Design Space Exploration For Every Expertise: Pseven Introduction For Automotive Industry

DESIGN SPACE EXPLORATION FOR EVERY EXPERTISE
pSeven introduction for

Automotive industry
ableMAX
ableMAX | Engineering Total Solution Service
CAE TOTAL SOLUTION ableMAX
http://www.ablemax.co.kr
Data Analysis
Surrogate model
Surrogate model
Optimization

Automotive examples


pSeven
Software Developer AIRBUS Group

A global leader in aerospace
industry.
Institute for Information Transmission
Problems of the Russian Academy of
Is a joint venture company between AIRBUS Group
Sciences
and private Groups Spin-off Academics Russia
One of the leading mathematical centers
Evolved out of a collaborative research program
in Russia
between

Customer
pSeven is industry-proven solution: Current users base
4
pSeven
Generic Tools
Approximation Optimization
Design of Data Fusion Dimension Important

Experiments reduction variables

pSeven
Approximation

.
()
Data , ,

.
Optimization
CAD/CAE
.
,
.
6
pSeven
(Sensitivity)
(X) (Y)

data

.
7
pSeven
Data Fusion
Data set data
set .
alpha angle
Simulation Data Data
.
Measurements data
Mach number
.
Adaptive DoE(Design of an Experiment)

Data Analysis
Surrogate model
Surrogate model

Data analysis : Surrogate Model
- X Y .
- A B .
- , Data .
Surrogate Model
?
Real Data
()
pSeven Surrogate Model ()

Data Point .
Data Point 2d_in+2

Data analysis : Surrogate Model
Approximation Techniques Surrogate model export
Training
Data
MACROS surrogate model can be import
to
- Human readable format

Test Data (Matlab/Octave)
- Standalone application (C, C++,
JAVA source code)

Data analysis : Approximation techniques
Approximation techniques
High Dimension Approximation
Splines
(HDA)
Polynomial
Sigmoid functions
ANN
- intern al nod e
- inp ut/output no de
AUTO
. . . . . . . . . . . . . . . . . . . . .
Option Tensor Approximation
Input vector Output vec tor

(n numbers ) (n numbers )
Middle layer
(m num bers )
Input layer Middle layer Output layer Surrogate model

F (x)
RBF Radial Basis Function
Multi regression
Kriging / Gaussian Process
Automatic decision tree

Save time in expertise
Data analysis : Surrogate Model (1)

Surrogate model ()
Surrogate Model
- , , Data .
- Data , , .
- , , , .

Data analysis : Surrogate Model (2)
Predictive maintenance / Diagnostic
Analyze signal pattern and early detection of events
Life Time Prediction for component equipments
Significant cost savings reached

Minimize service interruption and non planned maintenance

Data analysis :
pSeven Surrogate Model
Automatization & Decision

- (Embedded intelligence) , .
- Auto Option Approximation Method .
- Methods & Algorithms

- pSeven Method .
- 1000 , 1000 .
Scalability
- Matlab C .
- Data .

Data analysis :
Automatization & Decision

- (Embedded intelligence) , .
- Auto Option Approximation Method .

Data analysis :
- Methods & Algorithms

- pSeven Method .
- 1000 , 1000 .
X Input
Y Output
Variables of
Constraints of
X input + Y output dimensions 500
Number of samples 100 000
Time CPU for training: 4 hours on a standard laptop !!
17
Data analysis :
Scalability
- Matlab C .
- Data .
18
Optimization

Optimization
?
best values
.

Optimization
Sample : a linear objective function

Optimization : MDO

Single-objective problem Multi-objective problem

- one objective - multiple conflicting objectives
- no uncertain parameters - yet no uncertain parameters
- most preferable and simple to solve - hard to solve and analyze

Optimization : MDO, SBO, RO
Optimization interesting features
Multi Objectives Optimization

Best for Objective F1
Infeasible
Surrogate Based Optimization
Mass F
region
objective 2 Feasible region
Compromise
Best for
Objective F2
Better
cost
Better objective
Robust Stochastic Optimization
Nominal
maximum
Robust
maximum
Uncertainties

Optimization : process
process

Optimization : Process Integration
Process Integration in pSeven : design process

Optimization : techniques
F(X) Initial Guess /
MACROS GT OPT Starting Point
Newton
Quasi Global
Optimum
Steepest Newton Local
Optimum
Gradient AUTO Surrogate X
Option Based
Optimization
Derivative Free
Automatic decision Optimization Optimization
tree of optimizers techniques
Save expertise time Robust
Optimization
Multi-objective
SQPCP Constrained Adaptive Filter SQP gradient based Optimal
Quadratic Programming Sequential Quadratic Descent
Programming

Optimization :
Why GT opt in pSeven?
Integrated part of pSeven : use GT Approxmodels in optimization

Modern optimization algorithms: GT Opt automatically chooses the most
appropriate for the task
Gradient-based methods (use analytical, numeric and framed gradients)
Primary aim: reduce the number of user function calls
Easy multi-objective optimization
Surrogate optimization global surrogate and iterative surrogate based

Automotive industry

Application of Simulation in Automotive Industry
Valves & regulators Cylinder head cooling Transmission Crash
External aerodynamics
In-cylinder
flows
Batteries
Engine manifold
Electric traction motor
Throttle
Exhaust
& aftertreatment
Turbocharger Steering &

& pumps Filters suspension Brakes & squeal HVAC Tires

pSeven Application Scenarios
Problem Hard to find the best product in a big number of design variables
Solution Design Optimization:

Define input and output parameters in a simulation or analytical model
Run optimization cycles to evaluate the best input and output parameters
Benefit Find the best product design parameters
Simulation Parameters Optimization

Problem Unstable product behavior due to variability of input parameters
Solution Robust Design Optimization:

Define input and output parameters in a simulation or analytical model
Define distribution (variability) of input parameters
Run optimization cycles to evaluate input parameters that gives the most robust output
Benefit Design reliable and robust products
Simulation Parameters Distribution Optimization

Problem Expensive test rig experiments
Solution Test rig data analysis:

Create surrogate model from experimental data series
Explore surrogate model to predict product behavior in different conditions
Benefit Reduced number of test runs
Experiment Data Surrogate model Analytics

Problem Expensive wind tunnel experiments and time-consuming simulations
Solution Predictive modeling with Data Fusion:

Create surrogate model of a product from various simulation, analytical and/or experiment
data series
Explore surrogate model to predict product behavior in different conditions
Benefit Reduced number of experiments/simulations
Simulation
Surrogate model Analytics
Experiment

Problem Growing need for systems modeling
Solution Surrogate models for co-simulation:

Create surrogate model of a product from simulation, analytical and/or experimental data
Import surrogate model to systems modeling software in C or FMI format for co-simulation
LMS Amesim, ANSYS Simplorer, SimuLink, MapleSim, SimulationX etc.)
Benefit Fast systems simulation and optimization
Simulation Surrogate model Export System model

Problem Preserving IP rights
Solution Black-box surrogate model:

Create surrogate model of a product from simulation, analytical or experimental data
Send model in C, FMI, Excel or native format to contractor to develop auxiliary equipment
Benefit Contractor gets the results safely and fast
Surrogate model
Product model Contractor
Export
Problem Hard or impossible to determine unknown system parameters
Solution Model identification (data matching):

Run experiment and collect data
Create simulation or analytical model with unknown input parameters (damping, friction, etc.)
Set up residual check and run optimization to match predictive and experimental data and
dentify unknown input parameters
Benefit Less expensive research and more reliable simulation
Experiment Data Simulation Input

Problem Unknown causes of production failures
Solution Production data analysis:

Collect data series describing production process and failure rate
Run sensitivity analysis to identify input parameters and/or their combinations that affect fa
ure the most
Benefit Problem identification and less failures
Production Data Analytics

Problem Underused and underrated data from in-operation sensors
Solution Predictive modeling and data analysis:

Collect data series describing exploitation process and failures
Run sensitivity analysis to identify input parameters and/or their combinations that affect
failure the most
Create and explore surrogate model to predict product behavior in different conditions
Benefit Understand how to improve the next generation design
Exploitation Data from sensors Analytics Surrogate model Analytics

Problem Equipment goes out of service before scheduled maintenance
Solution In-operation data analysis for Predictive Health Management:

Create predictive models from data series describing acceptable exploitation process
and failures
Compare predictive models with real-time exploitation data to predict failures
Benefit More operational time and less repairs costs, shift from scheduled to predictive
maintenance
Train data
Exploitation Predictive models Health monitoring
Exploitation data

Problem SPDM systems collect valuable data, but its not used
Solution Predictive modeling and data analysis:

Run simulations and collect data in SPDM system
Create predictive surrogate models and perform data analysis in pSeven
Benefit Extra insights from data for next product design cycles
SPDM pSeven
Surrogate Analytics
Simulation Data model

Problem Growing need for engineering software democratization
Solution Run-ready workflows:

Create workflow with pSeven license
Deploy workflow into the product development process for less experienced users
Change inputs, run workflows and get outputs without the ability to change workflow itself w
ith pSeven Runner license
Benefit Increase efficiency and save time of experienced users
User 1 Workflow User 2 Results

Problem Growing complexity of product development cycle
Solution Collaborative workflows:

Create workflows with global inputs and outputs
Import them to another workflow as a composite block (template)
Benefit Enhanced collaboration between engineers and different departments
User 1 Workflow
User N+1 Workflow
User N Workflow
pSeven Application Examples
Optimization of external aerodynamics using simulation,

analytical and/or experimental data to reduce drag
Optimization of radiator and heat exchangers geometry to

reduce size and maximize heat transfer
Optimization of vehicle body elements to reduce weight

and minimize NVH
Optimization of impellers in the turbocharger to maximize

efficiency
Optimization of exhaust systems to reduce drag and

minimize NVH

Optimization of catalytic converter geometry to reduce
emissions by enhancing aftertreatment
Optimizing electric motor efficiency in different operating

conditions
Sensitivity analysis of geometry parameters and robust

optimization of breaks to reduce squeal
Optimization of HVAC systems to enhance temperature and

moisture comfort
Optimization of car seats structures to reduce weight and

improve reliability

Optimization of cams geometry in camshaft with d

imension reduction to enhance shape of lift, veloci
ty, acceleration and jerk curves and also dozens o
f other characteristics in valve train
Optimization of valve and intake/exhaust channels

geometry with dimension reduction to enhance in-
cylinder flows
Optimization of piston head geometry with dimens

ion reduction to enhance combustion

Use Case: Predicting Lift and Drag in a Formula 1 Car
Objective
Predict lift and drag in a Formula 1 car to improve car control s
trategies
Create Fast and accurate model of aerodynamic forces applie
d to a Formula 1 car
Challenges
Small database of available experiments as a base for model c
reation
Solution
Surrogate modeling methods applied
Several models created, their accuracy and robustness estima
ted
Result
Most accurate models predict lift coefficients with mean error <
0.007 and drag coefficient with error < 0.002
Models converted into several different formats including
Matlab/Octave and C++ functions

Use Case: Accelerated Fitting of Tire Dynamics in Formula 1
Objective
Accelerate fitting of tire dynamics for Formula 1 cars
Customer fitted the model with 80 parameters in ~20 ho
urs -> Reduce the fitting time to ~1 hour
Challenges
Dynamics of tires in Formula 1 cars described by Pacej
kas Magic Formulacontaining 80 free parameters
Parameters depend on specific driving conditions and c
an be fitted using track data
Solution
Calibration performed in pSeven
Original Excel implementation of Magic Formula identifi
ed as a bottleneck and replaced with a fast C++ implem
entation
pSevens Generic Tool for Optimization applied
Result
Fitting time reduced to ~10 minutes: more than 100 tim
es faster!
Use Case: Formula 1 Car Side Panel Design
Objective
Minimize mass of a side panel exposed to impact loads
Challenges
Impact data coming both from tests and simulations
Layered panel material makes the problem discontinuous
Solution
Create surrogate model using all available experimental and
numerical data (data fusion) and optimize it
Result
10% mass reduction with less number of simulations and full
scale experiments

Use Case: Optimization of Bus Suspension Beam Geometry
Objective
Beam mass minimization
Complying constrains on stresses and strains for two load ca
ses:
vertical loading
braking
Details
13 parameters are varied
Problem has 8 constrains
Geometry is prepared in PTC Creo
Stresses and strains are calculated in ANSYS Mechanical
Results
Mass is reduced by 6% (from 55 to 52 kg)
Number of iterations 450

Use Case: Optimization of IGBT Cold Plate
Objective
Find an efficient heat exchanger design
Details
10 input parameters:
Geometry of pins pattern has 6 parameters
Inlet flow rate and temperature
IGBT and diod heat rate
3 output parameters:
Maximum temperature to prevent electronics damage
Flow drag force for less fan power and battery charge saving
Temperature variation to provide equal lifetime i.e. service interval
FloEFD is used for CFD simulation
Challenges
Time of one simulation is 1.5 hour on 8 cores
Result
Pareto frontier is constructed with 120 simulations,
from which an optimal design was chosen
50
Why pSeven?
Academic-level algorithms in commercial software:
Complete set of tools for Design Space Exploration
State-of-the-art algorithms and techniques for uncertainty management,
sensitivity and dependency analysis, surrogate modeling and multidisci
plinary design optimization packed into user-friendly graphical interface
Powerful process integration platform:
Direct integration with SolidWorks, CATIA, PTC Creo, Siemens NX, AN
SYS Workbench, FloEFD, Excel and integration via external file with al
most any other engineering software (Abaqus, MSC etc.)
Capturing of complex project schematics and creating run-ready workfl
ows for further deployment
Democratization:
Creating surrogate models from simulation, analytical and/or experime
ntal data that are easy to use
SmartSelection technology implemented in pSeven allows even non-en
gineers to use advanced mathematics in their product development pro
cesses

Thank you

Design Space Exploration For Every Expertise: Pseven Introduction For Automotive Industry

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DESIGN SPACE EXPLORATION FOR EVERY EXPERTISE

pSeven introduction for

ableMAX | Engineering Total Solution Service

Software Developer AIRBUS Group

ableMAX | Engineering Total Solution Service

Design of Data Fusion Dimension Important

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

pSeven Surrogate Model ()

ableMAX | Engineering Total Solution Service

- Human readable format

ableMAX | Engineering Total Solution Service

Input vector Output vec tor

Input layer Middle layer Output layer Surrogate model

RBF Radial Basis Function

Kriging / Gaussian Process

Automatic decision tree

ableMAX | Engineering Total Solution Service

Analyze signal pattern and early detection of events

Life Time Prediction for component equipments

Significant cost savings reached

ableMAX | Engineering Total Solution Service

Automatization & Decision

- Methods & Algorithms

ableMAX | Engineering Total Solution Service

Automatization & Decision

ableMAX | Engineering Total Solution Service

- Methods & Algorithms

X input + Y output dimensions 500

Number of samples 100 000

Time CPU for training: 4 hours on a standard laptop !!

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

Single-objective problem Multi-objective problem

ableMAX | Engineering Total Solution Service

Multi Objectives Optimization

Robust Stochastic Optimization

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

Integrated part of pSeven : use GT Approxmodels in optimization

ableMAX | Engineering Total Solution Service

ableMAX | Engineering Total Solution Service

Valves & regulators Cylinder head cooling Transmission Crash

Electric traction motor

Turbocharger Steering &

ableMAX | Engineering Total Solution Service

Solution Design Optimization:

Benefit Find the best product design parameters

Simulation Parameters Optimization

ableMAX | Engineering Total Solution Service

Solution Robust Design Optimization:

Benefit Design reliable and robust products

Simulation Parameters Distribution Optimization

ableMAX | Engineering Total Solution Service

Solution Test rig data analysis:

Benefit Reduced number of test runs

Experiment Data Surrogate model Analytics

ableMAX | Engineering Total Solution Service