Simcenter ™
Enabling Predictive Engineering Analytics
Willy Bakkers, VP Siemens DF PL STS
Jean-Claude Ercolanelli, Sr VP Siemens DF PL STS
Realize Innovation
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Page 2 Siemens PLM Software
Simcenter launch
Dalian, July 11 th , 2016
The world is evolving…
Digitalization
changes
everything
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The world is evolving…
From mechanical components to
Smart systems integrating mechanical, electrical, controls
From defined options
to mass customization and personalization From known material and
production methods
to mixed materials, novel production methods
From internet connectivity to system of systems and
internet of things
One constant: addressing these engineering challenges…
…without compromising time-to-market, quality and cost
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3D SIMULATION
CFD SIMULATION
1D SIMULATION
From Disconnected Models and Data …
Customer Usage data Simulation data
Test data TEST MODELING
Historical data
CONTROLS
…to a Performance Digital Twin
3D SIMULATION
CFD SIMULATION
1D SIMULATION
Customer Usage data Simulation data
Test data TEST MODELING
Historical data
CONTROLS
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… enabling Predictive Engineering Analytics
3D SIMULATION
CFD SIMULATION
1D SIMULATION
Customer Usage data Simulation data
Test data TEST MODELING
Historical data
CONTROLS
System Driven Product Development
Simcenter ™ for Predictive Engineering Analytics
Verification & validation in the age of systems engineering
Simcenter™ Portfolio for Predictive Engineering Analytics System Mock-up
Managed in PLM Context - Multi-Domain Traceability, Change and Configuration
TEST
Digital twin
1D
CFD
Exploration - Analytics - Reporting 3D
Verification & Validation
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Introducing Simcenter ™ Portfolio for Predictive Engineering Analytics
Simcenter™
#1 Best-in-class
products
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Page 12 Siemens PLM Software
STAR-CCM+
Simcenter ™
World class portfolio for Predictive Engineering Analytics
CFD Simulatio n CFD
JC
Ford Motor Company
Design space exploration reduces drag while ensuring engine cooling
Aerodynamic Design for the Ford Ranger
• Reduced fuel consumption by reducing vehicle drag
• Reduced wind tunnel testing by a third
• Ensured condenser cooling air flow meet the demands for cabin comfort
• Achieved engine cooling requirements
“Simulation allowed aerodynamicists to quickly access many design alternatives minimizing the needs for time consuming physical tests.”
Neil Lewington, Senior Aerodynamicist
• Better aerodynamics of the vehicle is a key contributor to achieving fuel economy targets
Managed interaction with air flowing over roof and cargo boxes
Exploring design changes below vehicle
helped reduce drag over 7 %
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Reduce emissions and lower manufacturing costs
Kawasaki Heavy Industry (KHI) with B&B-AGEMA and FH Aachen University
Innovative Micro-Mix Hydrogen Gas Turbine Combustor Design
“Numerical design exploration helped us identify how to control NOx emissions while increasing energy density.”
– Anis Haj Ayed, B&B-AGEMA
• Reduced emissions 4x
while increasing energy density 11x
• Lower manufacturing cost (by reducing # of injectors 10x) while maintaining low NOx
• Reduced development time & cost
by reducing need for experimental testing
• Patent application is in-progress
B A C
D E
0 5 10 15 20 25
0.15 0.25 0.35 0.45 0.55 0.65
NO / NOx @ 15%O2[ppm]
Equivalence Ratio ФA [-]
0.3 mm - reference Simulation - 1.0 mm Experiment - 1.0 mm
From 6.2 to 1.6 ppm
@ 11 times higher energy density
15 ppm limit
Jet-in- crossflow
Air inlet
Fuel inlet
NOx
Improved Baseline
JC
“The cavitation prediction matched well with experimental data and enabled us to optimize the blade tip loading on the propeller.”
Keun Woo Shin, Research Engineer, Mechanics and Hydrodynamics
MAN Diesel & Turbo
Propeller blade design exploration improves fuel efficiency and reduces noise
• Reduce cloud cavitation
• Reduce propulsive efficiency loss from tip vortex
• Reduce noise and risk of erosion
A modern process for design exploration using multidisciplinary simulation
Calculate flow field around hull and through propeller: include actual ship
wake and rudder interaction
Vary blade pitch and vertical inclination to improve blade tip loading
Reference
High tip loading
Low tip
loading
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NX Nastran
Simcenter 3D
Simcenter ™
World class portfolio for Predictive Engineering Analytics
3D Simulatio n
WB
Simcenter ™
World class portfolio for Predictive Engineering Analytics
Simcenter™ 3D is our next-
generation 3D CAE solution
based on the NX platform and
expands on the heritage of NX
CAE, NX Nastran, LMS Virtual.Lab and LMS Samtech
NEW
PRODUCT
Aug. 2016
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Simcenter ™
World class portfolio for Predictive Engineering Analytics
Simulating Manufacturing Process
and Spring-back Effect Topology optimization
COMPOSITES
MANUFACTURING
ADDITIVE
MANUFACTURING
Simcenter ™
World class portfolio for Predictive Engineering Analytics
LMS Imagine.Lab Amesim
LMS Imagine.Lab
System Synthesis
1D Simulatio n 1D
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Generate a 1D sketch from a 3D CAD model
Simcenter ™
World class portfolio for Predictive Engineering Analytics
NEW
Leverage high
performance computing for
faster time to results
Simcenter ™
World class portfolio for Predictive Engineering Analytics
1D
NEW
“We launch about 1,000 simulations, with LMS Amesim performing the analysis at night. I have never seen such a powerful tool.”
Andreas Klein, Senior Expert for Hydraulic System Simulation, Bosch
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LMS SCADAS LMS Test.Lab
Simcenter ™
Worldclass Portfolio for Predictive Engineering Analytics
T esting Solu tions TEST
Simcenter ™
World class portfolio for Predictive Engineering Analytics
LMS Sound Camera
NEW
PRODUCT
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Simcenter ™
World class portfolio for Predictive Engineering Analytics
LMS
SCADAS Satellite
NEW
PRODUCT
Simcenter ™
World class portfolio for Predictive Engineering Analytics
HEEDS
Design Explo ration
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Teamcenter
Simcenter ™
World class portfolio for Predictive Engineering Analytics
R F
L P
Systems Engineering
Model & Data Management
Simcenter ™
Worldclass Portfolio for Predictive Engineering Analytics
CD-adapco Engineering
LMS Engineering
Engi neering Services
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Cloud
Licensing flexibility
Simcenter ™ Portfolio for Predictive Engineering Analytics Cornerstones for a future-proof engineering approach
Covering full range of methods
Analytics, reporting &
exploration
Deployment flexibility Openness & Scalability User Interface Industry & engineering
expertise Systems approach
Collaboration &
workflow Multidiscipline
& multiphysics
R F
L P
Controls 1D
3D
TEST
CFD
Simcenter Experience
#2 Multiphysics
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What our customers say
Streamlining the engine
design process
JC
Simcenter TM Portfolio for Predictive Engineering Analytics Combined CFD – 1D for scalable system level simulation
1D
LMS Imagine.Lab STAR-CCM+
CFD
Battery
System simulation models Battery design optimization (Chemical and thermal) with
realistic load cycles
Fluid systems
System simulation models Complex geometries
and complex fluids
(Phase change and rheology)
Powertrain
System simulation models Optimizing vehicle thermal
management and fuel
consumption
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• Optimize cooling of battery pack
• Enhanced passenger comfort
Expanding complexity of systems
Vehicle Electrification example with complete workflow for Heat Protection
• Interaction between Powertrain, battery systems, electric motor and cabin.
• Enable drive studies to test controls, determine vehicle range and battery lifetime estimation
Vehicle System Design Component Design
Feedback To System
Improved design:
35% weight reduction 30% Thermal Improvement
Design refinement
• Select critical operating points
• Optimize Battery cooling system
JC
Simcenter ™ Portfolio for Predictive Engineering Analytics Multiphysics simulation: Aero-acoustics
Ref. “Prediction of Exterior Wind Noise Generated by a Side Mirror of an SUV”, Published at Internoise 2016
Cooperation Volvo Cars Chalmers University Siemens PLM Software
A challenging subject in automotive engineering
CFD for Load Prediction
3D NVH Car Body Model
Review Design Alternatives
WIND NOISE
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Simcenter ™ Portfolio for Predictive Engineering Analytics Combining Simulation and Test
Validate simulation with
real-life tests
I. Test FOR Simulation
Combined use of
test and simulation
II. Test WITH Simulation III. Simulation FOR Test
Simulation for
productive & realistic tests
WB
Test FOR Simulation - example
Functionality to increase reliability of simulation based on testing
NVH
Acoustic
Motion Flexible body
Composite
Durability
FE Ana ly sis [M odal/ FRF] Corre lation & Updat ing
Propagate
Accuracy & Quality
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Assemble and calculate system level models Simulate what you design, test what you have
• Modal substructuring (CMS)
• FRF based substructuring
• Multibody system integration
Model reduction, Residual modes
Test & Simulation - example
Hybrid substructuring - integrating test and simulation models
Test & Simulation – example “Virtual Sensing”
Body force estimation applied to driving performance
Wheel Angles Speed/Position Strain/ Accel. …
Sensor data
Cornering Forces At Body Connections Virtual sensor
Measurement update
∆ (Measured value - predicted )
Kalman Filter based on Simulation ( Real-time )
Input maneuver
Objective evaluation of driving performance by estimating body cornering forces at suspension to body connection points using Test - 1D/3D modeling
Ti re s R o ad
Chassis/body
S uspe nsi on
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Simulation FOR Test - example
Real-time simulation – 1D, 3D and combined
Real-time
simulation
#3 Industry focus
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Aircraft fueling
Modelling the digital twin of an aircraft fueling system
Modelling the digital twin of an aircraft
fueling system
Real-time Simulation – 1D, 3D and Combined development of a shift simulator for shift quality
Feel shift quality before it is build
• No need to build transmission components
• No shift plate, no cable, no synchronizers
• No need of a car
Gaining months of time
Evaluating multiples of configurations
Committed force/velocity matching
delivered subjective
assessment quality
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#4 Analytics
JC
RUAG Aerospace
Leveraging design space exploration saves millions in lost facility revenue
“In one week of exploration, we improved the flow in the test section dynamic pressure by over 84% and identified potential designs that could significantly reduce pressure drop with good uniformity”
- Philippe Stephani,
RUAG Aviation• Avoiding costly extended wind tunnel down time saves millions of Euros in lost revenue
• Wind tunnel digital twin enables exploring upcoming improvements to facility without shutting it down
To improve wind tunnel performance RUAG developed a
flow conditioning grid
Design space exploration avoids several weeks of
downtime and allows for ongoing improvements
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Design exploration helps meet critical government regulations
Jaguar Land Rover
Piston bowl design exploration reduces Soot and NOX by 9%.
“Due to the advancements in es-ice automation, transient full cycle es-ice/STAR-CD in-cylinder design space exploration is now possible!”
Paul Dunkley, Project Engineer Engine “Digital Twin” delivers:
• 9% Reduction in Soot
• 9% Reduction in NOX
• 0.2% increase in Power
SOOT NO
Evaluation
Objectives Parameters
SOOT % Power % NO % Bowl
Centre Depth
Bowl
Depth Radius EGR SOI
Base case 1.9385 12.233 0.0269 0.0090 0.0165 0.0090 5 720.49
Rank 1 2.2041 13.702 10.227 -16.401 0.0012 - 95.424 0.0106 0.0160 0.0110 20 725.00 Design ID 4 1.7574 - 9.338 12.257 0.195 0.0244 - 9.227 0.0103 0.0169 0.0103 7.4 718.07
Design Exploration Results:
JC
ABEC Inc.
Mixing design exploration: 54% reduction in blend time, $1 MM materials saving
“Simulation and the improved process understanding that it provides can have a large impact on the performance of the process, reducing time to scale-up and minimizing wasted product samples”
Paul Kubera, Vice President, Process Technology
• 54% reduction in blend time in the scaled-up reactor
• $1 MM in product saved by getting full scale behavior right first time
• Reduced scale-up time by gaining insight of flow & mixing behavior
Baseline design to understand mixing behavior & validate against
lab data
Explore effect of impeller type and number of impellers on a
shaft on blend time
Reduced blend time for scaled- up design by exploring
alternative designs
Reduce Time and Cost of Scale-up
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#5 Customer focus
WB
Example Chinese partnerships
FAW
Weichai Power BAIC Motor BYD
Dongfeng Great Wall Motor CNR Qiaihar
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Summary
Thank you
Realize innovation.
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