REVOLUTIONIZING SIMULATION

48
REVOLUTIONIZING SIMULATION “Learn from Your Peers” Webinar Series Rev-sim.org/webinars 2020-2021 REVOLUTIONIZING SIMULATION: How Manufacturing Companies Successfully Deploy Next-Generation Technologies to Turbocharge the Impact of Simulation Toyota Motor Europe’s System-Centric Digital Thread: Improving System Performance with Cross-Discipline Collaboration and a Single Source of Truth Malcolm Panthaki VP of Analysis Solutions Aras Corp. Ernesto Mottola Sr. Manager, Model-Based Development Toyota Motor Europe Tim Keer Director NA Pre-Sales Aras Corp.

Transcript of REVOLUTIONIZING SIMULATION

Page 1: REVOLUTIONIZING SIMULATION

REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021

REVOLUTIONIZING SIMULATION:How Manufacturing Companies Successfully Deploy

Next-Generation Technologies to Turbocharge the Impact of Simulation

Toyota Motor Europe’s System-Centric Digital Thread:

Improving System Performance with Cross-Discipline

Collaboration and a Single Source of Truth

Malcolm PanthakiVP of Analysis Solutions

Aras Corp.

Ernesto MottolaSr. Manager, Model-Based Development

Toyota Motor Europe

Tim KeerDirector NA Pre-Sales

Aras Corp.

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REVOLUTIONIZING SIMULATION:How Manufacturing Companies Successfully Deploy

Next-Generation Technologies to Turbocharge the Impact of Simulation

Bob Farrell ([email protected]) | Rich McFall, [email protected] | Malcolm Panthaki, [email protected]

How Polytec uses Cloud-Based HPC for Virtual Non-Destructive Testing (NDT) using Finite Element Analysis of Elastic Wave PropagationSeptember 30, 202011:00 AM (Eastern US)

Toyota Motor Europe’s System-Centric Digital Thread – Improving System Performance with Cross-Discipline Collaboration and a Single Source of TruthOctober 21, 202011:00 AM (Eastern US)

How nTopology is enabling the aerospace industry to create stronger, lighter partsDecember 9, 202011:00 AM (Eastern US)

www.rev-sim.org/webinars

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Agenda

Overview: Systems Thinking enabled by a Digital Thread

Case Study: Digital Thread for Cross-Discipline Collaboration

Software Demo: Visualizing a custom Digital Thread

Q&A and Discussion

8

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Malcolm Panthaki | VP Analysis Solutions | Aras

Systems Thinking Enabled by a Digital Thread

9

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source: cnh

Accelerating Rate of Change & Disruption

Smart ConnectedProducts

Industrial Internet &Industrie 4.0

Product-as-a-Service

source: windpowerengineering

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Mechatronic

CI=105

Mech/Elec/Software/Network

CI=108

Mechanical

CI=103

Explosion of Complexity

source: SAFRAN Group

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Digital Transformation and the Digital Thread

Systems Thinking – a continuous journey

Systems Thinking andDigital Transformation

Silos: Tools, Data, ProcessesDigital Thread (intent and data)

– now and future

Evolution of Digital Thread

New markets, opportunities

Emerging technologies

Req

uir

emen

ts

Var

ian

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MB

SE (

Sys

Engg

)

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Silos Everywhere!

Domains

SoftwareElectronics ElectricalMechanical

Functions & Expertise/Tools SimulationMBSE VariabilityRequirements

System PartsSub-Systems Sub-Systems

Reductionism / Decomposition

DistributedDivisions &Supply Chains

US Team France Team Tier 1 SupplierAcquisition

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System Parts

Reductionism OR Systems Thinking?

Sub-Systems Sub-Systems

Reductionism✓ Tasks & Responsibilities

✓ Domain–Specific Engineering

Requirements Visibility

System Behavior Tradeoffs

System Optimization

Systems Thinking✓ Interactions & Interfaces

✓ Patterns

✓ Complexity

✓ Uncertainty Management

✓ Emergent System Behavior

Reductionism AND Systems Thinking

Mechanical

Electronics

Electrical

Software

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3D CAD

Product Lifecycle Management (PLM)Mechanical BOM-Centric Approach

Legacy PLM focused on Mechanical Design…

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PLM must be about Systems Thinking

System-Centric Approach Required

System

of

SystemsRequirements

Architecture

Variants

Mechanical

Software

Electronics

Product

is a

System

Networking

IoT

Infrastructure

Environment

Regulations

Industrie 4.0

AI / ML

Related

Systems

System

Context

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SystemsSystem

ArchitectureSysML Models

System Architecture at the Core: Connecting Data Silos

Silos inhibit cross-discipline collaboration

System Architecture

Simulation DataParts/CAD

System Architecture as connective tissue

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An agile, iterative, system design process

Continuous System Exploration & ValidationFEEDBACK

Continuous System Evolution

(Digital Thread)

Continuous

System Exploration & Validation

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C

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O SN #44

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Q SN #71

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R3

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R5

R6

R4

R9

R10

R11

R14

R13

R1

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Connected Data Across the Product Lifecycle

DEFINE DEVELOP BUILD OPERATE

Requirements Detailed Designs

ManufacturingProcesses

QualityAnalyses

Digital Twins &

Maintenance

L6

Q SN #71Q SN #71Q SN #53

H I

H IH IR7

R3

R6

R10

SIMULATION

SystemsModels

F4

F5

L6

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Customer Reality: Custom, Partial Digital Threads

Each engagement has customer-focused priorities

… but all data connects through System Architecture

System Architecture

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Connecting All Data – From Data to Knowledge

DEFINE

DESIGN

TEST

BUILD

MEASURE

CONNECTED to All External Applications & Data Stores

Spreadsheets Databases In-House Tools Parts Libraries

SYSTEM ARCHITECTURE

DIGITAL THREAD

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Ernesto Mottola | Sr. Manager, Model Based Development | Toyota Motor Europe

A System-centric Digital Thread

to enable cross-discipline collaboration at TME

22

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The perspective of automotive industry

All the traditional challenges…

Safety

Cost

Emissions

Comfort

Regulations

Customer appealStyle

Quality

Production

Platform commonisation

Lightweight

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…and a “once-in-a-century” shake-up from C.A.S.E.*

Toyota evolving from a car company to a mobility company(source: Toyota annual report 2018)

(*) C.A.S.E.ConnectedAutonomousSharedElectrified

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How systems thinking is developing

ISFuel econ.

Body

Chassis

E/G

D/T

Control

Body

NV

Ride

Control

Handling

Chassis

Drivability

Durability

PowerTrain

Target

HiLS

Simulator

Customer

VPM Virtual Environment Real Test

Concept

PM

MBD* to realise a holistic vehicle/systems development approach through simulation

(*) MBD = Model Based Development

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The reality of many large corporations

In practice, valuable data are trapped in legacy silos and require effort to extract

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TME’s proof of concept project on systems lifecycle

Demonstrate the feasibility of improved process between data producers and consumers

DMPlatform

Data sources Designers Simulationengineers

3D-CAD

Test Results

Specifications

Chassis

Body

PT

Digital prototype

Increase speed and quality of simulation model making by

automated process3

Enable data re-use

2

Suppliers

Purchasing

Establish a single source of truth for engineering specs

1

Benefitswhen fully developed

1. Reduce data gathering effort

2. Capitalise past knowledge

3. Enable faster simulation studies, with higher quality data

Scope of proof of concept project

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A single source of truth? One more needed?

The intended data model should complement and integrate with existing PLM solutions

BOM = Bill of materials

Systemspecifications

Vehicle project phases

Leve

l of

dat

a d

etai

l

“Traditional PLM” 3D CAD

eBOM (detailed product structure)

3D Structuralsimulation& SPDM

Requirements management

System performanceSimulation

Requirements for managing engineering specifications:▪ Flexible product

structure & data▪ Tool independent

process automation▪ Data federation from

other sources

Existing

Needs devel.

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What are the characteristics of this data structure?

A structure flexible enough to support current simulation tools and developing SE thinking

TomorrowA system structure defined by more formal

methods → The data model for Systems Lifecycle Management

Technical breakdown structures

RFLP structures

SysML diagrams

Defined by…

Or:

Or:

Systems

Vehicle variant CVehicle variant B

Vehicle variant A

Requirements

Part lists CAD DBOther DBs…

TodayA container for all parameters required

by existing simulation models

Vehicle variant CVehicle variant B

Vehicle variant A

MBS models

Vehicle variant CVehicle variant B

Vehicle variant A

Vehicle variant CVehicle variant B

Vehicle variant A

Calc. sheets

Defined by…

Simple models

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How to use this system structure?

As the main carrier for engineering specification I/O during performance development processes

eBOM

System Lifecycle Management Platform

StudyPhase 1

StudyPhase 2

StudyPhase 3

Sim. engineers

Designers

Perf. engineers

Milestone for development

Gather data, Build simulation models

Performance studies by sim.

Proposal for updated

specifications

Review, update & approve data

Design studies, feasibility checks,…

All using the same up-to-date specifications across domains

Gather data, Build simulation models

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TME’s proposed system centric approachEx

amp

le d

ata

SystemRoot

System

System

System

System

EDC

EDCData object

Data object

Data object

Data type

Data type

VehicleBodyFr. AxleRr. AxlePT…

EDC = Engineering data containerFr. StrutCoil springShock absorberAntiroll barBushing…

Data object = collection of dataLocationInertiaBushing direction…

Data type = atomic dataParameterArrayDocumentData maturity…

Built-in

Custom Built

We designed a system lifecycle management architecture and implemented on ARAS

Can manage system / component variants

Change tracking & revisions management

Controlled access

Flexible data structure, can use from early stage

Can attach files & documents

Manage all data needed by simulation models

(focus on mechanical in PoC)

Architecture of system data model Implementation in Aras Innovator

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Development of usability & acceptance

A user friendly GUI hides the complexity of the underlying database for easy I/O

Traditional working way:Spreadsheets

▪ Not flexible, not robust, difficult to re-use▪ BUT very easy to use → well accepted

With smart system structure:Spreadsheet-like

▪ Data interface automatically generated for all Engineering Data Containers

▪ Convenience features are provided (copy/paste, edit arrays, etc.)

Data object block

Data I/O(defined by Data type)

SystemRoot

System

System

System

System

EDC

EDC

Data object

Data object

Data object

Data type

Data type

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Features for data re-use and capitalisation

We secured flexible data access and re-use → basis for value, enabler for data science!

Various ways to access data

PLM

Data comparison at any level

Select 2+ items

See differences

Data re-use by flexible queries

Visual query builder

▪ Any object can be searched▪ Any related object data or property

can be used as search criteria

Example:Search all front suspension systems which knuckle has Z location at 1000-1200mm, belonging to 123A series, with trimmed body mass > 700 kg

Native client = web browser

Export/Import (via macro)

AML Console

SOAP

Http/AMLRest

Http/JSON

.Net

VB, C#, Python, C++

Custom connectors

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Workflow and process automation

With suitable data model set, various (x-func.) processes can be automated with confidence

Example 2 – Formal process to release and approve data

1. Model owner kicks off modelling process → all data owners get notified of the request, with link to data to fill in

1 2

2. Each data owner enters and marks his data as checked

3. Each manager gets notified and can review and approve data from his team member

3

Example 1 – Bushing model parameter identification

[Hz] [mm] [N/mm] [Ns/mm]

15.00 ± 0.50 800.000 1.050

45.00 ± 0.20 900.000 0.450

100.00 ± 0.05 1050.000 0.240

±

±

Frequency CdAmplitude Kd

Design data

Test data

▪ Can store design / test characteristics of dynamic bushing▪ Can trigger automated PI process and store results

Custom PI tool

Model data

Bushing model identification

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The system structure as the foundation for SPDM

Model generation process is flexible:▪ To any system complexity / simulation tool▪ To different model fidelities with same sim. tool

Process automation can be used to generate simulation models from system specifications

Simpack model▪ Flexible body▪ Simple PT model▪ All dynamic bushings▪ MF/Swift tire

Vehicle variant X

Project 123A, phase “A”▪ 5 Door body▪ PT var. 1▪ Suspension var. 2▪ 18” Wheels

Vehicle variant X

Project 123APhase “A”…Phase “B”

Vehicle variant CVehicle variant B

Vehicle variant A

This data model achieves full traceability:▪ System specifications lifecycle▪ Simulation models (not yet full SPDM)

Sim. Model templates

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Example 1 – System variants coverage

Syst

em v

aria

nts

Solver rules

Managing complexity, enabling the digital twin

Once the process has been developed, it can be scaled to expand application scope

Model generation can be executed in batch and feed SPDM process:▪ Full virtual validation coverage▪ Worst case selection for physical

testing

Example 2 – Tracing different system conditions

Vehicle variant X

As designed

Vehicle variant X

As built

Instantiate as a new revision

Update system with data from the field

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Towards our vision for pervasive simulation

▪ One click process from engineering data

to performance evaluation

→ Anyone can leverage simulation power to

predict performance of a system

▪ ML assisted design space exploration

→ manage uncertainty in design phase, and

worst case / robustness in validation phase

▪ Seamless development process

▪ Extract system data from detailed product structure

▪ Data federation to leverage existing data & processes

Process automation & integration

Data backbone

Select datasets Select load cases

Launch sim.Parameters…

Project APhase 1Phase 2

HV17”18”

Project B

KnCHandlingSteeringComfort

HarshnessSpeed bumpCleat

Live dashboard & issues tracking

Perf. 1

Per

f. 2 Nominal

Robust

Compatible performances

Design var. 1

Des

ign

var

. 2

Feasible design

Perf. 1Perf. 2

Feasible region

Perf. 1→OKPerf. 2→OK

Simulation+ smart DoE

PLM 2

Vehicle variant CVehicle variant B

Vehicle variant A

PLM 1

Vehicle variant CVehicle variant B

Vehicle variant A

eBOMSystem structureVehicle variant C

Vehicle variant BVehicle variant A

sBOM

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Tour of the Software:

A System-Centric Digital Thread

38

Tim Keer | Director NA Pre-Sales | Aras

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Managing

Requirements

& Systems

Architecture

Engineering

Data

Management

Variant

Management

Simulation

Automation:

Systems to

3D

Digital Thread Showcase: MBSE to Automated

Simulation & Back

Closed-Loop

V&V:

Bringing it all

together!

Product

Engineering

Variant

Management

Simulation

Management

Systems

Architecture

Requirements

Engineering

Quality

Management

Systems

Manufacturing

Process

Planning

Technical

Documentation

DigitalTwinCore

Maintenance

Management

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Managing

Requirements

& Systems

Architecture

Engineering

Data

Management

Variant

Management

Simulation

Automation:

Systems to

3D

Digital Thread Showcase: MBSE to Automated

Simulation & Back

Closed-Loop

V&V:

Bringing it all

together!

Product

Engineering

Variant

Management

Simulation

Management

Systems

Architecture

Requirements

Engineering

Quality

Management

Systems

Manufacturing

Process

Planning

Technical

Documentation

DigitalTwinCore

Maintenance

Management

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Managing

Requirements

& Systems

Architecture

Engineering

Data

Management

Variant

Management

Simulation

Automation:

Systems to

3D

Digital Thread Showcase: MBSE to Automated

Simulation & Back

Closed-Loop

V&V:

Bringing it all

together!

Product

Engineering

Variant

Management

Simulation

Management

Systems

Architecture

Requirements

Engineering

Quality

Management

Systems

Manufacturing

Process

Planning

Technical

Documentation

DigitalTwinCore

Maintenance

Management

Page 42: REVOLUTIONIZING SIMULATION

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Managing

Requirements

& Systems

Architecture

Engineering

Data

Management

Variant

Management

Simulation

Automation:

Systems to

3D

Digital Thread Showcase: MBSE to Automated

Simulation & Back

Closed-Loop

V&V:

Bringing it all

together!

Product

Engineering

Variant

Management

Simulation

Management

Systems

Architecture

Requirements

Engineering

Quality

Management

Systems

Manufacturing

Process

Planning

Technical

Documentation

DigitalTwinCore

Maintenance

Management

Page 43: REVOLUTIONIZING SIMULATION

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Managing

Requirements

& Systems

Architecture

Engineering

Data

Management

Variant

Management

Simulation

Automation:

Systems to

3D

Digital Thread Showcase: MBSE to Automated

Simulation & Back

Closed-Loop

V&V:

Bringing it all

together!

Product

Engineering

Variant

Management

Simulation

Management

Systems

Architecture

Requirements

Engineering

Quality

Management

Systems

Manufacturing

Process

Planning

Technical

Documentation

DigitalTwinCore

Maintenance

Management

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Use Case

Lower Control Arm

3-D Finite Element Stress Analysis

Full Vehicle Curb Collision

Modelica System Model (Modelon)

Suspension Geometry

Parameters

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Managing

Requirements

& Systems

Architecture

Engineering

Data

Management

Variant

Management

Simulation

Automation:

Systems to

3D

Digital Thread Showcase: MBSE to Automated

Simulation & Back

Closed-Loop

V&V:

Bringing it all

together!

Product

Engineering

Variant

Management

Simulation

Management

Systems

Architecture

Requirements

Engineering

Quality

Management

Systems

Manufacturing

Process

Planning

Technical

Documentation

DigitalTwinCore

Maintenance

Management

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PLM backbone

Conclusion – the importance of the digital thread

46

Connecting data = Connecting processes = Connecting people

Data Model(Custom, flexible, scalable)

Usability & Workflow(Digitalised process)

Roles & responsibilities

TME’s case study of engineering data management

System architect

Model masterData owners

Backend integratorBusiness

analyst

Infrastructure leader

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REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021

A call for action to accelerate SPDM

▪ Let’s not forget: SPDM ≠ one domain, one toolchain

(and new technology emerges any time)

▪ Demand your SW vendors to enable tool independent process integration

▪ Open data model to manage and exchange data across tools / disciplines

▪ Open APIs and standards, on top of black box connectors, for process integration

▪ Balance customisation with technical debt (easiness, sustainability)

▪ Team up at pre-competitive level to accelerate the technical development

▪ Clarify and consolidate requirements, share technology assessment

▪ Work with vendors to jointly develop demonstrators

Please get in touch if you are interested in collaborating on further development of system centric SPDM

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REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021

Thank You!

Questions?

Please type in the “Q&A” window!

[email protected] [email protected]@aras.com