Computer Aided Engineering: Cad, Cam & Cae

Erasmus LLP Intensive Programme
Computer Aided
Engineering
CAD, CAM & CAE
Powering the Future With Zero Emission and Human Powered Vehicles Terrassa 2011 1
Tutors
Dr Byron Mason
University of Bradford
Mr Kalevi Vesterinen
Turku University of Applied Sciences
CAE Course Overview
The product development process (2hr lecture & case
study)
Introduction to Solid Modelling (9 hrs lecture &
practical)
Opportunity to work on vehicle design
Introduction to solid modelling
(CAD)
Parametric modelling, features, wire- surface- and solid
models.
Sketch, parameters, dimensions, constraints
Extrude, cut, fillet, chamfer
Assembly constraints, assembly features
Drawings, BOMs, pictures, small analysis
Opportunity to develop vehicle designs
The Product Development Process
(An Introduction)
Overview of product development.
Motivation.
Sequential vs concurrent engineering in product
development.
CAE tools for product development.
Optimising product development.
Model based development
What is computer aided engineering?
Defined very broadly as; computer tools used to assist
in engineering design, development and optimisation
tasks.
Models of systems may be separated into static or
dynamic systems, each having a particular purpose.
Static models are independent of time.
Dynamic models are time varying.
Example 1
Example 2
Example 3
Mechanical
system
or a
or v
Dynamic (time varying systems)
Dynamic systems;
- Continuous
- Discrete
- Hybrid
Computer aided engineering overview
Drafting &
design
Modelling &
analysis
Manufacture
Production
planning &
control
Computer
Aided
Engineering
Computer aided engineering overview
Drafting & design
Design for assembly
Computer aided
manufacture
Modelling & analysis
Dynamic analysis
Rapid control prototyping
Finite element analysis
Mechanism design
Discrete event simulation
Manufacture
Computer aided part
programming (CNC)
Distributed numerical control
Coordinate measuring
Flexible assembly/manufacturing
systems
Production planning & control
Scheduling
Quality control
Materials requirements planning
Just-in-time manufacturing
Computer Aided
Engineering
Main focus within IP is on tools for Drafting & Design
and Modelling & Analysis.
Product Development why bother?
Required to ensure delivery of quality
products in a timely and cost efficient
manner.
Modern customers demand higher quality
at low cost - custom goods mass produced
with increasing competition from developing
countries.
Pressure from legislators, customers & shareholders for sustainable
products (and development).
Pace of technology is high requiring short product development
cycles to remain competitive.
Risk of litigation / losses due to increased technology/safety critical
(complex) systems increased test burden
Pressure from shareholders to reduce costs i.e. maximise profit.
Specification
Design & prototyping
(virtual & physical).
DFMA & prodn
planning
Manufacture
Components
Assembly &
inspection
Customer Use
The product development process
Customer
appraisal
Development
The traditional design
process is sequential with
one action completed before
the next, over the wall
engineering
Move toward concurrent
engineering through virtual
prototyping (development)
method.
Modern process tends to be
both concurrent with
intensive use of virtual
protyping.
Improving the process
Modern computer based tools offer opportunities for
improvement of the development process.
Change from sequential (over the wall) to concurrent
engineering design.
Engineering
specification
Electrical
engineers
Mechanical
engineers
Production
engineers
Validation
engineers
Engineering
specification
Electrical
engineers
Mechanical
engineers
Production
engineers
Validation
engineers
Virtual
prototype
Improving the process
A good design procedure will
enable engineers to mature
designs quickly & eliminate the
need for late design changes.
Late design changes are usually
a result of a lack of testing in
early design stages (particularly
for multi-part systems.
T
o
t
a
l

c
o
s
t
time
cost of changes
# of changes
A good design procedure will enable engineers to mature
a design quickly & eliminate the need for late changes.
Virtual prototyping and testing enables truly concurrent
development.
Case studies
You have 30 min minutes to complete the case study
examples in groups of maximum six members.
Each group then to present their findings (3 mins).
Design process primarily used for
embedded control though increasingly
applied to mechatronic design.
Model employed for defining engineering
specifications (executable), design,
simulation (early prototyping), prototype
development, integration, etc
Executable model forms the engineering
specification.
A model serves as the
definition of the system.
Real time simulation
techniques are used
SiL/HiL/CiL.
More hardware is included in
Loop as further fidelity
increase is required/for
integration.
Real time simulation definition & Use
One second simulation time = one sec real time.
Possibility of software or hardware in loop
simulations.
Application range unlimited with any combination of
hardware/software. Driveability study using analogue
computer (Penn, 1968).
Typical use; individual component testing e.g. ECU,
failure simulation, controls development, pre-
calibration/calibration.
Pictures from www.dSPACE.com Benefits include decreased time to
market and development costs,
automated testing, hardware
testing burden reduced.
Real time Simulation Method
(HiL example)
Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Purpose of study/selection of hardware.
Realtime models cycle time typically 1 msec consider
overruns and queuing.
Real Time Workshop generates C-code for the realtime
platform.
Model-hardware interaction i.e. delays in data exchange.
Interface using breakout box or other connector.
RT full & functional bypassing modes
Realtime Powertrain Simulation
Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Identify the System
J
t
J
c2
J
h
J
g2
J
c1
J
g1
J
e
J
g3
J
p
Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Model Development Prime (& secondary) mover
Torque / Force generation function representing some input (depends
on vehicle design)
Human leg
Crank F
T
T
Auxiliary
device
T
t
T
Model Development - Clutch
Torque transferred approximated by
Friction coefficient (dynamic)
No locked/slipping states and dependent
J
c1
J
c2
T
i
T
o
out N
T F =
( )
,
N rel
f F e =
rel
e
0.47
clutch
T
N
F
rel
e
N
F
out
T
Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Torque flows from clutch driven plate.
Algebraic constraint substituted in DAE for ODE and solution.
Gear ratio (r
2
/r
1
) and inertias (J
g1
and J
g2
) determined by the selected gear (driver model).
Model Development - Gearbox
T
out
k
T
clutch
J
g1
J
g2
J
c2
b
2
b
1
T
in
, 1 2 3 4 5 driven driver gear gear gear gear gear
J J J J J J ( =

2 2 2 2 2 2
1 1 1 1 1 1
1 2 3 4 5 gear gear gear gear gear
r r r r r r
r r r r r r
(
| | | | | | | | | |
= (
| | | | |
( \ . \ . \ . \ . \ .

( )
2 2 1 2 2 1 c c in Jc Jc Jg
J T b k e e u u =
2 2
2 2 1
1 2 2 2 2
1 1 2
g g clutch out
r r r
J J T b T
r r r
e e
(
| | | | | |
( + =
| | |
(
\ . \ . \ .

Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Code Generation & Interfacing
Modelled in Simulink.
External links using blocks.
C-code generated using Real Time Workshop (RTW).
Support for the majority of simple blocks and S-functions.
Simulink optimisation not advisable for realtime use.
Compiled C-code uploaded to target -
dSPACE DS1006 processor board
(2.6 GHz AMD Opteron).
Inputs/outputs linked to graphical
display (Control Desk) simulation
continuously running (inf).
Realtime turnaround time vs step
time and overun/overun queuing.
Parameter editing on the fly -
asynchronous transfer.
Identify
the System
Model
Development
Code
Generation
Interfacing
Simulation
and
Testing
Simulation & Testing
Realtime Simulation
Simulation & Testing
Offline Simulation Comparison
Change of parameters before simulation, not on-the-fly.
Re-parameterisation in Simulink can be labour intensive.
Inputs mainly step, ramp and slider.
No user or hardware interaction.
Concluding Remarks
Realtime simulation one second simulation = one second reality.
Hardware/user/environment interaction.
Automotive realtime use increasing, controls development (ECU),
component testing, pre-calibration/calibration, failure testing.
Reduced time to market and development costs. Increased inter
design group interaction at early stages. Testing prior/parallel to full
prototype development.
Future possibilities as computer processing power increases - full
vehicle Product Lifecycle Management (PLM). Major automotives
may require dynamic component models to be as interchangeable as
real components (eg. Ford).

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Erasmus LLP Intensive Programme

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