lms international: research portfolio in ict for green cars

PolSCA Meeting "ICT for green cars“ – Brussels, July 9, 2009

LMS International: Research Portfolio in ICT for Green Cars

Dr. Ir. Marcin Luczak

Postdoctoral R&D Engineer, LMS International

[email protected]

Outline

2 LMS Portfolio in field of ICT for Green Cars

1 About LMS International

3 R&D Project Examples

LMS International

� LMS International

� K.U.Leuven Mechanical Engineering spin-off, 1980

� LMS has 900 employees at 30 locations worldwide,

and delivers solutions for functional performance

engineering in mechanical product development

(Engineering Services, Test, CAE/Simulation,

Process Integration and Collaboration)

Europe 40%

US 23%Asia 37%

LMS worldwide revenue

distrubution

4 copyright LMS International - 2009

LMS SCADASMobile - Lab

A next generation Product Portfolio,

delivering Intelligent System Simulation and Testing

Enterprise-wide Collaboration

Simulation Integration in PLM

Product / Process optimization

LMS Test.XpressLMS Test.Lab LMS Virtual.Lab LMS Virtual.Lab

DesignerLMS

Tec.Manager

LMS

Engineering and

Deployment Services

Technology Transfer

Process Transformation

& Best Practices

System Support

LMS Imagine.Lab

ASAM

LMS, serving more than 5000 leading manufacturers

in the auto, aerospace, fabrication and assembly industries

Partnering with automotive manufacturers Partnering with automotive suppliers

Partnering with aerospace companies Partnering with manufacturing companies

6 Copyright LMS International - 2009

Towards a “Smarter” but “More Responsible” Planet (Ref. IBM-CEO vision)

Radical new product conceptsAdding intelligence

in infrastructure

Clean, secure

sustainable energy

New technology

� New materials

� Nano technologies

� Driver assistance systems

Smart systems “80% of all future innovations”

Mc Kinsey & Co

“Open”, “Collaborative”

innovation

Business priorities in manufacturing industries

Business driver for simulation

To help companies win by Product and Process Innovation

Brand valuesCreating unique brand values and customer experiences

Realistic Simulation

Sustainable

Environment

Responding to Eco trends, e.g. fuel and energy efficiency, more

stringent regulations for safety and environment

Handling Multiple Conflicting Constraints

“Smart Systems”

Mastering integration of technological advance in materials,

nanotechnologies, controls…Mechatronic Simulation“80% of product innovation will be software-driven or electronics-based”

McKinsey


Managing a continuous renewal and expansion of the product

portfolio to capture changing market needs

Simulation to enable Product AND Process Innovation

Process efficiency& productivity

LMS product innovation for Green Engineering

“ZERONIZE”

Minimal energy consumption

Reduced emissions

95%+ recyclable

Close to no casualties

“MAXIMIZE”

Full driving pleasure

Optimal comfort

Distinct sound quality

Power and speed

Demands innovations in vehicle system modeling & detailed analysis,

supported by innovative testing and validation

Engineering the “passion” in a “green” environment

Ref. TOYOTA “zeronize / maximize”


Smart

systems

drive

80% of the

future

innovations

Automotive Solutions Portfolio for Systems Simulation

Internal Combustion Engine

• Engine control

• Air Path Management

• Combustion,

• Emissions

Powertrain Transmission

• Performance and losses

• Comfort

• NVH

Vehicle Systems Dynamics

• Vehicle Dynamics

• Vehicle Dynamics Control

• Braking, Steering, Suspension

Energy

• Fuel Cell

Thermal Management

• Lubrication, Cooling System

• Refrigerant Loop, Passenger Comfort

• Engine and Vehicle Thermal

Management

Electromechanical

• Electromechanical components

• Electrical systems

ICE Related Hydraulics

• Fuel Injection

• VVT, VVA

• Engine compression brake

Outline





Example: Reduce CO2 emission by Vehicle Powertrain

CO2 target 2012: 120 g/km

“2-liter car” (46 g/km)

JSAE - 2030

Noise target 2020: -10 dBA

ICE

Increased

Efficiency

New Concepts

Hybrid

Hydrogen

Energy

Management

New Concepts

Transmission

Driveline

Challenge is to develop engine/powertrain,

that is eco-friendly and has delivers “brand” image

for performance & comfort

Support of Controls Engineering – MIL, SIL, HIL

Best off-line and real time functional models

Leveraging LMS’ hybrid (Simulation/Test) approach and

winning (back) LMS Test market share

Multi-functional System Simulation for Powertrain

� Fluids (e.g. Injection Systems)

� Thermal and Energy Management (e.g. cooling, HVAC..)

� Unique 1D-3D combined mechanical simulation

(e.g. valvetrain, transmission…)

� New solutions for hybrid and hydrogen engines


Example: Frontloading simulation System concept engineering based on 1D system simulation

Example: study of new concepts for engines/powertrains

to achieve both high performance & be environmental friendly

Lubrication

Cooling

Air path

Combustion

Transmission

Exhaust

Hybrid / Electrical

Fuel cells

Engineer to be eco-friendly

and to meet “brand” image - performance


Example: testing and calibration of Internal Combustion Engine to be

used in hybrid powertrain

� Simulate on the test cell the “working” of target build-in environment

� Process and analyze test cell data in context of target build-in environment

Example: testing and calibration of ICE to be used in hybrid powertrain

Simulation is key to enable frontloading of testing and validation

HiL

Pressure – Accel.

Load

Transfert Path

Receiver Model

(Target Vehicle)

Pressure – Accel.

RT Simulation model

for ECU, transmission

and electrical components


Example: Advancing 3D simulation & Grid Computing Improving realism for system level simulation

�Accurate modeling of interaction

between subsystems to simulate

loads, and load propagation

�Extending the “frequency” range:

� High frequency noise sources:

Injectors, modeling of engine bay

� Higher frequency noise radiation

Simulation at +500 Hz Fast Multipole - BEM

2004-2008

18.5 MEuro

EC FWP 6 – Grid Computing InitiativeData Grids for Process and Product Development

using Numerical Simulation and Knowledge Discovery

�Make use of continuous progress

with computing

� Multi-CPU computation

� Grid computing



Numerical tools

Front view of the 50Tflop computing power cluster in TASK Supercomputing Center in Gdansk

(fot. M. Gburski)

Related R&D projects (EC & National)

� HYBUS : Evaluation of an hybrid trolleybus using Supercap (Electro – Mechanical)

� CARE : Evaluation of additional heating strategies on vehicle fuel consumption abd pollutant emissions (Vehicle Thermal & Emission Management)

� OSCARR’NOx : Simulations and analysis tools of catalyst NOx reduction (vehicle NOx reduction)

� SIMBA1 : IC Engine Air path management modeling (Internal combustion engine optimization)

� HY-HIL : Evaluation of hybrid vehicle control strategy on high dynamic engine testbench (hybrid powertrains)

� SIMDAT: Data Grids for Process and Product Development using Numerical Simulation and Knowledge Discovery (Grid Computing)

� SmartLM : Smart Licensing Management for GRIDs (Grid computing)

� ELANO: Entwicklung und Konstruktion von innovativen Leichtbauprodukten unterkonsequenter Verwendung adaptierter Analyse- und Optimierungsmethoden (CAE technologies for lightweight structural design)

� ECOQUEST: Efficient Cooling Systems for Quieter Surface Transport (Reduce Noise Emission)

� AETHER: AEro-acoustical and THermo-acoustical coupling in enERgy processes (Vehicle Aero-Acoustics & relation to Thermal Acoustics)

� Development of Durable Vehicles: Durability Recorder for truly rugged data acquisition in extreme conditions

� HYPER: Intelligent Systems for Low-emission Powertrain

� InMAR and Smart Structures: Active Noise Control in Vehicles

� JTI "Cleansky" : Joint Technology Initiative (JTI) on “Green Rotorcraft” (from which also lessons for the automotive sector can be learned)

System

Simulation

for Green

Vehicles

ICT & Grid

Computing

Detailed Design

& Simulation

of Green

Vehicles

Mechatronics

Vehicle Systems

Testing

Outline




CARE

� CARE : Evaluation of additional heating strategies on vehicle fuel consumption abd

pollutant emissions

� 3 years (2005 – 2007).

� Industrials : VALEO (VCC & VEC), LMS Imagine,

� R&D labs : IFP, EMN

� Thermal Management :

� Project manager : Renaud Meillier

� Solution : Vehicle Thermal Management

� Experimental tests (Engine testbench & Wind Tunnel)

� Development of a complete model of the vehicle thermal management

� Model Development of new technologies for additional heating

� Deliverables : Improvement of our VTM offer (models, demonstators)

HYBUS

� HYBUS : Evaluation of an hybrid trolleybus using Supercap

� 3 years (2007 – 2009).

� Industrials : IVECO France, ERTEEL, LMS Imagine

� R&D labs : labo AMPERE + LAI

� Electro – Mechanical :

� Project manager :Franck Sellier

� Solution : Hybrib Vehicle

� Experimental tests

� Prototype Development

� Simulations

� Deliverables : Urban Public transport simulator including Hybrid vehicles.

OSCARR’NOx

� OSCARR’NOx : Simulations and analysis tools of catalyst NOx reduction

� 2 year (2007 – 2008 )

� Industrials :RENAULT, LMS-IMAGINE,

� R&D lab : LCS, LRS, CERTAM

� Internal Combustion Engine

�Project manager : Vincent Thomas

� Solution : IC Engine Exhaust systems

� Development of NOx-trap & SCR models

� Development of automatic model calibration methodology

� Main deliverables : Improvement of our pollutant after-treatment models and

Exhaust systems solution

Lean NOx Trap Selective Catalytic Reduction

SIMBA1

� SIMBA1 : IC Engine Air path management modeling

� 3,5 year (2008 – 2011)

� Industrials :Faurecia, Honeywell Garret & Mark IV, LMS-IMAGINE,

� R&D lab : POLIMI, IFP, FEMTO-CREST, UTBM

� Internal Combustion Engine

� Project manager :Philippe Aubret

� Solution : IC Engine Air path solution

� Development of a CFD 1D solution with Imagine.lab

� Development of IC Engine actuators models including turbocharger

� Coupling 0D – CFD-1D and CFD-3D

� Applications : Diesel Engine and Gazoline Engine

� Main deliverables : CFD-1D solution and products for IC Air path solution

HY-HIL

� HY-HIL : Evaluation of hybrid vehicle control strategy on high dynamic engine

testbench

� 2 years (2008 – 2010)

� Industrials : Renault, d2t, LMS-IMAGINE

� R&D lab : IFP, LEG

� Transmission :

� Project manager :Fabrice Gallo

� Solution : Hybrib Vehicle

� Development of Real time model for Hybrid powertrain

� Improvement of Imagine.lab Real time capacity (multi time scale, RT code

export)

� Link with Morphee II (D2T) (Control of Engine testbench)

SIMDAT: Data Grids for Process and Product Development


Structures

NVH

Acoustics

Motion

Durability

Optimization

Simulation process capturing

� Create multi-disciplinary simulation workflows

� Automate execution – “Simulation” robot

Secure simulation knowledge, improved

simulation quality and simulation productivity

Organize process execution

� Deep-level parallelization of simulation workflow

� Support of HPC, Grid Computing

Saving process time,

enabling more simulations

Results processing

� Smart experimentation

� Data mining

Delivering more design insightsNVH

CRASH

EC FWP 6 – Grid Computing InitiativeData Grids for Process and Product Development


EC FP6 project (Sept 2004 – August 2008)

SmartLMSmart Licensing Management for GRIDs

New Licensing Mechanism for GRIDs

� Licenses as distributed services on the network

� Smarter management for large distributed computing

networks

Build innovative licensing management

and business models to exploit

GRID environments

New business models for GRIDs

� Creation of new industrial opportunities

exploiting GRID computing

� Extension of Service Level

Agreements

� Secure commercial revenues

while boosting usage on

distributed networks

Provide a new generic licensing

virtualization framework and integrate

in major Grid middleware solutions

EC FWP 7 – GRID Licensing Management

Grid-friendly software licensing for location

independent application execution

SmartLM will provide a

generic and flexible licensing

virtualization technology for

new service-oriented business

models across organization

boundaries.

Structures

NVH

Acoustics

Motion

Durability

Optimization

EC FP6 project (Feb 2008 – Jan 2011)

ELANOEntwicklung und Konstruktion von innovativen Leichtbauprodukten unter

konsequenter Verwendung adaptierter Analyse- und Optimierungsmethoden

� Main Topic: CAE technologies for lightweight structural design

� Aim: achieve Lightweight design: lighter, stiffer, more durable

& better products

� Virtual Prototyping Methodologies are developed for this purpose

(structural analysis, durability, optimization, topology optimization, …)

� LMS Activity: Shape optimization for

component & system-level fatigue

� Interface to shape optimization

tool TOSCA (+ Pre/Post)

� Optimal trade-off between efficiency/

accuracy for system-level fatigue

based shape optimization

� Other CAE Interfaces (PERMAS, initial step to ABAQUS)

Structures

NVH

Acoustics

Motion

Durability

Optimization

� Project Partners:

� Lightweight manufacturers: Freudenberg Forschungsdienste,

Index-Gruppe, TRW Automotive, ZF Friedrichshafen AG

� Method & Software Developers: FE-DESIGN, LMS GmbH Kaiserslautern

� Research Institutes: Universität Karlsruhe (Institute MKL/IPEK

& WBK), TU München (Institut für Statik)

BMBF project (January 2001 – April 2004)

ECOQUESTEfficient Cooling Systems for Quieter Surface Transport

� EC FP7 Collaborative Project

� Main Topics:

� Noise emitted by cooling fans in locomotive and automotive

� Tonal and broadband fan scattering in complex enclosures

� Thermal engineering

� Product Road Map: LMS Virtual.Lab Aero-Acoustics


� Univ. Siegen (Coordinator)

� Industries: LMS, Valeo, Voith Turbo, Sontec

� Universities: ECL, KTH

� Research centres: VKI

Structures

NVH

Acoustics

Motion

Durability

Optimization

AETHERAEro-acoustical and THermo-acoustical coupling in enERgy processes

� EC Marie Curie Research Training Network (RTN) � focus on training young researchers

� Main Topics:

� Flow-induced noise in confined flows

� Combustion noise

� System modelling and stability analysis

� Passive & active control

� Product Road Map: LMS Virtual.Lab Aero-Acoustics


� LMS (Coordinator), 4 other industries

(RR, ALSTOM, GASUNIE, SIDMAR)

� 6 universities (KUL, TU/e, UCAM,TUM, LTU, IST)

� 3 research centres (VKI, CERFACS, TNO)

Structures

NVH

Acoustics

Motion

Durability

Optimization

� LMS Fellows:

� Paula Martinez (07/07 – 06/10): Robust aero-acoustic prediction in confined flows

including resonances (accuracy of analogy-based prediction, vortex sound theory)

� Géraud Guilloud (10/07 – 09/08):Hybrid deterministic/stochastic approach for aero-

acoustics

� Karthik Balachandran (07/08 – 06/10): Thermo-acoustic

effects of sound production & propagation

JTI Clean Sky

Green Rotorcraft ITD – 6 platforms

� Large EC Joint Technology Initiative (JTI) on “Green Rotorcraft”

� Partners: LMS, AgustaWestland, Airbus, Alenia Aeronautica, Dassault Aviation, Eurocopter, Liebherr-Aerospace Lindenberg, Rolls-Royce, SAFRAN and Thales, …

� Objective: improve impact of air transport on environment through reduction of noise, emissions and fuel consumption for future aircrafts.

� LMS focus area is Green Rotorcraft platform: advanced testing methods, environmental flight paths, (co)simulation in VL Motion, aero-acoustics predictions, …

EC FP7 JTI project (July 2008 – June 2015)

Development of Durable Vehicles: Durability Recorder for

truly rugged data acquisition in extreme conditions

� Rugged design with true MIL-STD-810F compliancy

� Tested for 60gpk shock and 7.7grms vibration

� Stands up to climate conditions from -20°C to +55°C

� No moving parts such as fans or hard discs

reducing the risk of breaking down in the field

� dust & water-splash sealed version according

ingress protection code IP54

structure electronic

parts of

sensors

electronic

parts of

actuators

controller

(analog,

digital?)

air „solid“ parts

of sensors

„solid“ parts

of actuators

listening

points

Active Noise Control in Vehicles

InMar and Smart Structures CAE Projects

� CAE-based Design of Active Noise and vibration control systems

Intelligent Systems for Low-emission Powertrain

HYPER Project

� Objective: Rapid development platform for hybrid powertrains including the development

of a functional model of a hybrid powertrain for B/C segment passenger cars and vans of

similar size

� National funding project

� Coordinator: Punch Automotive

� LMS Project Responsible: Jan Anthonis (ES)

� LMS Tasks:

� On-line data processing

• CAN communication

• Online virtual car sound

� Development of optimization strategies

• OPTIMUS-Imagine-Lab interface and process integration

• Driveability optimization: optimize parameters of hybrid control unit

LMS

Int’l

Driveability &

Optimisation

Punch

Powertrain

Hybrid powertrain

CVT transmission

HCU &TCU

PsiControl

mechatronicsElectric motor/generator and

power electronics

Externalcomponents

and subsystems

Powertrainsimulation

tool

LMS

Int’l

Driveability &

Optimisation

Punch

Powertrain

Hybrid powertrain

CVT transmission

HCU &TCU

PsiControl

mechatronicsElectric motor/generator and

power electronics

Externalcomponents

and subsystems

Powertrainsimulation

tool

PolSCA Meeting "ICT for green cars“ – Brussels, July 9, 2009

Thank you – Any Questions?

Dr. Ir. Marcin Luczak

Postdoctoral R&D Engineer, LMS International

[email protected]

lms international: research portfolio in ict for green cars

Documents