Automatic, Flexible Configurable Report Generation for Safety Simulations
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Dr. Axel Hänschke; Dr. Vittorio Montuori Automatic, Flexible Configurable Report Generation for Safety Simulations - as part of CAE Process and Robustness Improvements 2011 European HyperWorks Technology Conference Bonn, November 8–9, 2011
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Transcript of Automatic, Flexible Configurable Report Generation for Safety Simulations
Dr. Axel Hänschke; Dr. Vittorio Montuori
Automatic, Flexible Configurable
Report Generation for Safety
Simulations - as part of CAE Process and Robustness Improvements
2011 European HyperWorks Technology Conference
Bonn, November 8–9, 2011
Agenda
• CAE in Ford development process
• Safety CAE process
– Load cases to support world car development process
– The safety CAE model build (Safety Modules), history and future
– Safety CAE error states
• PLM system to support CAE assessments
• Components to improve CAE assessment quality and
robustness
• The automatic report generator
Page 2
CAE in Ford development process
The Global Product Development System (GPDS) as defined in
Key node session:
• Has specific control points (gate ways), to assess the attribute
performance of the products
• CAE assessments are gate way deliverables
• Short time between gate ways requires high level of process
automation
• High quality of assessments to minimize the number of
physical verifications
Page 3
Safety CAE process
Load cases to support world car development process
Page 4
Safety CAE process
The safety CAE model build (Safety Modules), history and
future
Page 5
“Unique Model” for all test modes
Important Components for frontal offset impact • P/T assembly
• wheel and chassis assembly
• instrument panel
• fuel system
• load cases (i.e. barrier types, dummies etc.)
Manuel assembly process • time inefficient
• error sensitive
• no update compatibility
Frontal Impact Crash Model
Frontal Impact Crash
Components
Radioss Simulation
Model
(Model Build after Selecting the Wanted Model Content)
Body In Prime
Body
Closures
Body Exteriour
Body Interiour
Chassis
Powertrain
Electrical
Safety
1000500
Energ
y
(H. Ippen)
Overview of Modules
Safety CAE process
Module Example: Loadcases EuroNCAP frontal offset impact, def. barrier
Safety CAE process
Module Example: Standard Sensors EuroNCAP frontal offset impact, def. barrier
Vehicle model with load cases, box definitions and set of standard sensors
Safety CAE process
Safety CAE process
The safety CAE model build (Safety Modules), history and
future
• Web based
• file based
• no data management tool
• program specific
Safety CAE process
Safety CAE error states
• Module preparation – manual and time consuming process
• File based, unique solutions, on different locations
no/difficult traceability
• No link to CAD and property libraries
• Different tools and methods for Pre- and Post-Processing
different assemblies
• No common assessment support w/o common assessment
tools
• :
Page 10
PLM system to support CAE
assessments
Page 11
Model build in PLM Context
• Automated build of CAE structure
• CAD parts for CAE with link to revisions and versions
• Retrieve the right materials and properties
• Retrieve the right connection data
• Load the approved load cases from knowledge library
• Store the results with a permanent link to original CAD
• Compare results and requirements for fast decisions
One data model – one location for Meta Data – 100% Traceability
Components to improve CAE
assessment quality and robustness
• Common “model build” Guide Lines (descriptions)
• Common module base (same type of modularization)
• PLM based model / module delivery process
• PLM based model build and assembly process
• Common simulation environment (Codes)
• Common “nomenclature” in model / module syntax
• Common assessment methods and tools
– Pilot of “automated Post Processing”
Page 12
The automatic report generator
• Manage contents coming from any
supported sources
• Publish result das boards with 3D
results in “common”, well known
formats
• Evaluating results and manage
alternatives, comparing different
sources (CAE, physical tests, etc.)
Page 13
Simulation Comparisons & Result Clustering
Program for automatic post-processing and reporting of crash
simulations
The automatic report generator
(V. Montuori)
html-Report Power Point-Report
Configuration Parameters + Report Templates
Altair Binary File
(simulation_name.abf)
File results (RADIOSS file.t01 or ISO
test data)
Configuration Parameters
File results (RADIOSS results or ISO
test data)
The automatic report generator
(V. Montuori)
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Result comparison in
HyperGraph
• Automatic reporting (html-format or Power Point format)
• Delivery of numerical results to HyperGraph for overlay or
comparison of runs or tests
(V. Montuori)
The automatic report generator
Viewing html-Reports
1) Press button Simulation
Overview under button Ford
CAE Tools for an overview of all
generated reports of simulations
and tests
2) html-reports can be easily
accessed from the list by
pressing the corresponding
hyperlink.
The automatic report generator
Delivering Simulation or Test Data to HyperGraph
By pressing Show DB
Content, results are
delivered to HyperGraph
where channels are
accessible for further
analysis and detailed
review
The automatic report generator
Comparing Simulation/Test
1) Access the database by pressing Show
DB Content
2) select the simulations or tests to be
compared (simulations 00000182 and
00000311 in figure), press Compare
selected.
The automatic report generator
The chosen simulations/tests (even
more than two if needed, and in any
combination) are overlaid on each
page/window.
Different curve styles can be chosen
for each curve set.
The automatic report generator Comparing Simulation Results
Examples:
html-report: Simulation Side Impact
html-report: Simulation Frontal Impact
Model: Ford Fiesta frontal Impact
The automatic report generator
