avl’s methods and tools for knowledge management …

This document is subject to confidentiality agreements in force on the date of its publication between AVL LIST GmbH and AVL List GmbH. Copyright © 2013, AVL List GmbH.

Author(s): Franz Zieher, Head of Simulation & Mech. Development

Version: 2.1

Release date: 24.10.2013

Security level: Internal

Customer: AVL List GmbH

HOW TO MAKE THE RIGHT DECISIONS IN POWERTRAIN DEVELOPMENT – AVL SWEDEN SEMINAR

AVL’S METHODS AND TOOLS FOR KNOWLEDGE

MANAGEMENT – ICAE

AVL Sweden Seminar 2013, Götheborg, F. Zieher PTE/DA 2 Internal

AVL GLOBAL POWERTRAIN ENGINEERING TEAM

Global Powertrain Engineering team

More than 250 Simulation engineers globally

France

Germany

Croatia

Austria

Slovenia Slowenia

USA

China India India India India

Hungary

Sweden

UK

Japan

How to collaborate efficiently (globally) How to manage the engineering knowledge

Challenge


IMPROVING EFFICIENCY IN THE DEVELOPMENT PROCESS

Validation

Development Time

Product Requirements

Syst

em

Co

mp

on

ents

Validation

Product

Earlier integration and validation


DEMAND FOR STRONGLY INTERDISCIPLINARY AND CONNECTED SIMULATION AREAS MOTIVATION FOR DEVELOPING ICAE

System simulation

Thermodynamics

Mechanics, Heat transfer

Acoustics, NVH

Emissions, Aftertreatment

Electrics, Hydraulics

Energy management


Complete Vehicle

10000

Complete

Engine

20000

Assembly

Crankcase

20500

Assembly

Cranktrain

21000

Assembly

Cylinder

Head 21500

Assembly

Valve Train

22000

Assembly Oil

Circuit

23000

Assembly

Camshaft

Drive 22500

Assembly

Complete

Engine 20100

Assembly

Fuel System

24000

Assembly

Intake

System 24500

Assembly

Exhaust

System 25000

Assembly

Breather

System 25500

Assembly

Covers

26500

Assembly

Auxiliaries

26000

Assembly

Cooling

Circuit 23500

Complete

Electrics

70000

Complete

Chassis

40000

Complete ...

STANDARDIZED PRODUCT STRUCTURE POWERTRAIN ASSEMBLY SYSTEM

Complete Engine Crankcase Cranktrain Valve Train Timing Drive Oil Circuit Cylinder Head

Water Circuit Intake System Auxiliaries Breather System Exhaust System Covers Injection System


PROCESS MANAGEMENT ENVIRONMENT – AVL/ICAE (1) METHODS LIBRARY FOR STANDARDIZATION

Development task (methods) library

Development tasks are defined with metadata information

Development tasks are stored in database

Key task/method properties (metadata)

Has relationship to product structure

Describes Input / Output

Method/Workflow description

Related performance attributes

Access to related reports

Access to related simulation data

Benchmark performance attributes


PRODUCT DEVELOPMENT PROCESS (2) DATA AND PROCESS MANAGEMENT

Development phases

Prototype development (engine generation 1)

Concept development

Preproduction development (engine generation 2)

Production validation

Product development

Standardized Workflow Predefined Input & Output Data „Performance Attribute“ - Technical Release Criteria Associated to Product-Structure (PLM) Resource Management Development Documentation & Reporting

Development task instance

Percentage overall time (average across 11 companies of automotive

industry, aeronautic and aerospace industry, railway industry) Source: Prof. Anderl, DiK, TU Darmstadt

Data Handling

Data Preparation

Modeling

Analysis / Simulation

Interpretation / Presentation

51%

49%

Start

Stop

Pro

ject

exe

cuti

on

tim

e


DATA AND STRUCTURE MANAGEMENT IN ICAE

Project (product development)

Development task

System (component) model variant

Development job (e.g. simulation run)

… Managed documentation

Roles

Project Manager / Lead Engineer Does the report approval, project reporting

Manages the “Performance Attributes”

Manages the development tasks

Engineer Creates model- and job structure

Performs the engineering work

Does the documentation and reporting


4009 – CYLINDER HEAD, CYLINDER BLOCK FEA

WORKFLOW: Cylinder head, cylinder block FEA

Standardization of development methods

is mandatory for efficient and effective

frontloading (automation, optimization)


CASCADING REQUIREMENTS (3) PERFORMANCE ATTRIBUTE MANAGEMENT

Requirements definition

Component / HIL testing

Vehicle testing and validation

Integrated tool-chain / database

Powertrain testing and validation System and component requirements Performance attributes targets

Virtual product development, performance attribute monitoring digital prototype release


SIMULATION DRIVEN DESIGN DEFINITION OF SIMULATION AND DEVELOPMENT CONTENT

Development Target

Specification Manual

DVP Dev. Efforts

System attributes &

targets Development

Verification Validation

Simulation scope

Coolant flow

Heat transfer

Durability head/block assembly

...

System target definition

Max. head temperatur

Max. liner deformations

No. thermal-shock cycles

...

Functional development (T.b.,Veh.)

Durability testing (T.b./Veh.)

Load cycle testing

Thermal shock testing

...

Example: cylinder head Example: cylinder head

Base for “virtual release”

Performance Attributes (PA)


SYSTEM ATTRIBUTES, TARGETS EXAMPLE PERFORMANCE ATTRIBUTE MONITORING

System attributes and targets are

defined in relation to function,

system and development task.

Attributes are monitored along the

development phases and support the

„release process“

Target monitoring

System requirement

Design iterations/phases

Target is reached and system can be released for intended usage


BENCHMARK OF CRITICAL PERFORMANCE ATTRIBUTES EXAMPLE: CYLINDER HEAD TEMPERATURES FOR PASSENGER CAR ENGINES

Guidelines for design pre-selection (knowledge base) Performance attribute benchmark for systems / components Transfer information into knowledge creation through the working process

Passenger car engines


VIRTUAL RELEASE FOR SYSTEMS AND COMPONENTS

Measurable technical quality in the development

process

PA and targets are defined on bases of the development scope and customer boundary conditions

The product quality is assessed on the collective status of the performance attributes and can be assessed any time

The quality assessment can be done for the whole product, assembly groups or subassembly groups

Problem areas (not-achieved PA) are directly highlighted and can be immediately benchmarked against PA stored in the system

Design release supported on part and system level on bases of Performance Attribute status


ENGINE DEVELOPMENT PROCESS VIRTUAL DESIGN RELEASE - SUMMARY

Concept release

First engine (generation 1.1)

First engine (generation 2) First engine (generation 3)

Start Pilot Production

Development phases

First engine (generation 1.2)

Months before SOP

QG0 -42

QG1 -34

QG2 -27

QG3 -22

QG4 -15

QG5 -10

QG6 -6

QG7 0

QG8 +6

Prototype development (engine generation 1)

Concept development

Preproduction development (engine generation 2)

Production validation

Design releases

Hardware availability

Quality gates

Design release (generation 1.1)

Design release (generation 1.2)

Design release (generation 2)

Design release (generation 3)

-42 -36 -30 -24 -18 -12 -6 0 -45

SOP

AVL ENGINE DEVELOPMENT PROCESS

Mechanical development

Rig- and functional Rig- and functional

Durability Durability Verification

Vehicle Endurance Test

Targets achieved:

Fully reproducible/comparable

results due to standardized

workflows

Clearly defined targets

Association to assembly structure

Standardized documentation

evaluation

Knowledge database/management

Increase of efficiency (simulation

process and global process)

Quality Gate “x” VIRTUAL DESIGN RELEASE successfully accomplished


EXPERIENCE IN POWERTRAIN SIMULATION (LAST 8 YEARS) DATABASE STATUS OCTOBER 2013

Key benchmark information for advancing

state of the art technology

Support new product development (e.g.

battery systems) and capture key performance

criteria

270 engines analyzed from small

to large engines


SUMMARY & LESSONS LEARNED / SUCCESS FACTORS

ORGANIZATION & PROCESS

Find the right level of standardization and process

It takes a long time to change established working processes (especially in large organizations)

Sustainable commitment is required at every level in the organization

TOOL

Ease of use with focus on the end-user (development engineer)

Use conventions versus having every feature implemented

Document revision management („low hanging fruit“)

Connect with existing systems (ERP, other engineering systems)

Data Information Knowledge Wisdom


INTEGRATED TOOLCHAIN FOR COMMERCIAL VEHICLE POWERTRAIN DEVELOPMENT

AVL Instrumentation & Test Systems

BATTERY

TESTBED

HIL DEVELOPMENT

POWERTRAIN

TESTBED

ICE

TESTBED

Powertrain

Integration

Vehicle

Calibration &

Validation

Driveability

Assessment &

Prod. Sign-Off

Engine & HiL

Testing

Component

Testing

Vehicle Simulation

Component Simulation

AVL CRUISE

AVL BOOST

AVL Software Tools for Powertrain System Development & Optimization

AVL FIRE

AVL CAMEO

AVL DRIVE

AVL EXCITE

avl’s methods and tools for knowledge management …

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