Daniel Krätschmer Friederike Loerke

VIRTUAL ECU ANSYS BEST PRACTICE SESSION: „SIMULATION DRIVEN PRODUCT DEVELOPMENT FOR EVERYONE“

DANIEL KRÄTSCHMER FRIEDERIKE LOERKE

CASCON 2019 Simulation Process Management: Virtual ECU Motivation

System: How to establish a robust data / information Vehicle exchange between product-independent design

Load derivation from a system perspective 0 Level element assessments & product-specific load Sub-System: RB system derivation and load path design? (e.g. injection Level 1 Level system)

Manufactured Motivation Item:  Only with standardized load path methods Level 2 Level ECU transparent requirements for design elements can be derived ? Assembly

Level 3 Level  Standardized load path methods as enabler for Cut out design element load / load tool based, automatized evaluation of design for product integration capacity level Component elements in mechanical architectures

Reliability Assessments 4 Level geometry-independent stress / strength Material, design rule, e.g. 휎 ≤ 휎푚푎푥 level Level 5 Level Interface

4 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2017.2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Motivation

System:  Democratization in CAE-based product Vehicle Load derivation from a system perspective 0 Level development means to empower non-

Sub-System: experts to take advantage from simulation RB system technology (e.g. injection Level 1 Level system)  CAE experts could put the power of Automated setup of ECU models to feed Manufactured Item: simulation safely into non-experts hands to reliability models with needed information Level 2 Level ECU overcome the general lack of CAE engineers

Assembly Level 3 Level Cut out design element load / load for product integration capacity level Democratization ? Component

Hosting of detailed reliability models 4 Level geometry-independent stress / strength Material, design rule, e.g. 휎 ≤ 휎푚푎푥 level Level 5 Level Interface

 Motivation  Our journey to Simulation Process Management (SPM)  Drive ANSYS via Microsoft Excel / GUI  Process Automation & ANSYS WB Scripting by ACT  Simulation Process Management  SPM Framework “Concert Hall” by Dynardo GmbH  Virtual (Assembly of) ECU as automated solution for load derivation  “Deep-Dive” in customized workflow  Outlook and Summary

4 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Our journey to Simulation Process Management

Drive ANSYS via Excel / GUI

 APDL Scripting ‒ Excel-Front-End ‒ MATLAB & python GUI

2012

5 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Drive ANSYS via Microsoft Excel: smart-TC APDL-Driven ANSYS Backend

VBA-Driven MS Excel-Frontend

User Input defines APDL Code definition

Excel-based user interface Post processed Results visualized in Excel 6 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Our journey to Simulation Process Management

Automation & WB Scripting

Drive ANSYS via  Drive ANSYS via ACT Excel / GUI (Application Customization Toolkit) wizards  APDL Scripting ‒ Excel-Front-End ‒ MATLAB & python GUI

2012 2016

7 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Virtual Assembly of PCB/ECU

Component

Model component PCB PCB

Component models substrate Component

components & design elements

CL L

PCB Sub-

op. Assembly p

electrical layout ECU module database housing concept A B

ECU ECU ECU assembly manuals

ACT Extension

8 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Virtual Assembly of PCBs / ECUs-ACT

ACT-Driven ANSYS-Frontend ACT Wizard Programmierung: XML + Python + HTML

• XML: Konfiguration + GUI-Definition • Python: Implementierung • HTML (optional): Benutzerhilfe

Python-Datei

XML-Datei

Krätschmer, D., Zhang, Y.: “Automatisierter Workflow zur modellbasierten Bauelementbestückung von Leiterplatten elektronischer Steuergeräte“, © CADFEM 2017 CADFEM ANSYS Simulation Conference 2017 am 15.-17. November 2017 in Koblenz 13 CADFEM ANSYS Simulation Conference 2017

Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2018.2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Our journey to Simulation Process Management

Simulation Process Management

Automation & WB  Simulation Process Scripting Management based on Dynardo‘s optiSLang and Concert Hall Drive ANSYS via  Drive ANSYS via ACT Excel / GUI (Application Customization  Web Applications Toolkit) wizards  APDL Scripting ‒ Excel-Front-End ‒ MATLAB & python GUI

2012 2016 2019

10 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Virtual Assembly of ECUs requirements layout server-based web framework PCB traces model information KPI $ Web Application meta information PCB layout database components Bill of population materials feeds model information components meta information

database architecture design rules mechanics model information Fz (architecture F elements) meta information x database database ECU database design design elements Load at free-cut Fy elements assembly #1 assessments model information of design elements meta information

Various information Automated Virtual ECU Standardized Load Standardized Design Databases Lessons learned sources assembly Derivation Element Assessment

11 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU SPM Framework

Dynardo’s web framework hosts optiSLang projects offering user input and upload opportunities 12 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Embedding and extension of ACT solution Web-based provision of “Virtual Assembly of ECUs” Step by step approach

knowledge provided by choose substrate Component experts

Model component PCB PCB

Component models substrate Prepare PCB Component components & design elements Populate PCB CL Assembly

Sub- L PCB

Assembly Load Case

op. p electrical layout Solve ECU module database housing concept A B Post-processing ready to use for

ECU ECU everyone ECU assembly manuals choose components ACT Extension

Mission: CAE workflows are fully covered by SPM based on standardized database-hosted modules

Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU

14 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulation Process Management: Virtual ECU Embedding and extension of ACT solution Web-based provision of “Virtual Assembly of ECUs”

 Approach to host CAE engineering workflows by central web-service ready to use for AE associates  CAE Apps serve as baseline for highly standardized design element reliability assessments in ECU architectures  CADFEM-provided CAE workflow for general ECU-related simulations embedded in Simulation Process Management (SPM)-Framework  ACT-programming as a software project (architecture, documentation, testing,…)  Scalable framework solution ready to be extended by additional ANSYS modules

Relevant CAE workflows are fully covered by SPM based on standardized database-hosted modules

without with SPM SPM: Virtual ECU Consulting SPM Preparation 10% Get Information 10% Get Information SPM Tooling 25% 25% 10% Reporting Pre Process 20% source: Potential <1% Savings Solution Run Pre Process >33% 5% 20%

Post Process… Post Process Solution Run Consulting Reporting 20% 5% 10% 5% Simulation Engineer working split Future Simulation Engineer working today (advanced level) split Automation of time-consuming tedious tasks promises efficiency gains of 33% (mid-term perspective)

System:  Democratization in CAE-based product Vehicle Load derivation from a system perspective 0 Level development means to empower non-

Sub-System: experts to take advantage from simulation RB system technology ☑ (e.g. injection Level 1 Level system)  CAE experts could put the power of Automated setup of ECU models to feed Manufactured Item: simulation safely into non-experts hands to reliability models with needed information Level 2 Level ECU overcome the general lack of CAE engineers

☑ Assembly ☑ Level 3 Level Cut out design element load / load for product integration capacity level Component Hosting of detailed reliability models ☑ 4 Level Democratization ! geometry-independent stress / strength Material, design rule, e.g. 휎 ≤ 휎푚푎푥 level Level 5 Level Interface

Any Questions?

DR. DANIEL KRÄTSCHMER (AE/EBS) AUTOMOTIVE ELECTRONICS, ENGINEERING BRAKING SYSTEMS ECU

EMAIL: [email protected] TEL.: 07121 35 39127

18 Automotive Electronics | AE/EBS | 2019-08-07 © Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.