SIMDRIVE 3D Cross-Domain simulation for

Powertrain systems DeveloPment

0302

KEY FEATURES

•Reliableandfastpredictionmodels

• Fastmodelsetupthroughanunique

graphical3D-modelingandsimulation

environmentforallmodules

•Commondatabaseformodeling,

simulationandevaluationtoget

aroundco-simulation

•Convenientmodel/dataexchangewith

allmajorautomotivesuppliers

BENEFITS

•Scaleablemodeldepth

• Integrationofsubsystemsintocomplete

powertrainsimulationandunmatchedhigh

accuracyofthesimulationresults

•MethodologyapprovedbytheVDA(German

AssociationoftheAutomotiveIndustry)

andothercustomersworldwide

• Canbeusedincross-domainwayby

variousdevelopmentandprojectteam

Poly-VBelt

SIMDRIVE 3D™

SIMDRIVE 3D is a world-wide unique 3D cross-domain simulation platform for the development

of entire powertrain systems, merging the most important methods form different engineering

disciplines for predictive dynamic analysis in time and frequency domain.

CONTECS PROFIlE

CONTECS engineering services GmbH is a leading technology company, which specializes in

development and marketing of advanced simulation technologies, for the virtual assessment

of highly-developed powertrain systems and future drive concepts. Our mission is to provide

methodology, profound engineering consulting and related services to contribute to your product

development success.

engineering services GmbH

Kaiserin-Augusta-Allee111

10553Berlin,Germany

www.contecs-engineering.de

Telephone:+49(30)327689-0

Fax:+49(30)327689-95

E-mail: info@contecs-engineering.de

POlY-V BElT

Part of the SIMDRIVE 3D Standard Edition

is the simulation of friction belt drives (flat

belts and Poly-V belts) with automatic tensi-

oning systems containing solutions for all po-

lymorphic designs. As an additional module

the Multi Belt tool delivers the possibility of

multiple layers of belt and/or chain transmis-

sion drives, which easily can be combined.

• Internationallyacknowledgedplatformfor

FEADdevelopment

• Analysisofbeltflapping(transversalandtor-

sionaldeflection),slippageandpowerloss

• Belt-Lifetimepredictionmodel

• Integrationintocranktrainorcomplete

powertrainsimulation

3D ElEMENTS

The 3D Elements module provides a powerful

tool for coupled flexural and torsional vibrations

of crank trains and the entire driving shafts with

elastic or hydrodynamic bearings. Furthermore,

it it is possible to analyze the critical flexural

bending rotary speed in time domain. The Eigen-

modes of a complete structure can be displayed

in a 6 DOF animation.

• Interactivecreationofflexiblebodieswith

spatialflexiblebeamstructures(3Dbeam

elementsfordrivingshafts)

• Combinationof3Delementsand1Dele-

mentsinonesimulationmodel

•Definingtransversedrivestomodelthe

differentialgearunit

0504

3DCranktrain

Journal,Roller&BallBearing

Gearbox

DMFTypeI,IIandIII

LinearSpring ArcSpring ParallelSpringSystem

TypeI

TypeII

TypeIII

CompleteDriveTrain

3D CRANKTRAIN

The Advanced Crank Train module allows the

simulation of coupled flexural and torsional

vibrations of the crank train. A basic version

enables a reduced torsional vibration analy-

sis of the crankshaft.

• Eigenfrequencyanalysisofsupported

cranktrainwithallmountedcarryingparts

•Dynamicloadsanddisplacementpaths

forallbearings

•Massforcesandmassbalancing

• InfluenceofFEADortimingdrivesonthe

cranktrainthroughacoupledsimulation

DMF

The DMF module offers detailed multi-body

modeling of dual mass flywheels. This inclu-

des all common designs of the inner spring

setup, which can be combined at will.

•Nonlinearandrpmdependentfrictionand

geometryinfluence

•1Dtorsionalaswellasfull3Dmodeling

includingbearingsandflexplatebending

3D BEARINg

The Bearing module includes the simulation

and evaluation of journal bearings, ISO ball /

roller bearings or basic elastic bearings for

fast simulation.

JOuRNAl BEARING

•ComplexsolutionoftheReynoldsequation

intimedomainconsideringdrillingsandtil-

tingunderdynamicloadwithEHDapproach

•Significantlylesstimeconsumingapproach

availableusingapre-calculateddatamap

•Definitionofdiscretebearingracefor

correctapplicationofbearingforcesonthe

housing

ISO BAll / ROllER BEARING

•Realisticpressureconditionsontherolling

bodiesanddynamicbehaviorindependen-

cyofgeometry,loadanddynamicclearance

•ServiceliferatingaccordingtoDINISO281

gEAR TRAIN

The Gear Train module allows the simulation

of dynamics and vibrations of gear trains.

Furthermore, simulations of rattle and

dynamic transmission errors as well as

load dependent deformation of shafts, gear

wheels and housing can be analyzed.

• Exactgeometricmodelingofthetooth

• 3Dcontactwithcalculationofcontact

ellipseandHertz‘Stiffness

•Diversetoothcontactconsiderationfor

fastsimulationsand/orhighaccuracy

•Staticloadanddeformationanalysis

POwERTRAIN

The holistic powertrain consideration is a

valuable input for drive line development.

The module allows the analysis of transient

load conditions and predefined load cases

in the complete power train.

• Evaluationofstrainsasaresultofunique

eventsanddynamicbehaviorforsteadystate

• Simulationofinteractionbetweenengine,

gearboxanddrivenside

• Complexmodelingunderhybridapplications

ChASSIS AND TIRE

The Vehicle module offers a basic and advan-

ced tire model for the consideration of the

road-tire contact with realistic force feed-

back on the powertrain. Furthermore, the

influence of driveline and wheels on chassis

behavior can be analyzed.

•Dynamicchangeofwheelloadregarding

physicalpropertiesofthevehicle

• Drivingresistanceaccordingtovehiclespeed

includingrolling,airandclimbingresistance

• Considerationofcontactforces(brakingand

acceleration),lateralforces(steering)and

self-aligningtorque

0706

ChainDrivewithValveTrain

NVHAnalysis HydraulicTensionerModel SurfaceAccelerationAnalysis

StructuralAnalysisofPowertrain

TIMINg BElT

The Timing Belt module provides the simu-

lation and study of timing belt drives with

automatic tensioning systems for NVH

analysis, system load and power loss.

• Detailedmodelingofbelt-pulleycontact

• Ovalsprocketsforresonancecancellation

• Predictiveanalysisoftimingerror,transverse

deflection,dynamicloads,etc.

• 3Dtensionerforarealisticmodelingoffriction

tensionersusingCADgeometry

VAlVE TRAIN

The Valve Train module is designed to make a

complex analysis possible. Starting with basic

torsional cam excitations, increasing the

complexity with single valve elements up to

a complete dynamic contact simulation.

• Kinetostaticcomponentmodelingwithsingle

elementssuchascam,valve,valvespringand

rockerarm

•Modelingofdynamicbehaviorsuchaslever

lift-offorcoilcontactbyusingContourand

Contactelementsandstudyofthedeformati-

onofvalveandleverbyusingFlexibleBodies

• Structuralanalysisofadiscretespringusing

theBoundaryElementMethodmodule

• Rheologicmodelforhydrauliccamphaser

• Considerationofhydraulicvalvelashadjust-

mentandcombustionbackpressure

ChAIN DRIVE

The Advanced Chain Drive module covers

the analysis and optimization of entire chain

dynamics up to NVH studies of timing drives

with bushings, rollers and silent chains.

• Link-to-linkconnectionwithnon-linearchain

stiffnessincludingfrictionanddampingto

analyzepowerlosses

•Detailedsprocketgeometry:ISO,involute

aswellasauserdefinedoutlineforsilent

chains

•Non-circularsprocketsandirregularpitch

forresonancecancellation

• Physicalchaintensionermodelcovering

gapflowanddissolvedair

•Dynamicmodelforhighpressurepump

• Flexibleguiderailallowinganalysisof

linearelasticbehavior

ModelingClassesofValves

STRUCTURAl ANAlYSIS

For the advanced structural analysis the two

modules Flexible Body and Modal Calculation

complete the modern methods of simulation of

multi-dimensional MBSD and structural analysis.

The possibility to load reduced FE structures and

combine them with multibody simulation leads to

an enhanced modeling process, which then com-

bined with a modal reduced calculation method

additionally reduces simulation time. The modal

analysis is an independent analytical method,

which is directly embedded in SIMDRIVE 3D.

• Outputperipheryofthemodalanalysisalso

coverstheanalysisofcoupledstructures

• Comfortablemanualassignmentofmodal

massesand3Dmasses

• Possibilityofadditionalmodaldegreesof

freedom(nodes),whicharenotconnectedto

thehousing,foroscillationanalysis

• Completesystemwithmodularassembly,

e.g.3Dcrankshaft,FEAD,valvetrain,gearbox,

elastichousingaggregatebearing

NVh

The NVH module enables an integrated structural

analysis by applying operational loads on FEM

meshes via reduced FE structures.

• LinearizedstructuralbehavioroftheFEA

meshbymodalanalysisaspreprocessing

• Applicationofforcesandmovementby

connectionnodesofaFlexibleBody

• Triaandquadforsurfacesaswellastetra,

pentaandhexaforsolids.Mixedsurfaceand

solidelementsinonestructure

• Postprocessingbyanimationofdeformation,

surfacevelocity,surfaceaccelerationand

stress

CoupledNVHMesh

FullyFlexibleDMF

0908

SPRINg

TheBEM Springdepictsahighlyaccurateappro-

achtocreateastructuralmodelofaspring:

Startingwithanautomatedprocesstocreatean

MBS-Model,usingthedisplacementofatime

domainsimulationforthecalculationofstress

withinthespringtopredictthelifecycle.

• Parametric,userdefinedorimportedwire

contour

•Geometrydefinitionofthesurfacemesh

usingprecisedesignparameters

• Considerationofcutends

• Illustrationofthedisplacementandstress

onthespringsurface

BOUNDARY ElEMENT METhOD

The Structure module integrates structural

mechanics into MBS simulation. Stress

evaluation is combined with real time results

allowing the determination of coefficients of

safety and weakest point in the structure. In

combination with a powerful MBS simulation

and a highly advanced stress analysis under

realistic load condition the module simplifies

the DOE process. With the included versatile

elements a swift calculation of inertia and

stiffness tensors of any components is fea-

tured. Any BEM mesh can be exported as

a STEP file for further processing.

PARAMETRIC wEB

Asabasisforastructuredapproachincrank-

shaftwebdesign,theelementenablesa

simplevariationofspecificdesignparameters.

• Effectivemodelingofcomplexcrankshaft

webgeometrieswithhighdetail

BEMintegratedinMBSSimulation

TVD&IP

Crankshaft

BalancingShafts

SurfaceMesher

ThermoCalculator

TensionerSpring

• Fatiguelimitassistentwithmaterialdata

baseandconsiderationofconstruction

andgradientinfluence

• Automaticdefinitionofnodesetsforthe

stressanalysisofnotches

•Modernandrevolutionaryanalysisalgo-

rithmsforthecyclestresstensor

BODY OF REVOlUTION

TheBEM Body of Revolutionisapplicablefor

thesetupofshaftsusedintransmissionor

drivelineandtorsionalvibrationdampers.

Theautomationofthetransformationintoan

MBS-modelenablesafaultlesssetupofan

accuratesimulationmodel.

•Detaileddepictionofrotaryelementssuch

asshaftsthroughsectionalcalculation

•Comfortableeditingofthecontourusing

theCSketch-2D-Editor

• ImportviaISOSTEPfileformat

ThERMO CAlCUlATION

The Temperature module allows the coupling

of thermal and mechanical real time simulati-

on for components with high temperature de-

pendency, e.g. rubber dampers. It calculates

the 2D heat flow within rotationally symmetric

structures. This module also comprises the

features of the SIMDRIVE 3D sketcher tool,

which facilitates a fast and easy way to set up

models / assemblies for thermal analysis.

• Predictionofdamperheatingandtempera-

turedistribution

•Considerationofthermalinfluenceon

rubberparametersinmechanicalmodel

•Dissipatedenergyasheatsource

•Differentboundaryconditionsforheatflow

ontheoutsidebordersoftheanalyzed

structure

•Referencepointsfortemperaturecompari-

sontomeasurementresults

SURFACE MEShER

The BEM STEP FileallowstheimportofaCAD

modelinSTEPformatanditssurfacemeshing

forBEMcalculation.Anautomaticmeshing

ofthecompletesurfaceandmanualmeshing

ofsinglefaceswiththeCsketch-2D-Editorare

offered.

• PrograminternaleditingofSTEPfile,e.g.

mergingorsplittingoftwofacesorcutting

abodyinmultipleparts

• Precisemeshcontrolandvariablefineness

possible

• Triandquadmeshing

• Combiningmanualmeshingofsinglefaces

andautomaticmeshingofremainingsurface

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Engine Control

Clutch Control

The module allows the setup of controlled systems, thus

giving the possibility to assemble control structures comparable to real

engines. A library with E-components for synchronous and

asynchronous motor, inverter and battery completes the functionality.

Setup of controlled systems, e.g. idle speed control, gearbox

control, active tensioner and even full NEDC

All simulation parameters can be defined as a controlled

reference variable

Incremental and continuous sensoring and actuating

Consideration of influence of the control unit on the drive lines

dynamic behavior

Integration of dynamic link libraries for external processing

Controller

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CONTROLLER

THERMO CALCULATION

The moduleTemperature allows the coupling of thermal and

mechanical real time simulation for components with high

temperature dependency, e.g. rubber dampers. It calculates the

2D heat flow within rotationally symmetric structures. This

module also comprises the features of the SIMDRIVE3D sketcher

tool, which facilitates a fast and easy way to set up models /

assemblies for thermal analysis.

Prediction of damper heating and temperature

distribution

Dissipated energy as heat source

Different boundary conditions for heat flow on the outside

borders of the analyzed structure

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Consideration of thermal influence on rubber parameters

in mechanical model

Reference points for temperature comparison to

measurement results

Based on the fundamental wave model, predefined electrical

machine and inverter elements are used for the reliable

simulation of electrical systems. This analytic method allows

short calculation times and can be extended to take torque

harmonics into account. The determined torque can be combined

with the magnetic excitation force in order to do deformation and

vibration analysis.

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Idealized inverter and pulsed voltage signals for calculating

line voltages.

Easy editing of control algorithms due to standard control

schematics of the module.

Calculation of torque deviations within the electrical

machine which cause rotary speed irregularities.

Excitation maps for cogging torque and air gap field

harmonics can be acquired through FE-analysis with open

source tools such as FEMM.

Resulting magnetic forces necessary for deformation

analysis are read from FEM solutions, considering the

relevant operating conditions of the existing model.

Controller

E - SIMULATIONNEW

Displacement due to magnetic force

Calculation of magnetic field

FEMM Software

SIMDRIVE 3D

8TH INTERNATIONAL SIMDRIVE 3DPOWERTRAIN & USER CONFERENCE

CONTROllER

The Controller module allows the setup of

controlled systems, thus giving the possibility

to assemble control structures comparable to

real engines. A library with E-components for

synchronous and asynchronous motor, inverter

and battery completes the functionality.

•Setupofcontrolledsystems,e.g.idle

speedcontrol,gearboxcontrol,active

tensionerandevenfullNEDC

• Allsimulationparameterscanbedefined

asacontrolledreferencevariable

• Incrementalandcontinuoussensoring

andactuating

•Considerationofinfluenceofthecontrol

unitonthedrivelinesdynamicbehavior

• Integrationofdynamiclinklibrariesfor

externalprocessing

E – SIMUlATION

Based on the fundamental wave model, prede-

fined electrical machines and inverters are used

for the reliable simulation of electrical systems.

This analytic method can be extended to take

torque harmonics into account, which can be

combined with the magnetic excitation force in

order to do deformation analysis.

• Idealizedinverterandpulsedvoltage

signalsforcalculatinglinevoltages.

• Calculationoftorquedeviationswithin

theelectricalmachinewhichcauserotary

speedirregularities.

• Interfaceforacquiringcoggingtorqueand

airgapfieldharmonicsthroughFE-pre-

calculation

•Resultingmagneticforcesnecessaryfor

deformationanalysisarereadfromFEM

solutions,consideringtherelevantopera-

tingconditionsoftheexistingmodel.

TOOlS

ANIMATION

The Animation module is a tool that enables the

user to create animations and visualizations of

simulation results in 2D and 3D. Moreover, it

can be used to simplify the system analysis as

well as freshening up presentations.

• Enhanceddisplayoptions,suchasforces,

tensionandhubloadsforaneasyoptical

systemanalysis

• Additionaldisplayofresultswithinthe

3D/2Danimation

• Customcameramotionpathsofferdynamic

perspectivesandappealingpresentations

•StressvisualizationofBEMandNVH

elementsintheanimatedMBSmodel

• Surfaceoutlinesofcomponentsand

assembliesforenhancedvisualization

CASE STUDIES

The Case Studies module allows an easy

compilation and execution of simulations

for distinct design studies (replacement of

sub-assemblies), parameter- and load vari-

ations, as well as simulation task variations.

• Themodelinformationisstoredina

singlemaster-model

• Eachmodel-variantcanbeextractedas

afullyfunctionalstandalonemodel

• Accelerationofdesignstudiesusing

standardizedevaluationcases

PARAMETER STUDIES

The Parameter Studies module allows the

declaration of ranges and increments for the

variation of model parameters as well as the

specification of certain output parameters.

The built-in Model Optimizer allows the addi-

tional indication of an optimum or threshold

for a specified goal parameter.

•Understandingphysicaldependencies

throughmultidimensionalanalysisof

specificparameters

•Simpleresultevaluationusinga

specializedpostprocessor

OPTISTUD EVAlUATION

The OptiStud Evaluation is a powerful post

processing tool that aims at the evalua-

tion of a large number of model variants.

It allows a fast and easy way to make a

statement about variant quality, sparing

the necessity to examine a large number of

calculation results.

• Clearassesmentofresultsforoptimum

comparability

• Individualsetupofevaluationcriteria,limits

andanalysisrange

• Ratingsystemthattakesadvantageoflimit

analysisandoptimalvalueconsideration

• Visualizationbyvariouschartsandcolor

gradients

REPORT gENERATOR

The Report Generator allows an easy

standard analysis of simulations with a set

of predefined output results in a complete

customer defined layout, which suits any

corporate design. This tool also includes the

standard VDA-FEAD analysis as a template.

•Definitionofevaluationresultsinaspecific

report,usablefordifferentmodels

• Comparisonofvarioussimulationtasks

and/ormeasurements

•Datalinksforautomaticdisplayofmodel

parametersorresultvalues

• Easystandardizationfordocumentationof

simulationresultsClutchControl

CylinderPressureControl

E-Simulation

Displacementduetomagneticforce

Calculationofmagneticfield

11

engineering services GmbH

Kaiserin-Augusta-Allee111

10553Berlin,Germany

www.contecs-engineering.de

Telephone:+49(30)327689-0

Fax:+49(30)327689-95

E-mail: info@contecs-engineering.de