requirements driven
• Is a phased, iterative process
• Interactions between systems components are
  explicitly addressed
• Uses math-models extensively

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The Top-Down Design Concept
Customer Need
Understand
Define Functions
Synthesize (Design)
Form
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Automotive Vehicle Functions
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Vehicle Functional Physical Decompositions
Energy Management
Comfort
Enjoyment
VEHICLE FUNCTIONS
Safety
Information Management
What the Vehicle Does
Transportation
HVAC
Powertrain
Interior
How It Does It
VEHICLE
Body
Info Cntls.
Chassis
Electrical
Vehicle Subsystems
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Vehicle Functional to Physical Mappings
Example
Energy Management
Comfort
Enjoyment
VEHICLE FUNCTIONS
What the Vehicle Does
Safety
Information Management
Transportation
Form Follows Function
HVAC
Powertrain
Interior
How It Does It
VEHICLE
Body
Info Cntls.
Chassis
Electrical
Vehicle Subsystems
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Automotive Vehicle Subsystem Interactions
Heat, Noise, Vibration, Engine Vibration Torque
Torque Delivered to Driven Wheels
Heat, Noise, Driver Visibility, Airflow
Hydraulic/Pneumatic Pressure
Suspension Forces Vibration Noise
Hydraulic Flow, Electrical Voltage
Braking Torque
Engine Speed Coolant Temp.
Vacuum Electrical Voltage
Steering Angle
Powertrain
Body
Brakes
Accessories
Suspension
Steering
Vacuum Load Electrical Current
Steering Forces Suspension Geometry
Accessory Torque Load Battery Voltage Coolant
Flow Heat Loss
Wheel Rotational Speed
Body Attitude Position Aerodynamic drag
Hydraulic Pressure, Electrical Current
Hydraulic/Pneumatic Flow
Heating Cooling Loads
Driven Wheel Rotational Speeds
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Systems Engineering Based VDP
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The Cost Of Change
John Krouse, 1993
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Math-Based Synthesis Analysis

• The use of mathematical representations (models)
  to
• Design/configure (synthesis)
• Understand validate behavior (analysis)

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Analysis vs. Synthesis
Analysis
Given a Design
c
k
c1,k1
Response
ANALYSIS
m
F
c2,k2
x
What is the response?
Given a Design
Frequency
Synthesis
Given the Design Goal Subject to
Constraints Response Function Packaging Cost Man
ufacturing
Manufacturing Constraints
c,k
?
Damping , c
Response
Packaging Constraints
SYNTHESIS
Stiffness, k
Frequency
What is the Best Design ?
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Synthesis Analysis in the VDP
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Synthesis Analysis at Various Phases of
the VDP
SYNTHESIS MODE
ANALYSIS MODE
100
FREEDOM
50
Committed
Spent
INFORMATION
0
Time
PHASE 0
PHASE 1
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Use of Math Medical Analogy
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Virtual Product Development GMT360