Femap Case Study- Consumer Products

ASICS

CAE facilitates design direction and prototype reduction, cutting time for new product development.

Continuous commitment to CAE for a quarter of a century

ASICS Corporation, Institute of Sport Science (ASICS) is very popular in the sports footwear market. This includes both the general consumer and running shoe segments, where ASICS is among the market leaders.

The popularity of ASICS shoes is largely based on their superior functionality, which can be directly attributed to the company’s continuous efforts to improve shoe performance.

One of the major contributors to improved shoe performance has been the aggressive use of computer-aided engineering (CAE). At ASICS, serious commitment to simulation began around 1987.

For 25 years, ASICS professionals – both CAE specialists and other engineers/researchers – have actively utilized various analysis tools. Among these tools, the most significant contributor to performance enhancement has been the use of Femap™software with NX™ Nastran® software.

The CAE effort is led by Dr. Tsuyoshi Nishiwaki, Fellow and senior general manager of ASICS Institute of Sport Science.

Since joining ASICS, Dr. Nishiwaki has strived to implement and deploy the best CAE tools across the product development process.

Before devoting his time to shoe development processes, Dr. Nishiwaki worked on analyzing sporting goods, such as tennis rackets. Dr. Nishiwaki is not only experienced in the use of CAE software, he has personally developed a numerical model that represents the mechanical properties of composite materials.

CAE as a decision-making tool for development direction

Through experience, Dr. Nishiwaki has observed that CAE software is a great tool for decision-making across a number of areas, especially for development direction. He points out, for example, that because of the use of 3D computer-aided design (CAD) in conjunction with Femap with NX Nastran, ASICS has reduced and continues to reduce physical prototypes per project.

He also notes that reducing CO2 emissions is now becoming an important issue at the corporate level, as well as for virtually every manufacturer today. By using CAE early in the development cycle, the production of physical prototypes is significantly reduced, as are CO2 emissions.

“Using CAE effectively to decide product development direction, we estimate we are shortening turnaround by 30 to 35 percent for general development projects,” says Dr. Nishiwaki.

Many CAE users focus on how well analysis results match with experimental results. According to Dr. Nishiwaki, for purposes of shoe design, it is a rare case to have exactly the same results. To do so, all of the required information, such as material properties, constraints and loads must be completely known.

This is particularly true for products like sports shoes, which require factoring in certain physical conditions of the human body, although much of that information is highly variable or unknown.

For example, muscle flexibility/stiffness often varies as a person’s mental state changes. So even if just one of these characteristics is unknown, that often means that one cannot obtain a highly accurate result.

Nevertheless, Dr. Nishiwaki emphasizes how critical it is to use CAE tools to capture the impact of design on shoe performance, explaining that simulation can provide special insight on the design of a shoe’s sole, enabling important decision-making data regarding overall performance to be captured in the early phases of development.

According to Dr. Nishiwaki, it is just this type of use of Femap with NX Nastran that has enabled ASICS to reduce product development time by 30 to 35 percent.

Using subjective metrics to improve objective performance

When Dr. Nishiwaki began his work on sports footwear development, he soon tackled the issue of leveraging subjective metrics using CAE. “Although quite a few biomechanics professionals have been researching human body movement with respect to shoes, these findings weren’t leveraged to improve the shoe development process,” says Dr. Nishiwaki.

To quantify performance metrics that could only be evaluated in physical ways in the past, ASICS established eight domains of functionally: cushioning, stability, flexibility, fitting, durability, grip, weight and ventilation.

ASICS then established metrics within each domain through experiments and hypotheses. For example, to establish metrics for cushioning properties, ASICS hypothesized that such properties are tightly linked to the acceleration of the shin.

Through a series of experiments, the company found that when the sole absorbs low frequency waves, the shoes have better shock-absorbing characteristics. Moreover, with that knowledge in hand, ASICS set about to determine specific cushioning metrics using CAE.

“The design process for shoes is the same, whether it’s for a professional athlete or a casual jogger,” says Dr. Nishiwaki, pointing out, “Actually, shoes for the casual jogger have more performance features.”

According to Dr. Nishiwaki, shoes have two major roles. One is to improve the performance of the user; the other is to protect the user from injury.

For the professional athlete, the second role, protection, is secondary. While protection is meritorious, a professional athlete’s No. 1 priority is to improve performance.

However, for the casual athlete or young person first trying sports, protection from injury is very important.

Moreover, sports shoes for general consumers must serve highly diverse needs, so they must perform well for most individuals.ze in simulation.

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High analysis functionality + extraordinary ease-of-use = efficient product development

Dr. Nishiwaki notes that the use of CAE tools by all research and development (R&D) professionals – not just analytical specialists – is essential for efficient product development. However, he adds that ease-of-use is critical to engaging the software’s use by engineers and it is here that Femap with NX Nastran truly stands out, because it’s a powerful analysis tool that’s easy to navigate and satisfies the requirements of a broad spectrum of users.

“Femap with NX Nastran is very easy to use, even if an engineer has little to no experience using numerical analysis tools,” says Dr. Nishiwaki. “After one or two days of training, an engineer can start utilizing CAE on his own. Even a complete novice, an engineer with absolutely no CAE experience, can easily start numerical analysis by importing geometry from 3D CAD software, creating mesh using auto-mesh functionality, then analyzing the optimal depth of grooves in a sole and positioning of gels for shock absorption.”

Dr. Nishiwaki points out that such ease-ofuse is commonly associated with low functionality in analysis software, but that’s simply not the case with Femap with NX Nastran. “There are no issues in convergence; enhancement of the code for nonlinear analysis is exactly as we wished. The solution even has good enough functionality for appropriate use by numerical analysis experts, and we expect the software will get even better for such applications with subsequent releases. We are quite satisfied with the well-balanced functionality and usability of the software.

Femap with NX Nastran has helped us create a more efficient product development process. It is up to us to determine how much we make further use of the software for competitive advantage.” Indeed, ASICS is extending the use of Femap with NX Nastran. It is now deploying the software to its product designers. ASICS excels in terms of shoe performance; however, Dr. Nishiwaki notes that outstanding design is equally essential, particularly for running shoes for the general consumer. “No matter how superior a pair of shoes may be in terms of performance, unless the shoes have high appeal from a design perspective, the reality is, the shoes will not have strong marketability,” he says.

“To develop shoes that satisfy both design and functional requirements, and to develop the best products, we feel that use of analysis tools by our product designers is fundamental to improving our best practices. We are deploying Femap with NX Nastran for this role.”

Analysis software facilitates communication, marketing

Effective communication between engineers and non-engineers across the product development organization has grown since deploying Femap with NX Nastran. Even communication with consumers has improved. “It’s phenomenal…we are now using results from numerical analysis in conjunction with experimental data for promotional purposes, and it’s a valuable asset,” says Dr. Nishiwaki. “By leveraging numerical analyses, the development process can be described in the form of animation. Now, even people unfamiliar with the technology can understand our shoe development process, which helps them understand the science and art behind our ASICS brand. Such content is already used in sales meetings with ASICS distributors and representatives, and even at public seminars for general consumers.”

Ease-of-use and superior capabilities that satisfy even numerical analysis experts represent the distinctive attributes of Femap with NX Nastran. Moreover, these attributes are helping ASICS apply CAE across numerous development domains and projects. The results are valuable benefits at the front-end of design, especially from team members who don’t specialize in simulation.

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The EDGE software portfolio includes CAD, CAM, FEA & PDM solutions and EDGE fully supports and offers training and mentoring services on its entire portfolio. EDGE has been a business partner of UGS/Siemens since 2004. EDGE also configures and sells Dell hardware to assist our customers maximise their software investments. Read more about us…

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We offer scheduled classroom-style training, bespoke training to suit customer requirements as well as one to one mentoring for any of our customers around Australia and New Zealand. Our Solid Edge training courses are created with the aim to get participants up to speed with current industry software quickly and effectively, giving you and your company the competitive edge.

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Simcenter Amesim 2019.1: top 4 reasons to upgrade


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We are proud to introduce Simcenter Amesim 2019.1

 

With this version, we accelerate the software delivery model to provide access to new enhancements every 6 months, while maintaining focus on the technical excellence.

 

The latest release helps you build digital twins faster and earlier in the design cycle by democratizing access to system simulation. By further extending Modelica® support and integration with other Simcenter solutions, version 2019.1 enables you to set up a unique toolchain throughout various development phases and teams.

 

Among many other enhancements, new capabilities in Simcenter Amesim 2019.1 focus on the 4 main areas:

  • vehicle electrification,
  • aircraft systems performance engineering,
  • controls engineering
  • system simulation efficiency and ease of use.

Find out top 10 functionalities in 3 minutes:

 

 

Let us walk you through the major new capabilities in these 4 areas.

 

 #1 Vehicle electrification

 

  • Simcenter Motorsolve model import
  • Simcenter Battery Design Studio import for equivalent circuit battery models
  • Ready-to-use air cooled battery pack demonstrators

Many industries, such as automotive, aerospace, off-highway and marine, are making the shift toward e-mobility. After introducing the capability to import from Simcenter SPEED in the previous release, the latest Simcenter Amesim version reinforces its integration with other Simcenter solutions that support electrification challenges.

 

Simcenter-Amesim2019.1-Simcenter-Motorsolve-import.png

 

Using the same app for linear and nonlinear variants, you can import permanent magnet synchronous motor (PMSM) parameters from Simcenter Motorsolve to test your machine in the vehicle context earlier in the design cycle. 

 

Find out more in this blog post.

 

 

Moreover, battery equivalent circuit models from Simcenter Battery Design Studio can be imported into Simcenter Amesim 2019.1 to obtain a shared battery model. You can visualize parameters of the imported model before using them in Simcenter Amesim. For more details, read this article

 

New demonstrators allow you to easily re-use the complete battery pack model based on geometry, identify critical temperatures for controls design, apply a documented methodology for model reduction as well as integrate the reduced battery model into your vehicle energy management analysis.

 

 

#2 Aircraft systems performance engineering 

 

  • Upgraded CAD import capabilities for fuel systems
  • Enhanced postprocessing apps and scaling tool for aircraft engine and gas turbine
  • New rotorcraft engine demonstrators with the recuperated cycle and series hybrid variant

To support the aerospace industry, the latest release of Simcenter Amesim comes with upgraded CAD import Simcenter-Amesim-2019.1-CAD-import.PNGcapabilities that enable users to easily create rib submodels and generate all the required tank and rib data files. Therefore, you can drastically reduce the time required for creating data files and organizing your output files. Moreover, the new rib submodel allows users to account for flowing areas, speeding up parameterization while improving accuracy.


By using the enhanced postprocessing apps and scaling tool when exploring new gas turbine configurations, users can easily derive scaled performance maps starting from reference maps and looking at the surge margin.

 


Users can benefit from two rotorcraft engine demonstrators that are derived from a validated engine model. The first derivative is a recuperated engine cycle and the second is a series hybrid variant assessed during an oil and gas mission.

 

 

#3 Controls engineering

 

  • Extracting a nested signal bus
  • New tool for proportional–integral–derivative (PID) controller calibration
  • New real-time components for thermal and valvetrain systems

With the industry shift towards connected, software-intensive, complex products, Simcenter Amesim 2019.1 offers a large set of new or enhanced capabilities for controls design and validation to enable you to simultaneously optimize the mechanics, electronics and software as an integrated system.

 

You can now use signal buses to manage data transfers between physical subsystems. This redesigned capability facilitates visualization of all data flowing through any given bus component and simplifies information propagation across nested buses.

 


In addition, the latest release comes with a new tool for PID controller calibration, which is associated with two demos for speed and position control. Hence, you can visualize closed-loop step response and check the robustness with stability margins. 

Whether you are a system designer who just wants to quickly make the PID controller work, or a control expert interested in stability margins, find out the step-by-step process in this article

 

 

Additionally, new real-time components of thermal and valvetrain systems will allow you to greatly reduce CPU time and run hardware-in-the-loop (HiL) simulations.

 

#4 System simulation efficiency and ease of use 

 

  • New Modelica compiler and full Modelica Standard Library (MSL) v3.2.2 support
  • Model conversion from hydraulic to thermal-hydraulic domain
  • Two-phase flow thermodynamic cycle analysis app 
  • Valve builder

To boost the efficiency of your system simulation activities, Simcenter Amesim now offers you full MSL 3.2.2 support and greater openness thanks to Modelon’s compiler, which is integrated into this Simcenter Amesim version. You can easily couple Modelica and native Simcenter Amesim library components: Using Modelica Editor enables you to automatically import Modelica models into Simcenter Amesim and get the best of both.

 

 

Moreover, existing hydraulic models can be converted into thermal-hydraulic models with one click while maintaining model structure and parameters. 


With a new app for two-phase flow thermodynamic cycle predesign, within just a few seconds you can assess steadystate cycle performance by adapting your design points from predefined cycles. Watch how this app works in the demo here. 


Finally, the latest improvements in valve builder functionality allow users to create pilot-operated directional valves and connect them to the hydraulic or pneumatic pilot stage, as well as integrate nonreturn valves into the design of your directional valve to avoid unnecessary volumes and dynamics.

 

 

Stay tuned

 

Those are only a few of the major capabilities introduced to Simcenter Amesim 2019.1. For instance, a large set of capabilities has been introduced for shipbuilding as well as for internal combustion engine vehicles helping automotive manufacturers to meet the RDE standard. 

 

Want to know more?

- Don't miss our blog posts and how-to articles

- Contact your local Siemens PLM office

- Upgrade your Simcenter Amesim license

 

 

Turning up the heat: ensuring efficiency in high temperature processes

Humans have used fire for thousands of years. From cooking meat to make it easier to eat and digest, to firing pottery to make watertight containers, to managing grass or moorlands through controlled burning, fire has been a vital tool for many aspects of human existence. These days, combustion is used in many industrial processes. These may be less visible to the general public, but are essential to produce materials and products used by everyone on a daily basis. Coal burners, dryers and kilns, and steel furnaces are just some of the areas where high temperature processes and combustion are used.

 

GettyImages-178607562.jpgIndustrial gas furnaces are used in many chemical processes

Today, process engineers must ensure these high temperature processes are as efficient as possible: inefficient processes lead to costly and excessive energy consumption, with the potential of excess emissions and non-optimal product yields. The use of Computational Fluid Dynamics (CFD) to virtually investigate high temperature processes is now an established design tool in many industries, including the process industry, but are you using it to its full potential?

 

This on-demand webinar takes a look at recent advances in simulation capabilities in Simcenter STAR-CCM+, which make simulation and optimization of combustion processes even easier. Our technical experts will cover:

  • Recent advances in CAD maneuverability for geometry setup
  • Different reaction modeling approaches available in Simcenter STAR-CCM+
  • Combining CFD and design space optimization for intelligent geometry optimization

HighTempSim_1980x1080.jpgOptimize burner geometry via simulation

Successful use of simulation is enabling process engineers to reduce design costs and create innovative, efficient designs. Join us to learn more, and discover how CFD can help to optimize your high temperature processes.

Simulation Automation

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There’s no doubt about it: simulation is delivering value in product development.

 

Some are avoiding multiple rounds of prototypes. Some are reducing the cost of goods in products. Some are making designs both lighter and stronger simultaneously. Some are coming up with more innovative designs that work functionally. Overall, many companies are reaping the benefits of applying simulation early and throughout the design cycle. And if there are any issues with simulation, it’s that managers seem to want more.

 

So how can an engineering team get more productivity out of their analysis tools? One clear answer is automation. It removes repetitive tasks from users hands, allowing them to concentrate on the value-added aspect of simulation. It also promotes standard best practices across a company. Here are some capabilities that do just that.

 

Macros

 

One of the most simple, yet valuable, ways to automate a simulation process is to leverage macros.

The idea is straightforward. A user can record a sequence of user interface interactions, such as selecting menu options or entering values. This sequence of actions is then mapped to a trigger, often a specific combination of keyboard keys or mouse buttons. Then, whenever the users want to initiate that sequence of actions, they simply hit the trigger.

 

This approach provides the most value when applying repeated actions within the same model. It reduces repetitive work for the user. However, it also eliminates any potential human error likely to occur in a heavily repeated action. Furthermore, executing macros happens very quickly, far faster than the sequence of actions could be executed by hand. Lastly, macros are an opportunity to apply analysis standards across a company.

 

In all, macros allow users to avoid repetitive work, reduce human error, accelerate their simulation processes, and distribute analysis standards.

 

Templates

 

Where macros automate repetitive tasks within a simulation model, analysis templates automate entire sets of tasks by offering an accelerated starting point.

 

Analysis model templates include standards that should be included in all simulations of that type. For some cases, a template might include a parametric model of a pump that has already been meshed to the correct level of detail. For other cases, a template might include standard loading cases based on data collected from physical tests. For yet others, a template might encompass all of the standard materials and their properties that are officially approved by a company.

 

Templates, however, do not just apply to entire models. Loads and boundary conditions can be applied as templates. Solver selections, method selections, and their corresponding parameters might be included in a template.

 

The value in templates is also straightforward. Templates simply allow users to avoid creating everything from scratch. They start their process several steps farther than a clean sheet. But just as importantly, templates are another way to distribute best and standard practices within a company.

 

Simulation Workflows

 

A different kind of automation builds on top of templates. Simulation workflows apply the concept of workflows to simulation.

 

The idea here is that each analysis template requires several inputs to be run. Once those are provided, the simulation can be solved, producing a number of outputs. With simulation workflows, the outputs from one analysis is fed as inputs to another analysis. This chain of simulations can be used to connect disparate types of engineering physics that are interrelated. For example, a fluids dynamics analysis of a wing would yield loads that are then passed on to a structural analysis of the internal stringers. In another example, a complex combustion analysis of a turbine engine would pass temperature fields to a structural analysis of a turbine blade.

 

Such simulation workflows can be used to automate very complicated analyses, but they can also provide guidance to novice users as well. They simply ask for standard inputs and produce standard outputs that can be interpreted.

The value here is more advanced than in other cases. Expert users can automate an entire complex simulation process. Novice users get guidance on how to complete a range of analyses, ranging from the simplest to incredibly complex. Both use cases deliver value.

 

Application Extensions

 

The last, but not least important, means of automating simulation is through application extensions.

Here, a company will build out new functionality by coding software extensions to an analysis application. This is done using an Application Programming Interface (API) toolkit, which often is an externally available version of the code used to build the analysis application by the software provider.

 

This toolkit can be used to build brand new functionality on top of the solution. This functionality can dramatically automate simulation processes and procedures. It can add completely new interfaces such as dialog boxes and menus. It can tweak or modify how the application prepares models and passes them to solvers.

 

The toolkit can also be used to integrate with specialized homegrown simulation tools. Doing so allows data and other information to be passed back and forth between the applications. This is applicable when the company is dealing with custom calculations, ranging in complexity from programmed spreadsheets to their own internal software.

 

The value here is strong. Companies that seeking new ways to automate the simulation process has an opportunity to build it the way they want with the API. Companies with custom applications for specialize calculations can wrap their work into the simulation software.

 

Recap

  • Companies that are looking to get more value out of simulation can look to automation, which comes in a variety of flavors.
  • Macros allow users to record and then execute a sequence of actions through a trigger. This is of value to users repeatedly applying the same actions within an analysis model.
  • Templates allow users to accelerate their simulation process, applying and reusing prior analysis work.
  • Simulation workflows stitch the output of one analysis to the input of another, enabling the automation of several interconnected simulations.
  • Application extensions add new capabilities to existing tools by coding with the software’s API toolkit. This is an opportunity for automation or integration with a company’s custom analysis application.

Automation can provide a lot of additional value to companies already leveraging analysis. What has your experience been with simulation automation? Let me know your thoughts in the comments.

 

Siemens PLM provides a range of capabilities that directly address automation of modern simulation processes. For more details on how FEMAP addresses these needs, download our complimentary eBook.

Electric vehicle NVH challenges: The mindset and tools you will need

 

 

The question of the day is – would you buy an electric vehicle (EV) today?


Maybe. Although, during the upcoming years, you are more likely to answer: “Yes!”. Let’s face it. Avere, the European association for electromobility, estimates that there are already 1 265 441 passenger electricity powered cars driving around the Europe, using 161 426 public charging points. And both numbers will increase in near future. Countries world-wide are introducing the mobility visions promoting and supporting electric cars (e.g. Electromobility in Germany: Vision 2020 and Beyond,etc.). According to Bloomberg New Energy Finance, 55% of all new car sales and 33% of the global fleet will be electric by 2040.

 

Electric car development hits bumps in the road


However, there are also some important bottlenecks that cause reluctance to switch to electric cars. One of the most important is the driving range of the electric vehicles. The EV development teams strive to reduce the vehicle weight to increase the driving range. But reducing weight of the vehicle chassis and body is not given! Finding the optimal balance between vehicle weight and performance attributes, such as durability, NVH, ride and handling, becomes more important than ever. Yes, you need to increase the driving range, but on the cost of reduced durability performance that could lead to earlier vehicle damage. Also, reducing vehicle weight can deteriorate handling performance. It means your vehicle may lose stability when performing certain driving maneuvers.


Here is another engineering dilemma - how do you balance the vehicle body stiffness while keeping up with the right NVH characteristics? At Siemens Simcenter, we recognize these challenges and we aim to provide our customers with solutions for different vehicle development teams to tackle all these problems and help to find optimal lightweight vehicle conditions without loss in performance.
What are the other electrical cars development shifts?

 

Simcenter Sound Camera for EV Development.jpg

 

Electric vehicle noise in the spotlight

The trend towards electrical vehicles poses both challenges as well as opportunities for car developers. The absence of the internal combustion engine (ICE) changes the signature of the interior cabin noise dramatically. The most obvious game changer is the fact, that the withdrawal of the traditional powertrain unveils the other noise contributors or make them more audible and prominent. In 2011, G. Goetchius (Leading the Charge – The Future of Electric Vehicle Noise Control, Sound & Vibration) estimated the noise contributors in ICE vehicles and predicted the noise morphology in the electrical ones. According this publication back then, in the traditional ICE vehicles, the biggest noise contributor is the powertrain followed by the road, wind and ancillary system noise. While in electrical vehicles, the road noise and wind are the most dominant noises. And what’s more, the new structure reveals noises that were originally masked by the combustion engine (such as ancillary system - whine gears, steering rack, air conditioning system, wipers, ABS module, pumps etc.).

 

EV vs ICE vehicles NVH challenges.jpgEV vs ICE vehicles NVH challenges

 

Without any surprises, the structural changes in electric vehicle noise will need new engineering approaches to optimize the NVH performance with appealing sound quality.
Here are three strategies you should focus on to make the ride in your electrical vehicle to sound as a symphony.

 

Act on the present noise source

Firstly, you may need to find the noise root cause and act on it. Depending of the origin of the noise source, different NVH analysis techniques are required. Reducing wind noise, for instance, happens most effectively in wind tunnels. These allow to effectively isolate the wind noise from other noise sources and find the most effective measures to reduce this annoying source. However, as these tests are extremely costly, it is crucial to test with extremely efficient measurement techniques. The use of industrialized testing processes based on large beamforming arrays that allow identification of the exterior noise sources, and use this data to decide what to test next, becomes more and more a reference.

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Road noise needs to be handled with effective and reliable techniques, such as transfer path analysis (TPA). This technique allows to pinpoint the noise critical paths on the chassis and car body contributing to the interior noise. To be able to handle the complexity and closely spaces loads of suspension systems, more advanced techniques such as strain-based TPA becomes another necessary building block.

For other auxiliaries, the key information can be provided by wide toolset of NVH tests and analysis techniques. And again, for many of these subsystems the traditional transfer path analysis (TPA) can help to identify the component or structure causing the noise issue.
Acting on the noise source, however, does not always provide solutions early enough. In case it is not too late in the vehicle development cycle, the responsible team can proceed with component design adaptations and improvements. But in real life, there are situations, when design adaptations are impossible or cause conflict with other attributes (such as weight, durability, etc.). Or often, the results of the TPA leads to pragmatic and expensive additions of damping and trimming to the vehicle. The disadvantage is that damping material increases the vehicle weight - which will directly reduce the vehicle range, add extra cost and prolong the vehicle assembly. What’s more, this strategy is limited and doesn’t offer an optimal solution in all the cases.

 

Master the electric vehicle sound quality including active sounds

There is good news. The shifted noise structure of the electric vehicle brings an option to add new noises. This opens an opportunity to create new and pleasant driving experience for your customers. From this perspective, sound quality engineering is the key tool to develop high-performing sounds within the vehicle. This technology is currently gaining ground in the automotive industry.
It all starts with the acquisition of realistic sound data, including for instance binaural recording. Secondly, to be able to analyze the acquired sounds, you can proceed with audio replay, using different filtering and analysis through different sound quality metrics. And finally, you shall organize a Jury testing, which is based on subjective audio perception. Sound quality engineering combines objective analysis metrics with subjective analysis. This strategy will provide you with detailed insights to find answers to questions like – what do the customers like to hear? What sounds do they prefer in different corners of the world?

 

Simcenter Testlab Neo Jury testing.jpgSimcenter Testlab Jury testing for EV NVH development

Another application, where sound quality is currently gaining importance, is the exterior artificial sounds generated by the acoustic vehicle alerting system (AVAS). This system warns pedestrians of an approaching vehicle. Developing new exterior warning sounds is something of a novelty. Different countries around the globe currently impose new certification requirements for electrical cars. Car producers need to design and certify warning sounds that the electrical cars must exceed traveling at low speeds.  Anc at the same time, automotive OEMs are highly concerned about the perception of the new vehicle sounds. Designing new artificial sounds that reflect the brand DNA requires the right toolset for sound quality engineering.

 

Speed up vehicle development time by blending simulation and testing together

To keep up with the market, automotive OEMs need to react fast and develop advanced vehicle models rapidly. This creates the need to take control of the vehicle NVH performance as quickly as possible, earlier in the development cycle ever. This translates into the demand to be able to predict the component or subsystems behavior before integrating them into the vehicle. In practice, this also leads to introduction of new technology that merges the simulation and physical testing together throughout the vehicle development cycle. While in the past simulation and testing where two separate worlds, the future evolves more into hybrid approaches. This concept can drastically impact and improve the development time.
Component-based TPA is one example (here you can find a related white paper). The compelling combination of test and simulation enables the NVH engineers to predict the final vehicle NVH performance before assembling the first full prototype. In a nutshell, this technology enables you to predict a component or subsystems behavior prior to integration. Consequently, it enables the dream to create a virtual vehicle prototype by assembling different components (e.g. electrical engine, suspension system, body, etc.). Component-based TPA is very powerful concept not only because you may get an accurate prediction of the vehicle NVH behaviour in development stage, when implementing design improvements is still easier. But also, the component-based TPA enables you to work with a standardized platform to virtually assembly countless vehicle variations with much lower time investments.


Another example is the trend to combine 1D simulation and test in a more hybrid approach, so called Model-based system testing (MBST). With MBST technology, the use of physical component in combinations with 1D models becomes more and more the industry standard. 

 

Simcenter EV NVH testing.jpg

 

These are the key trends in NVH testing that will drive electrical vehicles development in near future. Besides, it is important to realize, that is not only the product changing. It is also the OEM’s frame-work that will change soon too. There will be new requirements and expectations that team members will have to fulfil and skills the engineers will need to learn.
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Testimonials

“Using Solid Edge with synchronous technology I can actually do many more iterations now that I wasn’t able to do before. And because of that, the cost of the product comes down. The weight of the product comes down. The performance goes up. The warranty is a lot longer. Quality loves it. We love it. The profit margin loves it.”
John Winter , Mechanical Engineering Manager, Bird Technologies
“Siemens’ synchronous solver overcomes the order dependencies that have plagued history-based CAD programs by solving for the explicit and inferred constraints at the same time. The synchronous solver doesn’t use a history tree, but rather holds user-defined constraints in groups associated with the surfaces to which they apply…Ultimately, though, I believe this to be a transformative technology – one that represents an important inflection point in the CAD industry. If you hear someone say ‘that’s nothing new,’ don’t believe them. Synchronous technology is a big deal.”
Evan Yares, CAD Industry Analyst
“Synchronous technology breaks through the architectural barrier inherent in a history-based modeling system,” “Depending on model complexity and how far back in the history that edit occurs, users will see dramatic performance gains. A 100 times speed improvement could be a conservative estimate.”
Dr. Ken Versprille, PLM Research Director, CPDA
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