siemens plm university of ontario institute of technology cs z3
TRANSCRIPT
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Industry
Education
Business challenges
Integrate an electric motorand energy storage system
into a production modelvehicle
Keys to success
NX quick routing functionalityfor wires and tubes
Finite element analysis
Visualization of complex
assemblies
Use of digital data for stress,crash and ow analyses
Results
Packaging studies completed
in weeks or days vs. months
Fast design changes keepteam up-to-date with contest
rule changes
One software solution formany disciplines
Students model complexshapes after only minimal
instruction
NX helps engineering studentstransform Saturn Vue to cleanand green
Clean competition
The University of Ontario Institute of
Technology (UOIT) is one of 17 NorthAmerican Universities participating in
EcoCAR: The NeXt Challenge, a three-yearengineering competition established by
the United States Department of Energy
and General Motors, and managed byArgonne National Laboratory. The compe-
tition challenges the participants to reducethe environmental impact of vehicles by
minimizing fuel consumption and reducingemissions while retaining the vehicle’s
performance, safety and consumer appeal.Students use a real-world engineering
process to design and integrate their
advanced technology solutions into a 2009Saturn Vue.
UOIT’s EcoCAR team is turning the gaso-
line-powered Vue into a full-functionelectric vehicle. Such a dramatic transfor-
mation posed a number of engineeringchallenges for the students, including
designing and integrating a fairly large
onboard energy storage system (ESS) intothe competition vehicle. To qualify for the
project and receive an actual vehicle, theteam had to demonstrate the validity of its
concept through virtual simulations. GMsupplied a digital model of the Vue and the
UOIT team used the NX™ digital product
NX
www.siemens.com/nx
University of Ontario Instituteof TechnologyAcademic competition leads the way to a new electric car
development solution from Siemens PLMSoftware on three main areas of the ESS:
wiring layout, thermal management andstructural component design and mount-
ing. The team created a unique battery
mounting approach that incorporates wir-ing looms, chassis mounts and a thermal
management system. The students alsoproved the validity of their design by con-
ducting nite element analyses using NX
Nastran®. This enabled them to avoid anypotential performance failures and theneed to test physical prototypes.
Wiring made easy
The proposed ESS required high-voltagewiring running the length of the battery
tray to connect the batteries, as well as
wiring to connect the motor with the bat-tery management system. The limited
amount of space in the existing vehicle
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“Without software such as
NX Nastran, the complexityof our design would take an
unrealistic amount of time
to analyze within the con-
text of the EcoCAR competi-
tion. The software provided
great time savings and
accurate results.”
Shawn Sandham
Automotive EngineeringStudent and EcoCAR Team
Member
UOIT
made wire routing a challenge. “It would
have been difcult if not impossible to dothis work using 2D routing diagrams andengineering drawings,” says Nicholas
Shopian, an automotive engineering stu-dent at UOIT and an EcoCAR team
member.
“A three-dimensional digital model and the
NX quick connect tool provided a rapidway to set up several points and generate
a wiring path,” Shopian continues. “Thismade it relatively simple to see the high
voltage lines laid out inside the ESS
module. With the wiring laid out, it alsoallowed for several necessary changes tobe seen, enabling the wire routing to
safely clear all obstructions. The electrical
routing tool proved invaluable when gen-erating a wiring design. Using the routing
tool and with all of the other systems intheir place, it was possible to ensure any
one system would not overlap and that theproper clearances were maintained.”
Temperatures controlled
To maintain the ESS at the correct operat-ing temperature, the team had to nd a
way to extract internal heat buildup and
also to supply heat to the system if neces-sary. The proposed thermal management
system encloses all the batteries withsmall Teon or nylon cooling tubes. A sys-
tem of this nature was very hard to visual-
ize on such a large scale. Determining thequantity of material necessary for con-
struction was another problem.
The students used NX to design the ther-mal management system around a central
supply line and one main return. With
these laid out, routing software was usedto construct the individual battery cooling
system. This was done with the NXmechanical routing application using
mostly the quick path tools. The mechani-cal routing application allowed for easy
layout of the main path, and then for sev-
eral iterations to be made based upon thenumber of batteries in each stack to gen-
erate the entire system. After all of theindividual pipes were made, they were
then linked into the main tees and themain line.
One very helpful feature was the volume
calculation tool, which was used to deter-
mine the amount of material needed forconstruction. The use of NX was also help-ful for seeing how the various systems t
together and if there was any
interference.
Secure attachment
Perhaps the biggest challenge encoun-
tered over the course of the preliminarydesign related to packaging the ESS mod-
ule and feasibility of the proposed supportstructure. To achieve the desired range
and vehicle performance, it was deter-
mined that 88 to 90 battery cells wererequired. With an individual cell weight of
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Customer’s primary business
Founded in 2002, the Univer-
sity of Ontario Institute of
Technology (UOIT) offers anew type of degree that is
putting it at the top of theclass in student and employer
satisfaction surveys. Clean andgreen are at the core of UOIT’s
research and academic pur-suits. Wind, solar, nuclear,hydrogen and more are all
under the microscope. UOIT’sundergraduate and graduate
programs provide pathways tothe jobs and careers
of tomorrow.
www.uoit.ca/ (University)www.uoit.ca/ecocar/
(EcoCAR team)
Customer location
Oshawa, Ontario
Canada
ve kilograms (approximately 11 pounds)
this capacity translates to a signicant
amount of additional mass.
Using the digital model of the existing
vehicle, students used NX to take measure-ments and then design components. Thisprocess was crucial in testing overall t
and design feasibility to ensure that the
ESS module integration would in fact bepossible. The team performed structural
analyses of the proposed design using NX
Nastran to ensure that displacements andstresses were within acceptable limits for
individual components and assemblies.
NX makes it possible
“A competition of this magnitude would
not be possible in the context of an aca-demic setting without software such as
NX,” says the co-leader of UOIT’s EcoCARteam, Mike Maduro. “We wouldn’t have
the time or the resources. We are basicallyredesigning a vehicle. It would be
extremely expensive to do packaging stud-
ies by putting rapid prototypes together,and it would probably take six months to a
year. That would put us out of the run-ning. Using NX, we are doing packaging
studies in weeks, even days.” Dr. GregRohrauer, the team’s faculty advisor,
notes, “The complete vehicle model sup-
plied by GM is very large, constituting over10 gigabytes spread across thousands of
parts. However, with our $3,000
(i7-920 based) workstation running NX,we can open the entire model at once and
navigate to any area nearly as fast as onecan drag the mouse. My students habitu-
ally section across the entire vehicle torene on our very tight packaging
constraints.”
Another area where the NX suite of tools
has been especially helpful is for quicklymaking design modications, such as
those required in response to contest rulechanges. One recent change involving
ground clearance could have been disas-
trous for the UOIT team, whose batterypack ts below the vehicle. “We had to
basically move everything up an inch,”says Maduro. “Without the ability to easily
modify an assembly in NX, that wouldhave been impossible.”
NX is the only CAD solution being used byUOIT’s 20-person EcoCAR team, which con-
sists of electrical, industrial, mechanicaland software engineers. Maduro notes
that the students are doing amazing thingswith NX, pointing out, “They are modeling
shapes I would have thought required a 3Dscanner to create.”
In subsequent years of the three-year
EcoCAR competition, the team plans to useNX to conduct ow and crash analyses.