1 Automotive News - May 20, 2008 Enhancement of Virtual Development in FGA Harald J. Wester Chief...

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Automotive News - May 20, 2008

Enhancement of Virtual Development in FGAHarald J. WesterChief Technical OfficerFiat Group

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Virtual DevelopmentVirtual Development

1. Standardization of Technical Solutions and

Components

2. Widespread use of Virtual Analyses in all

Development Phases

1. Standardization of Technical Solutions and

Components

2. Widespread use of Virtual Analyses in all

Development Phases

1. Reduce the TTM

2. Improve Product Performances & Quality

1. Reduce the TTM

2. Improve Product Performances & Quality

OBJECTIVESOBJECTIVES

APPROACHAPPROACH

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FIAT: Pioneer in Virtual Reality FIAT: Pioneer in Virtual Reality

Dante Giacosa, the father of “500” and “600”, :

“electronic brains will become fundamental to the

creation of better automobiles in the future”

Dante Giacosa, the father of “500” and “600”, :

“electronic brains will become fundamental to the

creation of better automobiles in the future”

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Con

cept

de

finitio

n

Tech

nica

l co

ncep

t de

finitio

n Technical / technologicalDevelopment

&Tooling Pr

e-se

ries

Ram

p-up

Approval of the initiative

Kick off Briefing Job 1

- 4- 4-16,5-16,520012001

-2.5-2.5-9-920062006 -18-18

-26-26

Launch

00

-2.5-2.5-8.5-8.520082008 -16-16

What we achievedWhat we achieved

Technical release

Prod

uct

/

pro

cess

valid

atio

n

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Key Drivers of Virtual Development Key Drivers of Virtual Development EnhancementEnhancement

Frontload V.D. in Technical Concept Definition Phase

Enhance multifunction integration and optimization in

Technical / Technological Development

Develop integration with Manufacturing V.D., involving

also Logistics & Quality

Frontload V.D. in Technical Concept Definition Phase

Enhance multifunction integration and optimization in

Technical / Technological Development

Develop integration with Manufacturing V.D., involving

also Logistics & Quality

Con

cept

de

finitio

n

Tech

nica

l co

ncep

t de

finitio

n

Pre-

series

Ram

p-up


Kick off Briefing Job 1 LaunchTechnical release

Technical / technologicalDevelopment

& tooling Pr

oduct

/

pro

cess

valid

atio

n

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Virtual Coverage in Technical ReleaseVirtual Coverage in Technical Release

Ergonomics & Driver InterfaceClimateFuel Economy and DriveabilityVehicle DynamicsAerodynamicsPassive SafetyNVHOperational StrengthElectric / Electronic ComplianceEnvironmental Compliance

Ergonomics & Driver InterfaceClimateFuel Economy and DriveabilityVehicle DynamicsAerodynamicsPassive SafetyNVHOperational StrengthElectric / Electronic ComplianceEnvironmental Compliance

80 % of the targets are now evaluated in virtual

Physical verification is done with Process Verification Vehicles

In few cases physical evaluation is not needed

80 % of the targets are now evaluated in virtual

Physical verification is done with Process Verification Vehicles

In few cases physical evaluation is not needed

Con

cept

de

finitio

n

Tech

nica

l co

ncep

t de

finitio

n

Pre-

series

Ram

p-up


Kick off Briefing Job 1 LaunchTechnical release

Prod

uct

/

pro

cess

valid

atio

nTechnical / technologicalDevelopment

&Tooling

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Technical / technologicalDevelopment & tooling


Technical release

Technical Targets Covered in Virtual

2001 20-30% 40-50%

2007/8 40-50% 80%

2010 80% 85%

With reference to the set of targets relevant in each phase

Tech

nica

l co

ncep

t de

finitio

n

The Growth in Virtual Coverage of TargetsThe Growth in Virtual Coverage of Targets

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Virtual engineering has enabled

the initial less significant test

cycles to be eliminated and the

number of prototype vehicles to be

reduced or even cancelled.

Virtual engineering has enabled

the initial less significant test

cycles to be eliminated and the

number of prototype vehicles to be

reduced or even cancelled.

From physical to virtual: From physical to virtual: no prototypes no prototypes

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From physical to virtual:From physical to virtual:infinite number of testsinfinite number of tests

Computer simulations enable a limitless number of

virtual prototype configurations to be realised and

subjected to practically infinite number of tests, far

greater than ones feasible with physical prototypes.

Computer simulations enable a limitless number of

virtual prototype configurations to be realised and

subjected to practically infinite number of tests, far

greater than ones feasible with physical prototypes.

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From physical to virtual: From physical to virtual: deeper insightdeeper insight

Mathematical models to perform highly complex

analyses enables our engineers and designers to

gain an understanding of the vehicle which is

significantly deeper and more detailed than was

possible in the past.

Mathematical models to perform highly complex

analyses enables our engineers and designers to

gain an understanding of the vehicle which is

significantly deeper and more detailed than was

possible in the past.

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A company-wide evolution now involving Engineering & Development, Manufacturing, Parts & Services, and others

A company-wide evolution now involving Engineering & Development, Manufacturing, Parts & Services, and others

From physical to virtual: From physical to virtual: paperlesspaperless

Traditional drawing: 3D Annotated CAD model:3D View: Section

3D View: Section

3D View: Mid-plane

3D View: composite view

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From physical to virtual: From physical to virtual: product / product / process integration process integration

Product optimization and robustness are achieved assuming the real properties given by the process.

Product optimization and robustness are achieved assuming the real properties given by the process.

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From physical to virtual:From physical to virtual:product / process Integrationproduct / process Integration

StampingStamping Body in whiteBody in white PaintingPainting Final assemblyFinal assembly

Each assembly step has manufacturing virtual validation

in parallel with each step of product development

Each assembly step has manufacturing virtual validation

in parallel with each step of product development

First process verification vehicle is virtual

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From physical to virtual: From physical to virtual: the Digital Mock-Upthe Digital Mock-Up

The Digital Mock-Up enables all

aspects of layout, assembly and

accessibility to be evaluated

with the option of using a total

immersion approach employing

state-of-the-art virtual reality

equipment.

The Digital Mock-Up enables all

aspects of layout, assembly and

accessibility to be evaluated

with the option of using a total

immersion approach employing

state-of-the-art virtual reality

equipment.

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Functional virtual prototypes:Functional virtual prototypes:Aeroacoustics Aeroacoustics

Today we can carry out virtual checks before

prototypes are made, even for performances

involving complex phenomena

Today we can carry out virtual checks before

prototypes are made, even for performances

involving complex phenomena

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Functional virtual prototypes:Functional virtual prototypes:Handling and Ride-Comfort Handling and Ride-Comfort

Simulation models also embrace the wide range of

active systems such as ABS, Stability Control, Damping

Control which may be incorporated into the vehicle.

Simulation models also embrace the wide range of

active systems such as ABS, Stability Control, Damping

Control which may be incorporated into the vehicle.

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2004 2005 2006 2007 2008

Co

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Po

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In

dex

Index of Virtual Development Index of Virtual Development Computation PowerComputation Power

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Achieved performancesAchieved performances

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The investment in virtual techniques

pays those companies trusting them

through the full exploitation in Product

Development.

The investment in virtual techniques

pays those companies trusting them

through the full exploitation in Product

Development.

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Our Vision for the FutureOur Vision for the Future

Achieving the fully virtual Product-Process Development

Optimization of Product performances through a rigorous multi-objective approach

Improved quality

Reduced time-to-market, constrained only by tooling time

Optimization of Product performances through a rigorous multi-objective approach

Improved quality

Reduced time-to-market, constrained only by tooling time

to gain excellence in customer perception

THIS IS THE NEW FIATTHIS IS THE NEW FIAT

1 Automotive News - May 20, 2008 Enhancement of Virtual Development in FGA Harald J. Wester Chief...

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