Digital Transformation of the Vehicle Design Cycle

Driving the Convergence to Zero Prototypes

Q&A

Q1. What role do you see Model Based Systems Engineering will play in achieving Zero Prototypes and how do you bridge between MBSE (e.g. SysML models) and Physics-based simulation and modelling?

MBSE is critical in evaluating the system interactions between components across attributes and domains. Here’s where a multi-physics approach in the analysis is of essence to evaluate potential error states as well as its system performance against target objectives.SysML is one of the key tools for system evaluation since it can combine the various aspects of analyses with objective targets to ensure a robust product is delivered.

Q2. Can you expand on some examples of reduced order modelling into a 1D simulation?

ROM is used to reduce the complexity of a complex 3D model that takes a huge amount of CPU time to converge and get a solution.This makes it impossible to perform robustness studies through DOEs of hundreds of design iteration. Hence, once a team has a large experience in exercising large 3D model with deep understanding of its performance, then a 1D model approach can be taken by developing a mathematical technique to reduce the dimensionality of the model while preserving key characteristics.These ROM models are correlated to the 3D model to ensure similar performance. One example can be the use of CFD to determine the fluid flow characteristic through the tube.The ROM model may be reduced to the use of 1D Navier Stokes equation to evaluate the flow of fluid through the tube.

Q3. What are your thoughts on software defined vehicle?

“Software defined vehicle” relates more to applications in Autonomous Vehicle development and a critical element to driving the design of Advanced Driver Assist Systems.Can’t expand more than this since I don’t work in this field!

Q4. How do you incorporate individual CAE Engineer skill/experience into the reliability level of a tool/method?

Basically, CAE Engineers must be trained in Six Sigma. This requires a minimum certification in Green Belt, but most preferrable a Black Belt Six Sigma certification is needed for CAE analysists so they can fully implement DFSS as part of the CAE process.

Q5. In your "Loop-back" Process (Slide 16), you emphasize the importance of a cross-team of technical experts to determine the maturity level. Can you talk to the sociology, compositon, varied interests, incentives and motives of members of that team?

Yes, the cross-team of experts are made up of Technical Experts in the field of Testing, Attribute experts (e.g., NVH or Durability, etc.), Simulation Experts.All coming from different functions and evaluating the performance of CAE against test data base on acceptable error margins already established and review of historical performance of physical test data across time as well performance of CAE over time.The goal is to eventually replace physical test with the highest confidence possible.

Q6. Currently, how widespread are reduced order models in the industry? Is this trend increasing?

Based on my observation, ROM is being used more and more by the industry, however it is not to the level it needs to be. The good news is that the trend is increasing exponentially!