design in the loop bridging the gap between subjective ... · pitch ‘n’ roll behavior consumer...

Design in the Loopg p

Bridging the gap between subjective perception and objectiveevaluation to achieve desired handling characteristicsg

"apply & innovate 2012" - IPG Technology Conference, September 18-19, 2012 Dieter Scharpe, Chief Operating Officer, Dept. of Vehicle Engineering, TU DresdenProf Dr Ing Günther Prokop Dept of Vehicle Engineering TU DresdenProf. Dr.-Ing. Günther Prokop, Dept. of Vehicle Engineering, TU DresdenBernhard Schick, Managing Director, IPG Automotive GmbH, KarlsruheDavid Golloch, TU Dresden

The Problem:Customer is slightly displeased with your carg y p y

Folie 2 von 36Karlsruhe, 18.09.2012 Design in the Loop

The Problem:Consumer tests compare and criticize your carp y


The Challenge:You need to improve but can‘t get a handle on “how“ and “where“!p g


The Reason:The consumer‘s perception is subjective! p p jBut as an engineer, you need objective criteria


The Solution:“Design in the Loop“ for cars that customers wantDesign in the Loop for cars that customers want


Design in the Loop

Design in the Loop

undefinedcustomer

targetcarin the Loopcustomer car


Design in the Loop

SubjectiveEvaluation

House of Quality

Chassis Guide

y

undefinedcustomer

targetcar

Simulation

customer car

Multi Body Simulation


Simulation

Design in the Loop


House of Quality

Chassis Guide

House of Quality

C G

Simulation

Multi Body

Simulation


Simulation

Design in the Loop


House of Qualityy

Chassis Guide

Simulation



Simulation


Chassis Guide

House of Quality

Customer Needs


Simulation Knowing and meeting the consumer‘s real wishes

HoQRanking6

Technical specifications4

Engineer‘slanguage

Importance of customerwishes

Link betweentechnical specification

Customer /media target

1Customer /media wishes

2 5

Technical specifications4

Subjectivebenchmarking

3

ting

2 3

rget

lin

e

technical specification and customer wishes

Benchmarking

media target group, market

media wishes

7

benchmarking

Ra

Ta

Customerlanguage

Medialanguage

Result8

Tech. targets9


Translating consumer speech into designable engineering languageSource:TÜV SÜD Automotive GmbH


Chassis Guide

House of Quality

Subjective EvaluationMulti Body Simulation

C ass s Gu de

Simulation

Subjective EvaluationReduction of motion and road excitation on standardized maneuvers

Driving Dynamics Comfort

aneu

ver

euve

r

andt

“ Ma

Vertical dynamics Ditch

C rbSO

Man

e

“Vibration DNA“1

ISO Slalom 18m“B

ertr

a Curb Different speed levels

IS


1 [Bertrandt/Hubbel]ISO Slalom 18m


Chassis Guide

House of Quality

S bj ti E l tiMulti Body Simulation

C ass s Gu de

SimulationSubjective EvaluationTraditional rating & subjective rating

Criteria: ride harshness Problem of subjective evaluation

9mark10

9mark10

9+10

9-identified optimum9

8

7?

[too smooth] [too firm]

?9

8

7

9

8+

7+

6+6-

9

8-

7-

optimum

6

5

4

[ ] [ ]6

5

4

6

5+

4+

3+

6

5-

4-

3-

[state of the art]

d lM l l @ 30k /h

3

2

1

3

2

1

3

2+

1+

3

2-

1- [too less] [too much]


measured valueManeuver: slalom @ 30km/h


Chassis Guide

House of Quality

S bj ti E l tiMulti Body Simulation

C ass s Gu de

SimulationSubjective EvaluationDescribing driving emotions / experiences

S bj ti l ti d f t R ti E l t /C t

km-StandM ilage

1. Customer

2. Competitor3 Benchmark

BeladungLoad

FahrzeugVehicle

FahrzeugtypVehicle Type

Subjective evaluation onroad-comfort

Bewertung10 excellent (state of the art)9 v ery good8 good7 satisf y ing6 minimum acceptable5 not satisf y ing

BORDERLINE 4 poor

Evaluator / Commentexpert / not deteectible

expert / hardly detectableexpert / nominal complaintcritical consumer / slightly detectablecritical consumer / detectableregular consumer / explicit detectable

regular consumer / displeasing (claim)

Rating10 excellent (state of the art)9 very good8 good7 satisfying6 minimum acceptable5 not satisfying

Evaluator/Commentexpert/ not detectableexpert/ hardly detectableexper /nominal complaintcritical consumer/slightly detectablecritical consumer/detectableregular consumer/explicit detectable

3. Benchmark

1. 2. 3. 1. 2. 3.

8,0 6,5 8,0 8,0 7,0 8,0

6,5 8,5 10,0 7,5 6,5 9,0

7 0 8 0 10 0 7 0 8 5 8 5

Federung/ DämpfungSuspension/ Shock absorberFederungs und Dämpferkomfort Suspension- and shock absorber comfort

Nickfederverhalten Pitch behaviourWankfederverhalten

Ergonomie und AkustikÜbersichtlichkeit und FunktionalitätOverview and functionalitySitzkomfort und IsolationSeat comfort and insullation

Sitzseitenführung

p3 insuf f icient2 bad 1 v ery bad

egu a co su e / d sp eas g (c a )consumer / inacceptable (corrupt component)consumer / inacceptable (limited activ ity )consumer / inacceptable (without activ ity )

BORDERLINE 4 poor3 insufficient2 bad1 very bad

regular consumer displeasing (claim) consumer/unacceptable (corrupt component)consumer/unacceptable (limited activity)consumer/unacceptable (without activity)

7,0 8,0 10,0 7,0 8,5 8,5

8,5 6,5 8,5 8,0 7,0 9,0

8,0 7,0 9,0 8,0 7,5 8,5

1. 2. 3. 7,5 7,0 9,0

7,5 8,0 9,0

8 0 7 0 8 5Stuckern

Abrollkomfort Rolling comfort

Schluckvermögen mechanisch Absorbing capacity(mechanical)

AufbaucharakteristikBody charakteristic

Roll behaviour

DröhnenDrone

Schluckvermögen akustischAbsorbing capacity (acoustical)

Vorderbauunruhe Front end behaviour

AbrollgeräuschRoad noise

Seat lateral traction

Decomposing into:

Longitudinal Acc.

Lateral Acc8,0 7,0 8,5

8,0 8,0 9,0

7,0 8,5 9,5

7,0 7,5 9,0

6,5 8,0 8,5

Stuttering

UnterbauvibrationenBody vibration

QuerschüttelnTransversal shaking

Aushängen Detaching

PuffereinsatzBump stop working

Lateral Acc.

Head Position

Acc. Gradient


Gaining quasi-objective ratings in highly decomposed test procedures


Chassis Guide

House of Quality

Subjective EvaluationMulti Body Simulation

SimulationSubjective EvaluationDisintegrated subjective driving impressions

Driving Dynamics

Braking HandlingRideComfortAcceleration

Driving Dynamics

Relevant tod

NVHTransmis

sionBehavior

SteeringBehavior

Pitch ‘n’ RollBehavior

consumer and carmagazine

Only subjectively

CopyingRoll Steer

Lateral Torso

Support

HeadShake

Only subjectivelyratable

LongitudinalAcceleration

HeadPosition

Acc.Gradient

LateralAcceleration

Quasi-objectively perceptible+

objectively measurable


Resolution of evaluation criteria into measurable quantities


Chassis Guide

House of Quality

Obj ti E l tiMulti Body Simulation

SimulationObjective EvaluationMeasuring the way a human being feels

Road Test

Steering Robot

IMU / DGPS

Data acquisition device

CorrevitCo e t

Measurement steering wheel

A sensors

Strain gauge sensors

CAN signals


Tailored measuring in the right places


Chassis Guide

House of Quality

Obj ti E l ti

St


C ass s Gu de

SimulationObjective EvaluationHead shake

Stepinput

Sine sweep test VideoVideo



Chassis Guide

House of Quality

Characteristic CurvesMulti Body Simulation

SimulationCharacteristic Curves

Subjektive Beurteilung Fahrkomfort

km-StandM ilage

1. Customer

2. Competitor3 Benchmark

FahrzeugVehicle


BeladungLoad

j gSubjective evaluation onroad-comfort

Bewertung10 excellent (state of the art)

9 v ery good8 good7 satisf y ing6 minimum acceptable5 not satisf y ing

BORDERLINE 4 poor



regular consumer / displeasing (claim)3. Benchmark

1. 2. 3. 1. 2. 3.

8,0 6,5 8,0 8,0 7,0 8,0

6,5 8,5 10,0 7,5 6,5 9,0

Ergonomie und AkustikErgonomics and NVHÜbersichtlichkeit und FunktionalitätOverview and functionality

Sitzkomfort und IsolationSeat comfort and insullation


Nickfederverhalten Pitch behaviour

4 poor3 insuf f icient2 bad 1 v ery bad

regular consumer / displeasing (claim) consumer / inacceptable (corrupt component)consumer / inacceptable (limited activ ity )consumer / inacceptable (without activ ity )

7,0 8,0 10,0 7,0 8,5 8,5

8,5 6,5 8,5 8,0 7,0 9,0

8,0 7,0 9,0 8,0 7,5 8,5

1. 2. 3. 7,5 7,0 9,0

7 5 8 0 9 0


Vorderbauunruhe

AbrollgeräuschRoad noise

SitzseitenführungSeat lateral traction

DröhnenDrone

Abrollkomfort Rolling comfort



Wankfederverhalten Roll behaviour

7,5 8,0 9,0

8,0 7,0 8,5

8,0 8,0 9,0

7,0 8,5 9,5

7,0 7,5 9,0

Front end behaviour



Stuckern Stuttering



6,5 8,0 8,5Aushängen Detaching


House of Quality


Chassis Guide

SimulationCharacteristic Curves

Subjektive Beurteilung FahrkomfortSubjektive evaluation onroad-comfort

Bewertung Evaluator / Commentkm-Stand

M ilage

1. Customer

2. Competitor3. Benchmark

1. 2. 3. 1. 2. 3.

8,0 6,5 8,0 8,0 7,0 8,0

Ergonomie und AkustikErgonomics and NVHÜbersichtlichkeit und FunktionalitätOverview and functionality

BeladungLoad

FahrzeugVehicle



Bewertung10 excellent (state of the art)

9 v ery good8 good7 satisf y ing6 minimum acceptable5 not satisf y ing

BORDERLINE 4 poor3 insuf f icient2 bad 1 v ery bad



regular consumer / displeasing (claim) consumer / inacceptable (corrupt component)consumer / inacceptable (limited activ ity )consumer / inacceptable (without activ ity )

cele

ratio

n

+6,5 8,5 10,0 7,5 6,5 9,0

7,0 8,0 10,0 7,0 8,5 8,5

8,5 6,5 8,5 8,0 7,0 9,0

8,0 7,0 9,0 8,0 7,5 8,5

1. 2. 3. 7,5 7,0 9,0

7,5 8,0 9,0

Overview and functionality


Vorderbauunruhe Front end behaviour

AbrollgeräuschRoad no ise

Sitzkomfort und IsolationSeat comfort and insullation

SitzseitenführungSeat lateral traction

DröhnenDrone

Nickfederverhalten Pitch behaviourWankfederverhalten Roll behaviour Abrollkomfort Rolling comfort



Suspension and shock absorber comfort

late

ral a

cc+8,0 7,0 8,5

8,0 8,0 9,0

7,0 8,5 9,5

7,0 7,5 9,0

6,5 8,0 8,5Aushängen Detaching


Stuckern Stuttering



time



Chassis Guide

House of Quality

Characteristic Curves


C ass s Gu de

Simulation

Characteristic Curves“Validated” measurement

ion mark 10

mark 8

t) car 2

l acc

eler

ati

mark 7

d m

ovem

ent car 2

[competitor]

late

ral

(hea

d

car 1[customer]

car 3[benchmark]

time

[customer]


Linking subjective evaluations with objective measurements


Chassis Guide

House of Quality

Ch t i ti CMulti Body Simulation

C ass s Gu de

SimulationCharacteristic Curves Curb drive over

BenchmarkCustomer Car

rated mark 6

rated mark 8

Comfort-critical phenomenon of the “noisy rear axle” can now be identified d l t d th h hi h l ti bj ti l ti


and evaluated through high-resolution subjective evaluation


Chassis Guide

House of Quality

Characteristic CurvesMulti Body Simulation

SimulationCharacteristic CurvesObjectivation of steering behavior

Validation – Weave testValidation Weave test

Criteria: Steering Torque Build-up & Turn-in Feeling

Criteria: SmoothnessCriteria: Smoothness

Criteria: Steering Effort at Center Point

Criteria: Steering Precision

Overall Criteria: On-Center Feeling


Source: IPG Automotive GmbH


Chassis Guide

House of Quality

M lti B d Si l tiMulti Body Simulation

C ass s Gu de

SimulationMulti-Body SimulationSecuring / covering consumer requirement in simulation

R l Vi t l Vi t l b h kReal vehicle

Virtual vehicle

Virtual benchmarkstudy

orce

_X [N

]

400

800

1200

1600

2000

Project: KnC Conversion DemoSkc-File: DemoKnC_Rear

Input File: 018713005001.txtDate: 2011/05/16

-2,0 -1,5 -1,0 -0,5 0,0 0,5 1,0 1,5 2,0 2,5Rear_LH_wheel_centre_X_disp. [mm]

Rea

r_LH

_whe

el_F

o

-2000

-1600

-1200

-800

-400

0

KnC-Measurement IPG KnC-Converter (before offset correction)

Comparison of KnC-Measurement and IPG KnC-Converter Output

RL Wheel Force X vs. RL Wheel Centre X disp

Systems Parameterization Vehicle

…


characteristics Parameterization variations


Chassis Guide

House of Quality


SimulationMulti-Body SimulationVirtualization of real vehicle

Sim Tools: CarMaker ADAMS veDYNA

Vertical Dynamics

Sim-Tools: CarMaker, ADAMS, veDYNA

Single Events Ditch

Public Roads Uneven cross-country roads Ditch

Curb Different speed levels

Uneven cross-country roads Different excitation characteristics Uneven cross-country roads with curves Different speed levels Closed loop driven

These maneuvers allow efficient

Incorporation of “validated measurements” as targets into a virtual

These maneuvers allow efficientreproduction / simulation of thevibration DNA


Incorporation of validated measurements as targets into a virtual vehicle model


Chassis Guide

House of Quality


C ass s Gu de

SimulationMulti-Body SimulationVirtual benchmark

SubjectiveRatings:

Roll Gain vs. Frequency

Benchmark: 9

Customer: 7Customer: 7

after digital

engineeringengineering

Modified: 8.5


Target CorridorCustomer Modified Benchmark


Chassis Guide

House of Quality


C ass s Gu de


SubjectiveRatings:

Steering Wheel Torque vs. Steering Wheel Angle

Benchmark: 9

Customer: 7

after digital

engineering

Modified: 8.5


Target CorridorCustomer Modified Benchmark


Chassis Guide

House of Quality

Multi Body SimulationMulti Body Simulation



Lap time optimization


Ch i G id

House of Quality


Chassis Guide


Speed Profile and Steering Effort

Real driver loss 0.5 secdue to risky section► Mental block

Virtual driver takes car closer to understeer limit► Perception problem► Perception problem



Chassis Guide

House of Quality

Fi t i f V hi l DNAMulti Body Simulation

C ass s Gu de

SimulationFinetuning of Vehicle DNA“Characteristics” optimization

P tParametersTarget #1

Target #2

RegulatorTarget-area

Target #3

Target #4

Target #5

Target #6

Target #7

Linking component parameters (suspension stiffness etc.) with “validated characteristics”. Finding OEM targets / respecting brand or

Target #7


g g p gvehicle model philosophy (vehicle DNA)

D i i th LHouse of Quality


Simulation

Design in the LoopImplementation

Chassis Guide


TIME TO MARKETKICK-OFF

C t CM k t A l iProduct

Concept CarFinal Concept Construction

Conception

Market Analysis

CoverageVirtual Concept Virtual Prototype

1st Prototyp Prototypes / Testing

Simulation

House of QualityChassis Guide Design in the Loop


Simulation

Design in the LoopChassis Guide

House of Quality


Design in the LoopImplementation

KICK-OFF

Simulation


TIME TO MARKET

ProductConcept Car

Final Concept ConstructionMarket Analysis

Product Final Concept Construction

Vi t l C t Vi t l P t t

Conception

Si l tiCoverage

Virtual Concept Virtual Prototype

1st Prototyp Prototypes / Testing

Simulation

House of QualityChassis Guide Design in the Loop


Simulation

House of Quality


Design in the LoopYour benefits

Simulation

Chassis Guide


Target / Obj ti

“First time right“ (before building a physical prototype) Saving precious development time Covering new car conceptsObjective Covering new car concepts “First time right” (90%) Minimize the risk of failing the market

Tools

St d di d t t d f bj ti & bj ti

QFD knowing designable customer wishes

Chassis Guide

Standardized test procedure for objective & subjective evaluation

Translation of subjective marks into objective scientific


values for simulation

D i i th LChassis Guide

House of Quality


Design in the LoopSummary

Process Description in Chassis Development

Simulation


Objectivee.g. speed

ObservingRoadtest

Physicalaction chain

Process Description in Chassis Development

Customerrequirement

g p

Intermediate step

EvaluatingRigtestSimulation

Subjectivee.g. comfort Objectivation

p

Under-standingSimulationTrial

Decisive factor

DevelopingThe vehicle dynamics characteristicsare key in this context- Pitch, yaw, roll- Dynamic response to driving


factormaneuvers…

Chassis Guide

House of Quality


Design in the Loop“Tailored Services”

Simulation

Chassis Guide


BasicPackage Chassis Guide

Chassis Guide Plus

(subjective AND objective evaluation process)ExtendedPackage

QFD (customer request)

Chassis Guide Chassis Guide QFD (customer wishes) Simulation (model building, virtual benchmark and

virtual development

PremiumPackage


virtual development

We develop concepts and design suspension systems with the desired handling characteristics for the automotive industry. As concept consultants, we deliver advanced

h l i A “ d i ” h l i d l

Dieter ScharpeTechnische Universität DresdenInstitute for Automotive Technologies Dresden - IAD

approaches to solutions. As a “co-driver,” we help steer entire development processes and accompany our customers into new markets.

Thank you!

Dieter ScharpeChief Operating Officer

Institute for Automotive Technologies Dresden - IADChair of Automotive EngineeringGeorge-Bähr-Straße 1c01069 Dresden

Phone: +49(0)351-46334547Mobil: +49(0)170-2862728( )Fax: +49(0)351-46337066Email: [email protected]: http://tu-dresden.de/kft


design in the loop bridging the gap between subjective ... · pitch ‘n’ roll behavior consumer...

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