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Automotive Benchmarking using High Energy X-Ray Scan Technology

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Disclaimer

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This document is for the intended recipient(s) and the organization employing the recipient(s) (“Organization”) only. No part of this document in whole or in part shall be shared with any third-party apart from the recipient(s) and the Organization.

Caresoft Global Inc. and all its operating units, subsidiaries, and its authorised representatives claim no responsibilities and/or obligations of any kind against any harm or perceived harm caused to the recipient and the Organisation by sharing this document in whole or in-part to parties other than the intended recipient(s).

Caresoft Global Inc. and all its operating units, subsidiaries acknowledge the rights of all the registered trademarks and names used in this document. Caresoft Global Inc. and all its operating units do not claim affiliation or arrangements of any kind with the OEM of the vehicles referred in this document.

By reading the contents of this document, storing, and distributing this document, the intended recipient is understood to have agreed to the terms in this disclaimer.

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Agenda

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q  Who we are

q  Automotive Benchmarking (Current Methodology)

q How has Caresoft Changed the Game?

q Beyond Commercialization: Educational Mission

q Q&A

Caresoft Global Who we are ?

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About Us

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Affiliated with the Sakthi Group in Detroit – a $2 billion global conglomerate §  Sakthi Automotive – Manufacturer of Chassis & Drivetrain components

Founded in 2007 and headquartered in USA

Social responsibility §  Food shelters, hospitals, schools, orphanages and old age homes in North

America, Belgium, Italy and India

A global engineering services and software company §  1,700+ global resources with 75% local citizens in various geographies §  ISO 9001, ISO 27001 §  ITAR certified

Groups Educational Institution §  9 Technical Institutions (2000+ Engineers graduating every year) and 12 schools

(all non-profit)

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Our Global Presence

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NorthDakota

WisconsinMichigan

IllinoisGeorgia

Iowa

Querétaro

Pennsylvania

Curi'baBeloHorizonteSeteLagoas

Portugal

France

UK GermanyBelgium Austria

HungaryItaly

NewDelhi

ChennaiBangaloreCoimbatore Pollachi

Pune

ChangshaShanghai

Japan

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Awards For Our Innovative Technology

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FordSmartPillarWorldExcellenceAward,2018

Automo'veNewsAll-StarsAward2018

Automo'veNewsPaceAward,2018

Automotive Benchmarking Current Methodology

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Traditional Benchmarking Process

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Teardown Photos of Systems

Optical Scan Key Systems

Manufacturer Information

Material Information

Vehicle Picture Package Optical Scanning

Vehicle Measurements Weighing

PRE-TEARDOWN

TEARDOWN

Traditional Way

Pre-Teardown Document

Teardown

Optical Scan

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Limitations of Traditional Benchmarking

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§ No actionable intelligence

§ Data limited only to photographs,

Bill of materials and elementary

optical scan data sets

§ No notes on strategic choices

made by OEMs

§ Non existent advance

engineering data – CAD and

Analysis

§ OEMs cannot decipher costing

data

Traditional way Traditional way

How has Caresoft Changed the Game?

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Benchmarking using High Energy X-Ray Scan Technology

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Precise internal and external geometries, opening a new frontier of scientific competitive assessment

§  Non-destructive method of automotive benchmarking using high energy scan technology

§  3D data of an entire vehicle with an accuracy of ~100-750 microns (0.1mm – 0.75 mm)

Technology Benefits of High Energy Scan

§  Ability to understand the design intent of the components and assemblies

§  Electrical Topology, Architecture, Connector and EDS

§  Digital mock-up view

§  3D assembly view with parametric

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High Energy X-Ray Scan Technology – Density Variation

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All Density Components Medium Density Components High Density Components

The Tesla Model 3 is fully operational after the high energy scan

Complete Vehicle

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High Energy X-Ray Scan Technology

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The vehicles are fully operational after the high energy scan

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High Energy X-Ray Scan Technology – Internal Layout

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High Energy X-Ray Scan Technology – Door Harness Routing

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High Energy X-Ray Scan Technology – Battery Layout

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Scan to 3D CAD: Electric Powertrain

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Electric Powertrain Detailed CAD Model

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All the components are captured & modeled to greater detail and

higher accuracy

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Scan to 3D CAD (Vehicle Architecture)

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Engineering Insights from High Energy Scan Technology

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High Energy CT Scan

Detailed 3D CAD CFD and other analysis

Electrical systems routing and should costing

Vehicle packaging and VR

..and a lot more

Mesh models

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Caresoft’s Innovation Vs Industry

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§  Point cloud data will only be provided with outer boundary whereas our deliverable will include internal part details.

§  Accuracy of the assembled point cloud data from competition is approximately 5 mm whereas Caresoft CAD accuracy is approximately 0.35 mm.

Optical Scan Optical Scan

3D CAD Data (STEP files) 3D CAD Data (STEP files)

Full Vehicle Selected Sections

Compe'tors

Careso<

Body and Structures

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BIW 3D CAD Model

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X-Ray Scan Input 3D CAD Model

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BIW 3D CAD Model

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X-Ray Scan Input

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BIW 3D CAD Model

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B pillar Exploded View

§  All internal reinforcements on A pillar, B pillar etc. are available in CAD

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BIW 3D CAD Model

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ü  Weld, Adhesive and sealant details in 3D CAD

ü  Infinite sections from CAD to study the design intent

ü  Higher Analysis co-relation % (using 3D CAD data)

ü  Better understanding on manufacturability and tooling

ü  Detailed study of the assembly sequences (Using 3D

assembly) can be performed

Section with Weld Details Shell with Battery Section

Weld Details

Adhesive /Glue/Sealant/Foam in 3D CAD

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BIW CAD Model (with component type)

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Extrusion parts Castings parts Stamping parts

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BIW CAD Model (with reinforcement)

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SillCrossSec'on

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FE Model – Joining Techniques and Material Properties

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BOLTS – RIGID-BEAM-RIGID e.g

RgdBody-BEAM-RgdBody

WELD (Seam, Fillet, Laser, etc.) - RIGIDS

ADHESIVE – HEXA WITH CONTACT

SPOT WELD & RIVETS – HEXA WITH CONTACT

COMP1-SOLID-COMP2 2T 3T 4T

BIW - MESH

StressStrain

ξ σ(MPa) 0.000 271.60.001 274.90.002 278.30.004 281.90.007 285.70.011 289.90.017 294.60.025 300.10.036 306.60.051 314.60.073 324.6

MATERIAL PROPERTIES

Example: STRESS STRAIN DETAILS

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Analysis and Simulations

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TORSIONAL STIFFNESS ANALYSIS

Front Suspension

Tower

Rear Suspension

Tower

Front Suspension

Tower

Rear Suspension

Tower

BENDING STIFFNESS ANALYSIS

MODAL ANALYSIS TORSION MODE

FREQUENCY- 24.3 Hz

BENDING MODE

FREQUENCY- 69.6 Hz

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Full Vehicle FE Model

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ü  AXLE SYSTEM ü  BATTERY ASSEMBLY ü  BIW ASSEMBLY ü  BRAKE ASSEMBLY ü  CENTER CONSOLE ü  CLOSURES

ASSEMBLY ü  COOLING ASSEMBLY ü  E-DRIVE ASSEMBLY ü  EXTERIOR TRIMS ü  FRAME ASSEMBLY ü  GLASS ASSEMBLY ü  HVAC ASSEMBLY

ü  INSTRUMENT PANEL ASSEMBLY

ü  INTERIOR TRIMS ü  LAMP ASSEMBLY ü  NHL ASSEMBLY ü  PEDAL ASSEMBLY ü  SEATING ASSEMBLY ü  STEERING ASSEMBLY ü  SUSPENSION

ASSEMBLY ü  TRIMS CLOSURES ü  WHEELS ASSEMBLY

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Full Vehicle Frontal Crash Simulation

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75 msec 100 msec

FRONTAL CRASH – FMVSS 208

25 msec 50 msec 75 msec 100 msec

25 msec 50 msec

25 msec

75 msec

50 msec

100 msec

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Full Vehicle Electrical and Electronics Architecture

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Separate Channel for Signal wires

Separate Channel for Power wires

Space claim strategy

Wire harness serviceability study

Special routing and channel system

Interface with other systems like BIW & Chassis

Safety Strategy (HV Cables)

Routing and fixation methodology

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Electrical Harness Routing

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Routing fixation and space claim strategy

Harness interconnection and component positioning

studies

Routing Strategy

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Electrical Harness Routing

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IP Harness

Routing and Fixation Strategy

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Electrical and Electronics

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Harness Drawings Harness Costing

ü  Splicing and crimping techniques

ü  EMI suppression techniques

ü  Wire size, materials used, multicore cables, special type of covering

ü  Wire table information (with connection information)

ü  Components (connector, terminal, etc.) and used for various

applications

ü  Harness Layout & Length Information

ü  Harness Fixations information(Cable tie, Fir tree & Support parts)

ü  Harness Manufacturing BOM information

ü  Wire table information (From and to end of wire)

ü  Harness cost analysis

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Manufacturing Process Analysis - Instrument Panel Findings at a glance Course of assembly

Assembly Sequence

Key Findings

ProKon units from assembly steps

Tool List

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Manufacturing Process Analysis - Powertrain

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Engineering Data in Virtual Reality

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Other Applications of HE Scan

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Automated Inspection

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ReferenceFrame ReferenceRegionofInterest

DefectFrame DefectDetec0on

ReferenceFrame ReferenceRegionofInterest

DefectFrame DefectDetec0on

ReferenceFrame ReferenceRegionofInterest

DefectFrame DefectDetec0on

Skip

Porosity

Und

ercut

ChassisFrameWelds

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Engine Head Analysis

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EngineHead EngineHeadCTScanAutomatedDefectEnhancement

TopSteelInserts

SteelInsertswithDetails

Minim

izedBe

am

Harden

ing

Improved

Dim

ensio

nalA

ccuracy

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Data Analytics

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Automa0cDefectEnhancement

Knuckles

DefectDetec'on,Classifica'onandQuan'fica'on

StudyofGasPorosityDefects

Benefits

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Digitized Data – Integrates Different Functions

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Engineering teams

Finance

Manufacturing

Product Validation

Latest Technology and Innovation

Electronics and CAN Analysis (when possible)

Costing

Vehicle Packaging and Digital Mock-up (3D CAD model of all systems in customer preferred CAD platform)

Simulation and Analysis (CAE)

Electrical Schematics and Harness Drawings (Full Vehicle)

Design for Manufacturing Assembly Analysis (DFA/EHPV)

Capability Assessment - Performance Analysis

Engineering Information (CAD) in PLM – Allows global access for OEMs

Extended Reality Simulation

Motoview.com

Beyond Commercialization

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Caresoft Benchmarking Data to Universities

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§  Caresoft has decided to graciously offer all of the work that they have done for the Tesla Model X for

free to colleges and universities

§  Caresoft has implemented their data sets in Michigan Technological University and are also working

with a handful of universities in Europe, China, and Japan.

We believe our complete vehicle level engineering data can be of immense value to the students studying engineering and the professors for research purpose

1 Western Michigan University

2 Saginaw Valley State University

3 Eastern Michigan University

4 Lake Superior State University

5 University of Michigan Dearborn

6 Lawrence Tech University

7 Wayne State University

8 Michigan State University

Universities/Colleges under discussion for Caresoft benchmarking data implementation

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Q & A

Thank you