LEVERAGING DIGITAL TWIN BASED TECHNOLOGY TO MEET LIGHTWEIGHTING GOALS
- 1. Confidential Property Copyright Information: © 2019 Caresoft Global. This document may contain confidential information pertaining to strategic plans, data and business relationships between Caresoft Global and its customers. This document is provided only for the intended recipients . Please do not distribute or copy the content in any form without a written authorization from Caresoft Global. Digital Twin Benchmarking using High Energy Scan Technology
- 2. Confidential Property Disclaimer 2 This document is for the intended recipient(s) and the organization employing the recipient(s) (“Organization”) only. No part of this document in whole or in part shall be shared with any third-party apart from the recipient(s) and the Organization. Caresoft Global Inc. and all its operating units, subsidiaries, and its authorised representatives claim no responsibilities and/or obligations of any kind against any harm or perceived harm caused to the recipient and the Organisation by sharing this document in whole or in-part to parties other than the intended recipient(s). Caresoft Global Inc. and all its operating units, subsidiaries acknowledge the rights of all the registered trademarks and names used in this document. Caresoft Global Inc. and all its operating units do not claim affiliation or arrangements of any kind with the OEM of the vehicles referred in this document. By reading the contents of this document, storing, and distributing this document, the intended recipient is understood to have agreed to the terms in this disclaimer.
- 3. Caresoft Global Confidential Today’s Agenda 3 ❑ Caresoft – Who we are? ❑ What is High Energy Scan Technology? ❑ What is the impact of High Energy Scan Technology in Automotive Sector? • Digital Twin Methodology • Analysis & Simulation • Electric Vehicle Technology • Light Weighting • Cost Optimization
- 4. Caresoft Global Who we are?
- 5. Confidential Property About Caresoft Founded in 2007 Headquartered in Detroit 2000+ Engineers ISO / IEC 27001:2013 Information Security Management Systems ISO 9001:2015 USA UK France Germany Italy Sweden Brazil Mexico Belgium Austria India China South Korea Japan UAE 5
- 6. Confidential Property Caresoft’s Business Pillars – Products & Services 6 Helps in Benchmarking, Cost reduction & Design Optimization Technology Products Digital-Twin Technology Cost Reduction Analysis Benchmarking and Cost Reduction HE Scan CAD CAE Teardown Analysis Idea Generation for Cost Reduction Technical Review Sessions Product Development Engineering Solutions Mechanical CAE Manufacturing Technical Information Virtual Reality Electrical Technical Placement
- 8. Confidential Property Current Methodology 8 Teardown Photos of Systems Optical Scan Key Systems Manufacturer Information Material Information Vehicle Picture Package Optical Scanning Vehicle Measurements Weighing PRE-TEARDOWN TEARDOWN Traditional Way Pre-Teardown Document Teardown Optical Scan
- 9. Confidential Property Limitations of Current Methodology 9 ▪ No actionable intelligence ▪ Data limited only to photographs, Bill of materials and elementary optical scan data sets ▪ No notes on strategic choices made by OEMs ▪ Non existent advance engineering data – CAD and Analysis ▪ OEMs cannot decipher costing data Traditional way Traditional way
- 10. How has Caresoft Changed the Game?
- 11. Confidential Property Benchmarking using High Energy Scan Technology 11
- 12. Confidential Property Post-processing of High Energy Scan Output 12
- 13. Confidential Property Post-processing of High Energy Scan Output 13 HE Scan Output Raw Format Postprocessing of HE Scan Output to Differentiate Components and Materials The Tesla Model 3 is fully operational after the high energy scan
- 14. Confidential Property Digital-Twin Technology: High-Energy Scan to 3D CAD Model 14 High-Energy Scan Output Raw Format Post-processing of High-Energy Scan Output to Differentiate Components and Materials Full Vehicle Engineering Data Full vehicle Mesh Model Detailed 3D CAD Crash Simulation and Analysis Electrical Systems Routing Engineering Data extracted from High Energy Scan Output Full Vehicle DeltaCostingTM
- 15. Confidential Property Exponential Acceptance of Digital Twin Technology Number of Customers Implemented this Technology 0 20 40 60 80 100 120 2016 2017 2018 2019 2020 2021 100+ Global Automotive Customers 15
- 16. Confidential Property 16 Actions, Integrated Approach, Global Learning, Speed and Flexibility Integrated Strategic Benchmarking • Strategic benchmarking from a Design, Manufacturing, Parts, Tooling, Costing and Serviceability perspective • Deep Technical insight of competitor vehicle/s enable by Digital Twin • Global learnings across platform • Risk sharing approach • Focus on Actionable Results Cost Design Performance 1 2 3
- 17. HE Scan to Digital Twin ▪ Full Vehicle Engineering CAD
- 18. Confidential Property BIW 3D CAD Model 18 HE Scan Input 3D CAD Model All engineered internal features are captured through HE scan
- 19. Confidential Property BIW 3D CAD Model 19 HE Scan Input All the components are captured and modeled to greater detail and higher accuracy
- 20. Confidential Property Sheetmetal Extrusion Rivet Fillet Weld Seam Weld Extrusion Extrusion BIW 3D CAD Model - Detailed BIW CAD SILL SECTION 20
- 21. Confidential Property Full Vehicle 3D CAD Model 21 Cut Section View
- 22. Confidential Property Full Vehicle 3D CAD Model with Electrical Harness Routing 22 Harness Topology – Top View
- 23. Confidential Property Full Vehicle Electrical and Electronics Architecture 23 Separate Channel for Signal wires Separate Channel for Power wires Space claim strategy Wire harness serviceability study Special routing and channel system Interface with other systems like BIW & Chassis Safety Strategy (HV Cables) Routing and fixation methodology
- 24. Confidential Property Electrical Topology – Comparative Analysis 24 24 The entire routing and topology is captured to a greater detail and higher accuracy
- 25. CAE – Virtual Validation ▪ Analysis and Simulation
- 26. Confidential Property CAE - BIW Intelligent Mesh Model and Analysis 26 Torsional Stiffness Analysis Bending Stiffness Analysis Modal Analysis BIW-Shell – xx Hz BIW Shell + CCB – xx Hz BIW Shell + Bumper – xx Hz BIW Shell + Windshield – xx Hz BIW Shell + Subframe - xx Hz BIW Shell + Battery – xx Hz BIW Shell + CCB + Bumper + Windshield + Subframe + Battery xx Hz
- 27. Confidential Property CAE - Material Distribution 27 High Strength Steel Mild Steel Ultra High Strength Steel Extruded Aluminium 6xxx Aluminium 5xxx Aluminium Cast Aluminium
- 28. Confidential Property CAE - Full vehicle Crash Model and Analysis 28
- 29. Confidential Property CAE - Frontal Crash Simulation Vs Test Results 29
- 30. Confidential Property CFD - External Aerodynamic Analysis 30
- 31. Confidential Property CFD - External Aerodynamic Analysis 31
- 32. Electric Vehicle Systems ▪ High Voltage Battery ▪ Electric Powertrain
- 33. Confidential Property HV Battery CAD Model 33 HE Scan Input HE Scan data can be converted to 3D CAD models at higher accuracy using our unique process and product experts
- 34. Confidential Property HV Battery CAD Model 34 Structure details, Coolant details, Cell arrangement etc. can be studied in detail Section from Front View Coolant pipe Battery Cells Structure
- 35. Confidential Property HV Battery CAE Simulations 35 Coolant Flow Analysis • The coolant Flow distribution analysis has been carried out at different flow rates to identify flow rate at each channel, Pressure drop and velocity of coolant. Thermal Performance Analysis • Thermal performance of the HV-Battery cooling plate and the Temperature of Battery. High Temperature Cooling Analysis (Rapid Charging) • Cooling performance of the HV-Battery cooling plate and the Temperature of Battery with respect to time at rapid charging) Low Temperature Heating Analysis • Heating performance of the HV- Battery cooling plate and the Temperature of Battery at low environment temperature (-20℃)
- 36. Confidential Property HV Battery CAE Simulations 36 Modal & FRF Analysis • Modal & FRF Analysis Carried out to find the Mode Shapes and Vibration behavior of the system Frontal Impact Analysis • Impact Analysis has been performed to investigate the Energy absorption and crush behavior of the system. Side Impact & Side Pole Analysis • Side Pole Analysis carried out to check the maximum intrusion, crush behavior of the system. Torsion & Bending Stiffness • Stiffness Analysis carried out for the HV Battery assembly Structure to find the Structural Strength & Stability
- 37. Confidential Property Electric Powertrain CAD Model 37
- 38. Confidential Property Electric Powertrain CAD Model 38 Tesla Model 3 Jaguar IPace All the components are captured & modeled to greater detail and higher accuracy
- 39. Confidential Property Confidential Property Electric Powertrain - EMC Analysis 39 ▪ Torques vs Speed Curve ▪ Electro Magnetic Performance Analysis ▪ No load Back EMF Analysis ▪ Cogging Torque Analysis ▪ Load Torque Analysis ▪ Flux Density Contour ▪ Electro Magnetic Force Analysis ▪ Iron Loss Contour ▪ Characteristics Curve ▪ Load Analysis based on PWM current ▪ Efficiency Map ▪ Thermal Analysis ▪ Harmonic Analysis EMC Analysis EMC Model Deliverables Electromagnetic density Harmonics Cogging torque Efficiency Map
- 40. Confidential Property Confidential Property Light weighting & Cost Reduction Digital-Twin Data Design Optimization and Validation Benefits to Customer Liftgate of Audi E-tron Design Validation Baseline Solution Design Optimization Baseline Solution Parameters Baseline Design Modified Design Savings Gross Material (kg) 11.23 9.70 1.53 Kg Gross Material Cost ($) $50.55 $43.65 Proposed Concept design - $7.89 Manufacturing and assembly process $21.75 $13.62 Total cost $72.3 $65.16 $7.14 Net weight (kg) 5.66 5.21 0.45Kg Die tooling investment ($) $2.9M $2.15M $750K
- 41. Thank you