REVOLUTIONIZING SIMULATION
Transcript of 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.
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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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)
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REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
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Malcolm Panthaki | VP Analysis Solutions | Aras
Systems Thinking Enabled by a Digital Thread
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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
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MB
SE (
Sys
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Sim
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Elec
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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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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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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
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SIMULATION
SystemsModels
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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
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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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
Tour of the Software:
A System-Centric Digital Thread
38
Tim Keer | Director NA Pre-Sales | Aras
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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
REVOLUTIONIZING SIMULATION – “Learn from Your Peers” Webinar SeriesRev-sim.org/webinars 2020-2021
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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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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Thank You!
Questions?
Please type in the “Q&A” window!
[email protected] [email protected]@aras.com