Competitive Assessment Overview · 2019. 10. 2. · Digital Twin Benchmarking Technology using High...

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COMPETITIVE

ASSESSMENT

BY

DIGITAL TWIN

TECHNOLOGY

Confidential Property

Disclaimer

2

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.

Confidential PropertySocial responsibility : Food shelters, hospitals, schools, orphanages and old age homes in North America, Belgium, Italy and India

Bangalore

Pollachi CoimbatoreChennai

Pennsylvania

North Dakota Wisconsin

UKBelgium

Italy

Germany

New Delhi

MichiganIllinois

Georgia

Iowa

Curitiba

Shanghai

France

Belo Horizonte

Hungary

Pune

Sete Lagoas

Querétaro

Austria

Japan

3

Founded in 2007 Headquartered in Detroit 1,800+ Resources

Truly a Global Company

About Us


Caresoft Achievements

4

Ford Honors Caresoft Global at

20th Annual World Excellence

Awards - 2018

Smart Pillar World

Excellence Award

Received for 2 Consecutive

Years - 2017 and 2018

Global PACE Award for

Innovation amongst 30,000

suppliers

Global All Stars

Automotive Award Diamond Supplier Award

2019 Automotive

PACE Award

2018 Automotive

All Star Award


Automotive Benchmarking

Current Methodology


Traditional Benchmarking Process

6

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


Limitations of Traditional Benchmarking

7

▪ 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?


Digital Twin Benchmarking Technology using High Energy X-Ray Scan

9

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


High Energy Scan

10

Low Density Components Medium Density Components High Density Components

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

Complete Vehicle


High Energy Scan

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

FR

ON

T

REA

R

Side

view

11


High Energy Scan

Battery Layout

Internal Layout Door Harnesses12


Digital Twin Process: Scan to 3D CAD (Electric Powertrain)

13


Rear Powertrain - High Energy Scan Vs Optical Scan

14

High Energy Scan - CAD Data (IGES files) Optical Scan - STL Data


CAD Model - Battery Package

15

Battery Module Exploded View

1

2

3

4

5

6

7

8

9

S. No. DESCRIPTION

1 TOP COVER

2 INSULATION PADS

3 CELL ASSEMBLY

4 COOLANT LINE

5 CONNECTOR

6 SUPPORT BRACKET

7 BUS BAR

8 RUBBER MOULD

9 BOTTOM COVER


CAD Model - Powertrain

16

Tesla Model 3Jaguar I Pace


CAD Model - Powertrain

17

Tesla Model XChevrolet Bolt EV


BIW 3D CAD Model

18

X-Ray Scan Input 3D CAD Model

All the components are captured and modeled to greater detail and higher accuracy


BIW – Section with Weld Details

Spot Weld

Packing sealant

Foam

Sill Inner

Floor Panel

Sill outer

Reinforcement Tube

19


B Pillar - Scan to Engineering 3D CAD

20Scan Data CAD Model


B Pillar 3D CAD Model with Weld Locations

21

CAD Model CAD Cut Section Exploded View


BIW 3D CAD Model

22

✓ Weld, Adhesive and sealant details in 3D CAD

✓ Infinite sections from CAD to study the design intent

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

✓ Better understanding on manufacturability and tooling

✓ Detailed study of the assembly sequences (Using 3D

assembly) can be performed

Section with Weld DetailsShell with Battery Section

Weld Details

Adhesive /Glue/Sealant/Foam in 3D CAD


Digital Twin - Full Vehicle 3D CAD Model

23

High Energy Scan Vehicle Architecture


Digital Twin – Full Vehicle 3D CAD Model

24


Ergonomics General Layout

25


Mechanical Component Simulation & Design Optimization

▪ Front & Rear Axles

▪ Driveline Assembly

Parts

▪ Chassis Structure

▪ Interior Cockpit

▪ Seats & Supports

▪ Braking Systems

▪ Traction Battery

▪ Power Electronics

▪ E-machine

Static Analysis

▪ Modal & FRF Analysis of

Exhaust System

▪ FRF & TFRF Analysis of

Chassis Sub Parts

▪ Spectrum Analysis of

Chassis Sub Parts

▪ NVH Analysis of

Suspension Supports

Dynamic Analysis

▪ Body in White

▪ Doors & Hood

▪ Instrumentation Panel

▪ Crash Analysis of Complete

Vehicle

▪ Durability Analysis of Most

Components

(Material Stress

Input Needed)

Explicit & Non Linear Analysis

▪ Drive Lines - Front

Axle, Rear Axle

▪ Transmission

▪ Transaxles

Kinematics Analysis

▪ Perform Competitive Assessment and

Competitive Analysis

▪ Quantify Competitive Threats

▪ Reduce Product Development Costs

Material Linearity (Density, Modulus & Poisson) & Non Linearity (Non Linear Stress Vs. Strain Data)

Design Optimization

Note: All these analysis are performed based on Customer demand 26


CAE Simulation

27


CAE Simulation

28

Full Frontal Crash Simulation

Tesla Model 325 msec 50 msec 75 msec 100 msec


CAE Simulation

Full Frontal Crash Simulation

Bending and Torsional Stiffness

29Tesla Model 3


Material Details

MAT_AISI_1018_Steel_565

Stress Vs Strain Curve

Str

ess

Strain

Body Closures

30


Class ‘A’ Surface and CFD Report

CAS and CFD Report

Class ‘A’ surface

CFD Analysis

CLASS ‘A’ surface of benchmarking car

Exterior Flow Analysis

▪ Neutral file format (IGES or STEP) for Class ‘A’ Surface

▪ Exterior Flow Analysis will be done using STARCCM+ and delivered in .SIM format

▪ Exterior Flow Analysis report will be provided in pdf format

Pressure Coefficient

Skin Friction

Coefficient

31


Electrical 3D Routing Topology

32

3D Routing of Complete Vehicle Harness


Electrical Harness Topology

33

High Voltage Scheme

Power and Signal Topology – Top View

Power and Signal scheme – With BIW


Electrical Harness Routing

34

Routing fixation and

space claim strategy

Harness interconnection and

component positioning studies Routing Strategy


Electrical Harness Routing

35

IP Harness

Routing and Fixation Strategy


Electrical and Electronics: High Voltage Harness - Schematics

36

Invert

er

Mo

du

le –

Ele

ctr

on

ics


Electrical and Electronics: Low Voltage Harness Drawings

37

CAD and Benchmarking

Software for Wire Harnesses


Wire Harness Costing

38

CAD Based Wiring Harness Costing Software

Advantages:

• Process Cost

• Copper material used cost

• Parts Cost

• Cost target can be fixed for their program


Design for Assembly (DFA) Report

• Tightening tool with external torx driver E10

• Lifting aid- Stator and Rotor Assembly

Course of Assembly

Prokon Units from Assembly Steps

Design for Assembly Summary

Tool List

Stator and Rotor Assembly to Gearbox Casing Assembly

Steps Description

1 Place spacer ring on table, Gasket seal fitment side up

2 Position gasket seal (green) on spacer ring

3 Rotate and place spacer upside down

4 Position gasket seal (grey) on spacer ring

5Place spacer ring with gasket into casing Assy gearbox RH,

Gasket seal (grey) inside

6 Place gasket assembly on casing Assembly gearbox RH

7 Place stator Assy on gasket on Casing Assy gearbox RH

8 Secure Stator Assembly with Torx screw

Key Findings

39


Optical Scanning

40

Point Cloud of the Full Exterior of the Vehicle

Point Cloud of Interior Surface of Car


Teardown Documentation in Caresoft Iceberg Software

41

A Caresoft proprietary benchmarking platform that provides users with an unique view and most

advanced information of the vehicle and its systems.

➢ Structured Bill of Material

➢ System and component photos

➢ Exploded and 360 view for Major

Parts & Assemblies

➢ Assembly and Part location

➢ Part level teardown images with

high resolution

➢ Eye Catching Features

➢ General Photos per vehicle

➢ Vehicle Measurements and

Ergonomics Reports

➢ Costing, CAD Data & CAE Reports

Data Hosted in Iceberg

360° Photos

Assembly Location

Exploded View


Teardown Documentation in Caresoft Iceberg Software

42

E-Machine System

Battery System

Seating System

Steering System

Suspension System

Wheels System

Braking System

HVAC System

BIW System

Light System


Vehicle in Caresoft Virtual Reality Software

With Virtual Reality, the users can explore and compare the features of the various vehicle models

• 360° 3D Virtual Walkthrough

• Digital Simulation

• Exploded View of the Systems

• Close Inspection of the Systems

43


CORNEA – Virtual Enterprise System

44

Virtual Reality Enterprise Suite allows the user to import and

visualize any format of 3D data into the application to collaborate and

review the content.

▪ Import standard and native CAD file formats into the stage,

maintain 3D data hierarchy and Optimize 3D model

▪ Authoring tools enable user to Pan, Move, Select, Rotate, Zoom,

Undo, Redo, Isometric view

▪ Explode/Implode, View cross section and Measure part

▪ Collaborate from remote locations, move around within the

virtual space, take notes and annotate

Automotive | AG & Construction | Heavy Engineering | Power & Energy | Aerospace | Home Appliances


Collaborate and Review

45

Multiple Users can CollaborateContent Creation Design Review

Grab/Explode/Implode Measure Explode


Performance Test Areas

46

Caresoft will provide the following performance test analysis for benchmarking vehicle

❑ PQ Evaluation

❑ Noise, Vibration & Harshness

❑ Steering, Ride and Handling

❑ Braking

❑ Water Management

❑ Headlamp Light Test

❑ Vehicle Power and Economy

❑ Thermal Management

❑ Static and Dynamic Stiffness Test

❑ K&C Testing

❑ Aerodynamics

❑ Vehicle Air Tightness

Vehicle Level


Performance Test Areas

47

❑ BIW stiffness (torsion, bending)

❑ BIW Modal Test

❑ Suspension Bushing Stiffness Test

❑ Mount Static Stiffness Test Thermal Management (Noise,

vibration and bushing stiffness test)

❑ Acoustics (Insulation, sound absorption, BIW air tightness test)

❑ Subframe modal analysis

System Level


Our Current Vehicles Database with Digital Twin Data Deliverables

48

Electrical SUV

Pickup Truck

Jaguar I-Pace

Audi e-tron (Work in Progress)

Tesla Model X

Tesla Model 3

RAM 2500 (Work in Progress)

Electrical Cars

Chevrolet Bolt EV


Vehicles Data Currently in Progress

49

Toyota Hilux – E Series Nissan Navara – E Series

Ford Ranger XLT Great Wall Wingle 7 LingHang

Isuzu D Max– Z Series

SUVs, EVs and More to come…

Confidential Property 50

Caresoft Evolution - Data >>Knowledge>>Actionable Results

Competition Vehicle Technical Digital twin Data

HE Scan

DATA KNOWLEDGE ACTIONABLE RESULTS

Digital Twin Benchmarking Data An OUTSIDE-IN ApproachIntegrated Approach for holistic actionable results


Competitive Assessment with High Energy Scan

51

Current Capability Output and Deliverables

Mechanical 3D CAD Models (2D Drawings, as requested by customer)

Vehicle Packaging Sub-systems, Systems, Complete Vehicle Assembly Bumper to Bumper

Electrical Topology Space Claim, 3D Harness Routing and Retention Strategy, 2D Harness Drawing, BOM, Electrical Schematics

Electronics Electronics Control Unit Architecture, Electronics Components used – BJT, FET etc.

Costing of Electrical Wire Harness Should costing of Electrical Wire Harnesses (costing of other components as requested by customer)

Electric Powertrain Construction of eMotor and transmission, Study of Power Electronics and Control System, BOM

Battery Architecture Battery attachment strategy, Battery Layout, HV and LV Architecture

Simulation and Analysis Meshed Model, Crash, CFD & Torsional and Stiffness Analysis

Material Analysis Chemical composition, Material properties & Equivalent ASTM/SAE material grade

Physical Teardown Detailed documentation of vehicle tear down with pictures and videos, Optical scan of critical components

Vehicle Measurements Gap and Flush measurement, vehicle ergonomics, Axle load dimension report, etc.

Design for Assembly (DFA) Analysis Manufacturing assembly process analysis by MTM-ProKon

Virtual Reality VR application to visualize the CAD data

www.motoview.com A free to use website for all design engineers, benchmarking team and auto enthusiasts


Use Cases of Caresoft Digital Twin Data

52

4. Electronics and CAN Analysis (when possible)

5. Costing

1. Vehicle Packaging and Digital Mock-up (3D CAD model of all systems in

customer preferred CAD platform)

2. Simulation and Analysis (CAE)

3. Electrical Schematics and Harness Drawings (Full Vehicle)

6. Design for Manufacturing Assembly Analysis (DFA/EHPV)

7. Capability Assessment - Performance Analysis

8. Engineering Information (CAD) in PLM – Enables global access

9. Virtual Reality

Engineering

Finance / Purchase

Manufacturing

Product Validation

Latest Technology

and Innovation


Motor Show Coverage

53

www.motoview.com

Motorshows Covered

35+

Photos Clicked

525,000+

Cars Covered

2300+

http://www.motoview.com/


Contacts

Caresoft Global Inc.28400 Denso Drive, Suite 340, Southfield, MI 48033, USA

7025 Veterans Boulevard, Suite A, Burr Ridge, IL 60527 USA

Caresoft Global Ltd.Suite 1, 3rd Floor, Acorn House,

Great Oaks, Basildon,

Essex, SS14 1AH, United Kingdom

Caresoft Global Private Limited • 5, West Wing, Shreyas, Chamiers towers, #24&25, Teynampet, Chennai - 600 018.

Tamil Nadu, INDIA

• Renaissance Altai, 5AC-952, HRBR 1st Block, Outer Ring Road, Bangalore - 560043,

Karnataka INDIA

• No.101, 1st floor, Pentagon 5, Magarpatta, Hadapsar, Pune 411 013

• 180 Race Course Road, Coimbatore -641 018, Tamil Nadu, INDIA

Caresoft Global China Co. Ltd.Room 609,Building 66,Lane 1333 Xin Long Road，Minhang district，Shanghai - 201101，China

Caresoft Global Hungary Kft.1077 Budapest, Wesselényi u. 66., Hungary

Caresoft Global Servicos De Technologia LTDAAV Archelau de Almedia Torres, 197

Conj: 03; Andar: 1

Centro, Araucaria, PR Cep: 83.702-185

www.caresoftglobal.comVisit us:[email protected]:

Caresoft Global Private Ltd/OXI S.r.l.Strada del Portone, 175– 10095 Grugliasco (TO), Italy

Caresoft Global GmbHMergenthalerallee 10 -12, 65760 Eschborn, Germany

Richard .A

Vice President – Sales

Prideep .S

Director -Sales & Business Development

Phone : +1 248 843 4304

E-Mail : [email protected]

Manoj Deep Singh

Director -North America

Phone : +1 630 209 2367

E-Mail : [email protected]

http://www.caresoftglobal.com/http://www.caresoftglobal.com/http://www.caresoftglobal.com/http://www.caresoftglobal.com/mailto:[email protected]://www.caresoftglobal.com/mailto:[email protected]:[email protected]

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