Spring 2003

1. ME 457 Special Lecture: Introduction to Virtual Product DevelopmentSteve Rohdesteve@quantumsignal.com Spring 2003

2. Outline • Math Models • Virtual • Math-Based Process • Product Development Processes • Benefits • Examples • History

3. The Significance of Modeling & Simulation “Modeling and simulation are emerging as key technologies to support manufacturing in the 21st century, and no other technology offers more potential . . . for improving products, perfecting processes, reducing design-to-manufacturing cycle time, and reducing product realization costs.” Finding of Integrated Manufacturing Roadmapping Initiative, May 21, 1999. Sponsored by NIST, DOE, NSF, & DARPA

4. Examples of Models • Clay, styrofoam or fiberglass models • Plastic models • Building/city models • Artists models • Clothing models • Electric circuit analogies • Analog computer models • Math models

5. What is a Math Model? • Mathematics - the scientific study of quantities, including their relationships, operations, and measurement, expressed by numbers and symbols. • - Academic Press Dictionary of Science Technology • Math Models - mathematical representations of physical or abstract entities which capture their form / their functional behavior / or other aspects of their behavior.

6. Examples of Math Models • Economic/world models • Enterprise models • Marketing models • Financial models • Computer system models • Chemical reaction models • Human anatomy/physiology models • Physics models • Biometric models • Product engineering models • Manufacturing engineering models

7. Examples of Math Model Use in GM

8. Virtual reality • Virtual - "of, relating to, or possessing a power of acting without the agency of matter” • - Webster's Third New International Dictionary • Movies • “Total Recall” • “Brainstorm” • Virtual reality – creation of an environment which seems “real” in important respects; usually computer-based.

9. Virtual Reality

10. “Collaborative” • Internally • Suppliers • Customers Data Integrated The “ Virtual Vehicle” Paradigm • Extensive use of math-models to guide decisions: • Marketing • Definition • Form • Fit • Function • Process • Sales & Service • Virtual clinics • Virtual studio • Virtual mock-up • Virtual test lab • Virtual proving grounds • Virtual tool-room • Virtual factory

11. Math-based Processes • Process - a series of actions, changes, or functions that bring about an end or result. • - The American Heritage Dictionary • Math-based process- a process based upon or enabled by the use of mathematical models. • A math-based process is usually implemented using a computer.

12. A Product Development Process • The set of all activities required to define, design, and engineer a product including its manufacturing and assembly processes.

13. The “Good Old Days. . .”

14. The Modern Automotive Vehicle

15. Major Automotive Vehicle Subsystems • Powertrain • Accessories • Brakes • Steering • Suspension • Body

16. Heat, Noise, Vibration, Engine Vibration Torque Torque Delivered to Driven Wheels Heat, Noise, Driver Visibility, Airflow Hydraulic/Pneumatic Pressure Suspension Forces Vibration Noise Hydraulic Flow, Electrical Voltage Braking Torque Engine Speed Coolant Temp. Vacuum Electrical Voltage Steering Angle Vacuum Load Electrical Current Steering Forces Suspension Geometry Accessory Torque Load Battery Voltage Coolant Flow & Heat Loss Wheel Rotational Speed Body Attitude & Position Aerodynamic Drag Hydraulic Pressure, Electrical Current Hydraulic/Pneumatic Flow Heating & Cooling Loads Driven Wheel Rotational Speeds Automotive Vehicle Subsystem Interactions Body Linear & Angular Motion, Heat Flow in/out Fuel Consumption Emissions Powertrain Accessories Brakes Steering Suspension Body Vehicle Configuration Loading Windows up/down • Accelerator Pedal • Shift Lever • Clutch Pedal Accessory Controls Brake Pedal Steering Wheel Road

17. Heat, Noise, Vibration, Engine Vibration Torque Torque Delivered to Driven Wheels Heat, Noise, Driver Visibility, Airflow Hydraulic/Pneumatic Pressure Suspension Forces Vibration Noise Hydraulic Flow, Electrical Voltage Braking Torque Engine Speed Coolant Temp. Vacuum Electrical Voltage Steering Angle Vacuum Load Electrical Current Steering Forces Suspension Geometry Accessory Torque Load Battery Voltage Coolant Flow & Heat Loss Wheel Rotational Speed Body Attitude & Position Aerodynamic Drag Hydraulic Pressure, Electrical Current Hydraulic/Pneumatic Flow Heating & Cooling Loads Driven Wheel Rotational Speeds Automotive Vehicle Subsystem Interactions Body Linear & Angular Motion, Heat Flow in/out Fuel Consumption Emissions Powertrain Accessories Brakes Steering Suspension Body Computer(s) & Intelligence Vehicle Configuration Loading Windows up/down • Accelerator Pedal • Shift Lever • Clutch Pedal Accessory Controls Brake Pedal Steering Wheel Road

18. Math-Based Engineering Process Hour 2-3

19. Traditional Product Development Process Build Test Fix Iteration FormFunction • For Complex Products: • Cycle Time Too Long • Facility Intensive • Cost High • Convergence Not Assured

20. Math-Based Design Process • Math-based design: The process of designing and refining vehicles and components on sophisticated computer systems. Once approved, the designs are sent electronically to machines that cut tools and dies for the vehicle, minimizing the chance of errors. Computers can also simulate the performance of components and modules, as well as assembly line systems. • --The Detroit News December 21, 1998

21. 1964 DC-9 Program Savings via Math* 1. Increased reliability and maintainability of product 2. Program cost decreased 50% 3. Increased quality and quantity of results 4. Fewer drawing changes after initial release 5. Improved competitive position • Bottomline • Investment: $300K • Savings: $2.5M • Time Reduction: >50% *from “Use of Computer Programs in Aircraft Design” by Melvin Stone, Douglas Aircraft Co., SAE 1964 referring to DC-9 stucture

22. Why move to math now?

23. Advanced Technology Vehicles

24. 50% productivity improvement in last several years Over $109 savings VDP time reductions >18 months CAE today is 7-10 times faster than hardware verification CAE costs are a fraction of test verification costs CAE will become the principle design verification & direction methodology! Identified CAE as a critical element in product development Welcome the merger of the combined capabilities of visualization and supercomputers for Digital Prototyping total solution Benefits of Math-Based Technology

25. The Math Advantage • Hardware test learnings are limited to what can • be made visible • Example: • For a durability test to be useful it must run to • failure

26. The Math Advantage • In math “tests” we can see both causes and effects & track things that we can’t measure! • Example: • We can “see” the flow of energy & the final shape during a crash test

27. 35000 $30000 30000 25000 Cost of Buick LeSabre Engineer's salary 20000 Computing Cost 15000 10000 5000 $2702 $1030 $9 $0.14 2001 ~ $0.02 0 1960 1962 1964 1966 1968 1970 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 Some Relative Costs

28. How do we implement math based design?

29. Answer: Using Systems Engineering! • Systems Engineering: • “Top down” vs. “Bottoms up” • Requirements driven • Is a phased, iterative process • Interactions between systems & components are explicitly addressed • Uses math-models extensively • ……

30. The Top-Down Design Concept Customer Need Understand Define Functions • Synthesize • (Design) Form

31. Automotive Vehicle Functions

32. Vehicle Functional & Physical Decompositions Energy Management Comfort Enjoyment VEHICLE FUNCTIONS Safety What the Vehicle Does Information Management Transportation HVAC Powertrain Interior How It Does It VEHICLE Body Info & Cntls. Chassis Electrical Vehicle Subsystems

33. Vehicle Functional to Physical Mappings: Example Energy Management Comfort Enjoyment VEHICLE FUNCTIONS What the Vehicle Does Safety Information Management Transportation Form Follows Function HVAC Powertrain Interior How It Does It VEHICLE Body Info & Cntls. Chassis Electrical Vehicle Subsystems

34. Automotive Vehicle Subsystem Interactions Heat, Noise, Vibration, Engine Vibration Torque Torque Delivered to Driven Wheels Heat, Noise, Driver Visibility, Airflow Hydraulic/Pneumatic Pressure Suspension Forces Vibration Noise Hydraulic Flow, Electrical Voltage Braking Torque Engine Speed Coolant Temp. Vacuum Electrical Voltage Steering Angle Powertrain Accessories Brakes Steering Suspension Body Vacuum Load Electrical Current Steering Forces Suspension Geometry Accessory Torque Load Battery Voltage Coolant Flow & Heat Loss Wheel Rotational Speed Body Attitude & Position Aerodynamic drag Hydraulic Pressure, Electrical Current Hydraulic/Pneumatic Flow Heating & Cooling Loads Driven Wheel Rotational Speeds

35. Systems Engineering Based VDP

36. The Cost Of Change* * John Krouse, 1993

37. Math-Based Synthesis & Analysis • The use of mathematical representations (models) to: • Design/configure (synthesis) • Understand & validate behavior (analysis)

38. Analysis vs. Synthesis Analysis Given a Design c k c1,k1 Response ANALYSIS m F c2,k2 x What is the response? Given a Design Frequency Synthesis Given the Design Goal Subject to Constraints: Response Function Packaging Cost Manufacturing Manufacturing Constraints c*,k* ? Damping , c Response Packaging Constraints SYNTHESIS Stiffness, k Frequency What is the Best Design ?

39. Synthesis & Analysis in the VDP

40. Synthesis & Analysis at Various Phases of the VDP SYNTHESIS MODE ANALYSIS MODE 100% FREEDOM 50% $ Committed $ Spent INFORMATION 0 Time PHASE 0 PHASE 1

41. Use of Math: Medical Analogy

42. Virtual Product Development: GMT360