Automotive Applications of GRID Technologies in Automotive Product Development OGF23 June 3rd 2008, Barcelona Automotive Activity - EC Research Project SIMDAT Josef Reicheneder AUDI AG

Automotive Introduction Conversion of Car Product Structures into Simulation Model Structures Meshing Brokering Service Virtual Organisations with OEMs, Suppliers and Engineering Services Simulation Data Management Systems on Distributed Locations Heterogeneous Data Structures of Simulation Data Management and Test Data Management Summary Contents

Automotive Motivation Model offensive for customer orientation and answer on tightened competition Audi 80 Audi 100 Audi Coupé Audi 80 Audi 100 Audi 100 Avant Audi Cabrio Audi Coupé Numbers of Variants A3/S3 A3 Sportback A3 Cabrio TT Coupé TT Roadster TTS Coupé TTS Roadster A4/S4/RS4 A4/S4/RS4 Avant A5/S5 A6/S6 A6/S6/RS6 Avant A6 Allroad A8/S8 R8 Q7... Derivatisation

Automotive Attributes in Car Simulation

Automotive Simulation Data Management Audi CAE Data- and Process Management Models Meshes Load Cases Preprocessing Applikationen: Ansa, Medina, Scripts vi-Editor Plots Cross sections Movies Images Values Individual Files Input decks Compute Solver: Pamcrash Nastran Abaqus Permas StarCD Powerflow Kuli Saber MagmaSoft … Simulations Postprocessing Programme: Animator, Evaluator Pamview, FeGraph Scripts Solver PreprocessingSolvingPostprocessing Output decks CAE Process

Automotive distributed Data Bases InformationManagement Solving PostprocessingPDM/CAD Preprocessing Inquiries Transparency Access Control Search Reliability Load Balancing Notifications Accounting AUDIExternal Engineering Companies VW Group External System Developers WorldSystem Suppliers Grid Challenges in Automotive Industry

Automotive Grid Challenges in Automotive Industry The challenge of integrating different disciplines: –Design (CAD) –Simulation (CAE) –Test (CAT) different locations different organisations

Automotive Only the CAE engineer knows, which part is used and in which form it is represented Product Structure - Simulation Structure CAD – CAE Integration Situation: For build-up of a simulation model structural information geometric and material data from CAD are needed Structure differs from load case to load case Geometric representation of the parts differs from load case to load case

Automotive A6_PFF_F_EU_W16_1005.pc - A6_b2_barriere_EU_1016.inc* 1K M TM : 3: K M TM : 3: K M TM : 3: A6_b2_fwk_hi_EU_W16_1035.inc* 1K M TM : 3: K M TM : 3: K M TM : 3: A6_b2_motor_w16_1035.inc* … - A6_b2_sitze_1011.inc* … - A6_b2_tuer_hi_1011.inc* … - A6_b2_tuer_vo_1011.inc* … - A6_pff_dummy_1000.inc - A6_pff_frontsf_1000.inc* - A6_pff_function_1000.inc* - A6_pff_fwk_vo_1005.inc* - A6_pff_karo_1001.inc - A6_pff_lenkung_1000.inc* - A6_pff_motorpac_w16_1000.inc* - A6_pff_mqtr_1000.inc* - A6_pff_pedalerie_1000.inc* - A6_pff_tank_1000.inc* - A6_pff_verbindungen_1001.inc* for every part use ontologies for every part CAE structure (e.g. Trimmed Body) A6_1 1.0 A6_Projekt ZSB:1:1.0 A6_Z_Vorbau_UTFlur ZSB:1:1.0 A6_M09_R4_FSI_VU ZSB:1:1.0 A6_M09_HG8_VU ZSB:1:1.0 A6_M09_Abt_VU ZSB:1:1.0 A6_M09_Abt_DAE_VU ZSB:1:1.0 A6_M09_Abt_DAEM ZSB:1:1.0 A6_M09_Abt_DA_LL_V ZSB:1:1.0 1K M – Teil:1: K M TM :3: A6_M09_Abt_VKL_VU ZSB:1:1.0 A6_M09_VKL_BO_VU ZSB:1:1.0 1K R TZ :3: A6_M09_Abt_WAS_VU ZSB 1:1.0 A6_M09_Abt_WAS_U__ ZSB 1:1.0 1K L- Teil:0:1.0 1K L TM :1: A6_M09_Abt_VKL_VU ZSB:1:1.0 A6_M09_VKL_BO_VU ZSB:1:1.0 1K R TZ :3: K L- Teil:0:1.0 ………… CAD structure ontologies - if bottom plate in description, part is for body-include and represented by a mesh - if mass < 5 g part is not needed - … file = KVS: xyz.CATPart mass = 1,1 kg material = St37 creator = Maier, A. position = -110; 45; 209 description = bottom plate front right … possibly creation of missing attributes - centre of gravity from geometry and material - matrix of inertia from geometry and material - … file = KVS: xyz.CATPart representation = mesh mass = 1,1 kg material = St37 centre of gravity = -140; 40; 180 creator CAD = Maier, A. creator model = Schmid, B. position = -110; 45; 209 description = bottom plate front right … Product Structure - Simulation Structure

Automotive Product Structure - Simulation Structure Selection of detected rules: –Structure parts are parts with the middle group number , , 813, 814, 817 –Structure parts were modelled physically (mesh) –Structure parts go into the include body –… Status: –CAD-CAE mapping of more than 80% of a car with 1500 parts for NVH trimmed body –prototype with ontobroker realised –35 rules only from structural information –in progress – search for more rules using more attributes

Automotive Meshing Brokering Service Meshing Specialist Meshing Broker Meshing Service PreSDM Engineer SLA Service Data Service Project Manager negotiates tasks uses SLAs monitors usage estimates and records work shares CAD data publishes meshing results notifies work done monitors task status OEMSupplier OEM DMZ

Automotive Virtual Organisations Service Provider OEM 1 OEM 2

Automotive Virtual Organisations GRIA Server Trusted site Workflow PAM-CRASH Visual DSS Sim Manager GRIA Client Data services Analysis services Data services Analysis services GRIA Client

Automotive Audi – SEAT collaboration –e.g. display of SEAT projects in Audi system Network limitations –Bandwidth 10 MBit/s for all Audi – SEAT issues Data amounts Audi Use Case for Distributed Data Access Example: Variant_1_EuroNCAP/Input KB Input Data Variant_1_EuroNCAP/Output KB Results Variant_1_EuroNCAP/Misc KB Descriptions Variant_1_EuroNCAP KB Sum Distributed Locations

Automotive Distributed Locations SIMDAT AutoMotive Demonstrator (SAMD) Data used: –SAMD Car (Sedan + Coupe) 2 SimManager systems running on two separate systems Audi SEAT

Automotive Distributed Locations Vault A MSC.SimManager Audi MSC.SimManager Seat Vault B Vault A Oracle Data Grid Replicated and Synchronized Meta Data A S Webservice / rvs with OFTP A S S A Each file up to 500 GB Webservice / rvs with OFTP

Automotive head acceleration vs. time chest acceleration vs. time pelvis acceleration vs. time validation of the complete system Heterogeneous Data Structures Test & Simulation

Automotive Coupe Convertible A3 (1354) A4 (356) A5 (170) A6 (107) A8 (325) TT (211) A3 (54) A4 (56) A5 (70) A6 (107) A8 (35) TT (27) Q7 (21) Heterogeneous Data Structures Audi use case for CAE/CAT integration: View and use CAT data in the same manner as CAE data in the CAE data management system

Automotive CAE (Simulation) Input Deck Model Design variant Load case Results Output files Post Process Objects Curves Animations Pictures Values Cross sequences CAT (Test) Vehicle configuration Test case Measured results Sensor output files Channels Movies Measured Values Evaluation of measured results Curves Images Values Heterogeneous Data Structures

Automotive CAE SystemCAT System Heterogeneous Data Structures 1.CAE System formulates request according to own data model 2.Request is transformed into data model of the CAT system 3.CAT System answers request. The answer is transformed again and sent back

Automotive CAE-System (MSC.SimManager) CAT-System (LMS Tec.Manager) PDM-System Bus Grid Middleware Registry- Service Ontology Service Semantic Layer OGSA-DAI-Connector Transport Layer Data-Service (OGSA-DAI) Bus- Connector (OGSA-DAI) Bus- Connector (OGSA-DAI) Bus- Connector (OGSA-DAI) Heterogeneous Data Structures

Automotive Summary Important steps for mastering the challenges in virtual car development 1.Conversion of car product structures into simulation model structures by use of ontologies. 2.Meshing brokering service based on GRIA. 3.Grid solutions for Virtual Organisations with OEMs, suppliers and engineering services. 4.Coupling of Simulation Data Management systems on distributed locations by use of Grid Technology. 5.Coupling of heterogeneous data structures of Simulation and Test Data Management via ontologies.

Automotive Thanks a lot Applications of GRID Technologies in Automotive Product Development