ifb success story 10-05-2016 - cadvision| … ifb automotive the business challenge customer success...
TRANSCRIPT
About IFB Automotive
The Business Challenge
Customer Success Story IFB AutomotiveIFB Automotive finds results from CEAD very close to those obtained fromADAMS and FEA.
IFB Automotive Pvt. Ltd. is a pioneer in design and manufacture of seating systems,
door systems and automotive motors. The company has built a reputation as a
leading technology provider for safety critical and comfort related products in the
automotive sector. To meet the growing needs of the auto industry, IFB Automotive
has spread its manufacturing base in different parts of India to ensure just in time
supplies to all their customers.
The state of art Research and Development Centre of IFB Automotive has the capability to develop new products responding to the diverse needs of its domestic and international customers. Operating in the backdrop of tough global competition, IFB Automotive strives to meet the highest quality demands of national and international regulatory bodies as well as stringent customer specific requirements.
The R & D Centre constantly strives to produce new technologies and new products, staying in close contact with developments in the auto industry. The R&D Centre is accredited by the department of science & technology, Government of India.
IFB Automotive's product development and design team consists of some of the most experienced and visionary professionals in the country to meet the rapidly growing demands from automobile manufacturers as well as end users for greater safety, reliability and higher cost-effectiveness.
Customer list of IFB consists of all leading OEM's and Tier 1 suppliers. Some of them are, Maruti Udyog Limited, Mahindra & Mahindra, Ford, Hyundai, Tata Motors, General Motors, Honda, Toyota, Fiat, etc.
IFB have to introduce a new mechanism in the market with reduced lead
time for development as per customer demands. A typical design of
mechanism starts with initial geometry and hand calculations, then
validation through CAE tools like FEM and ADAMS. Geometry is expected
to change till requirements are met. Every small change in critical geometry
requires updating or redefining of hand calculations. Currently MS Excel is
used as a parametric calculator that needs to be updated manually for
every change in geometry which is time consuming. Design calculations
using Excel is iterative and prone to error.
Once the geometry is changed then revalidation of the design using CAE
tools has to be done. This process is iterative. IFB was looking for dynamic
update of hand calculations on change in geometry and synthesis of
mechanism. Even though IFB had the right methodology, lack of
appropriate tools led to increase in numbers of iterations and hence lead
time.
The Engineering Challenge
R & D seating division of IFB came up with a
problem statement which required synthesis
of geometry with change in magnitude,
direction and point of application of force.
Challenge was to define optimum geometry
of teeth for engagement and transfer of
torque with out slippage. Geometry is
governed by many independent parameters
like teeth angle, teeth position, point of
application of force etc.
Customer Success Story IFB Automotive
IFB wanted to define the geometry of teeth and forces acting on the
teeth, torque transmitted by teethed male component to teethed female
component of the mechanism. Geometry had to be synthesized for
engagement and torque transfer without slippage of teeth. The
different parts involved in analysis are teethed male component,
teethed female component and guide plate.
Force analysis on a sector teeth at engagement was to be done when a
force applied on the forcing pin of male teeth component.
Design Brief
• Definition of teeth position, forcing pin, and guide pins location for teethed male component. • Geometry had to be defined or updated depending on the force applied on the teethed male component pin,
which had to pass through forcing center of male component teeth to avoid tilting and slippage.
• Definition of governing equations and equilibrium conditions. (IFB has the set of equations for geometry with initial parameters based on design history).
• Magnitude and direction (Can be taken from CAD geometry) of force acting on forcing pin of teethed male
component.• Distribution of forces to the guide pins and individual teeth of teethed male component. • If eccentricity in loading (forcing pin force should pass through forcing center), additional force components
will be generated apart from the direct forces.
This procedure requires a lot of calculations related to forces and moments for every change in geometry
of teeth.
Procedure
IFB Engineers used to resolve the forces in Excel for which they had to find the teeth angle, force direction and moment arms
from CATIA. After this the results were validated using ADAMS. This was an iterative process. They had to keep repeating
this until they had a satisfactory result compared to ADAMS. For every iteration they had to modify thoroughly or create a
new excel sheet. It usually took around 1 week time to get consistent results. During redesign if there was a change in
forcing conditions, then the whole process had to be repeated again to find the results.
Conventional Approach
CEAD ApproachIFB engineers tried to solve the problem
with CEAD. As CEAD provides a
combination of geometry, constraints
and equations, it was very simple to set
up the design problem in CEAD
compared to the convent ional
approach.
CEAD supports vector calculations
which allowed IFB engineers to perform
force and moment calculations by
defining forces using vectors graphically
and writing equations for force and
moment equilibrium conditions. This
reduced the effort of the engineers by
eliminating the need to do Excel
calculations at each contact point, which
is a rigorous and tedious process. Eccentric Force Calculation
Customer Success Story IFB Automotive
They imported the teeth profile
using DXF import. Then did the
force calculations for normal
force, resultant force, etc.
Calculating the forces at each
angle was eliminated because
giving the equation of equilibrium
resolves the forces. This process
in CEAD took only a day's
effort.
Another major advantage is moments and vectors are defined and are controlled with equilibrium equations. So if the force conditions like angle changes, changing that angle in CEAD will give the resultant data within a minute. In the conventional approach it would have taken a week's time again.
Mr. Ajay Wani, General Manager R & D of IFB Automotive Pvt. Ltd. says:
“We had to do lot of force calculations and moment conversion during the process using excel based methods. If we had
used the conventional approach, it would have been very tedious and time consuming. We appreciate vectors
functionality in CEAD which made it easy for us to do the force calculations. It also dynamically updated of calculations
and results on change of geometry. We can study the effect of changing any independent variable and plot graphs,
analyze and conclude on the best possible geometry. We validated the results and found the results obtained by CEAD
were very close to results obtained by ADAMS and FEA.”
Customer Testimony
IFB was able to reduce the design
time by reducing the number of
iterations. Once the geometry,
equations and parameters are
defined in CEAD, then time
requ i r ed fo r upda t i ng i s
considerably reduced. Design
c h a n g e s c a n b e e a s i l y
incorporated using CEAD without
the need to follow the whole
procedure again.
Overview Of Design Work
Torque Calculation and Condition for Zero Slippage
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