European HTC 2010あ CAE current status and future plan in Nissan Motor - October 29, 2010 Nissan Motor Co., Ltd. Integrated CAE Department ...
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European HTC 2010あ
CAE current status and future plan
in Nissan Motor
October 29, 2010
Nissan Motor Co., Ltd.
Integrated CAE Department
Toshihiro ARAKI
1
Agenda
CAE History of NISSAN
CAE value definition and current status
ー related with Process innovation as Nissan V-3P ー
CAE cover range and its expansion plan
ー with reference of R&D technology strategyー
Summary
2
Agenda
CAE History of NISSAN
CAE value definition and current status
ー related with Process innovation as Nissan V-3P ー
CAE cover range and its expansion plan
ー with reference of R&D technology strategyー
Summary
3
History of CAE
Computer-aided engineering (often referred to as CAE) is the
use of information technology to support engineers in tasks such
as analysis, simulation, design, manufacture, planning, diagnosis,
and repair.
Wikipedia
SDRC
SDRC (Lemon)
(Lemon) isis well
well known
known globally
globally asas one
one ofof
the
the first
first to
to coin
coin the
the term
term "MCAE"
"MCAE" (Mechanical
(Mechanical
Computer
Computer AidedAided Engineering)
Engineering) inin the
the 70's.
70's. He
He
said,
said,
••Only
Only CAE
CAE cancan innovate
innovate the
the design
design process.
process.
••Long
Long term,
term, huge
huge investment
investment will
will be
be needed
needed for
for
CAE
CAE to to be
be embedded
embedded inin development
development process.
process.
••But
But CAE
CAE willwill contribute
contribute to
to reduce
reduce process
process and
and
to
to develop
develop differential
differential products
products Dr. Jason R. Lemon, University of Cincinnati
4
History of Nissan CAE
Nissan started CAE in the late 70’s and expand after CRAY install at 1986.
Up to 2000, CAE cost was bigger than the value created by CAE
Around 2000, almost all system gathered and digital development started.
1960 1970 1980 1990 2000
STYLO
Styling
ALIAS/ICEM
CAD-Ⅰ(1-D）
Design CAD-Ⅱ (2-D)
I-DEAS (3D)
CADCEUS（die design）
Die design INCAM (NC work）
INCAM (die structure）
Process design DELMIA
NASTRAN
CRAY･XMP PAM-CRASH
CAE
CAE Gr. in Body design Digital development
CAE cost >> CAE value cost>value cost
History of Nissan CAE
Example (Crash CAE)
More than 1M elements for detail modeling (2005~) 衝突：ソフト＝１１７６０万円
ハード＝８３００万円
Become able to predict absolute value of performance 稼働日２５０日×３０ＪＯＢ＝７５００ＪＯＢ
２００００万円／７５００＝２．６７万円／ＪＯＢ
1990 1995 2000 2005
Model 10~20K elements 200K elem. 1M elem.~
modeling : 3 weeks
modeling : 2months calc. : less than 1day
calc.: 2 weeks
Accuracy low reliability High reliability
relative prediction absolute value
prediction
6
Agenda
CAE History of NISSAN
CAE value definition and current status
ー related with Process innovation as Nissan V-3P ー
CAE cover range and its expansion plan
ー with reference of R&D technology strategyー
Summary
7
CAE value definition and current status
< Basic Concept for CAE investment >
Value created by CAE should be bigger than its cost
equivalent
product value Fuel consumption
value
CAE Department KPI creation by
= ROI performance Safety
improvement Handling
Warranty cost
Reduction of
Parts cost
Outsourcing cost
minimize
maximize
System cost
Development Cost
• Prototype cost
• Tooling cost
Labor cost • Labor cost
Investment Value (Benefit)
8
CAE value definition and current status
Minimize CAE cost with combination of software cost and
labor cost (Automatization/LCC utilization).
Software cost is controlled strongly by TOP manamement.
Regarding model building, we need “CAD to FE-model
24h” is quite welcome. ⇒ waiting for Altair’s tool
9
9
CAE value definition and current status
< Basic Concept for CAE investment >
Value created by CAE should be bigger than its cost
equivalent
product value Fuel consumption
value
CAE Department KPI creation by
= ROI performance Safety
improvement Handling
Warranty cost
Reduction of
Parts cost
outsourcing cost
minimize
maximize
System cost V-3P
Development Cost
• Prototype cost
• Tooling cost
labor cost • Labor cost
Investment Value (Benefit)
10CAE value definition and current status
Validation
Validation CAE
CAE contribute
contribute to
to development
development cost
cost reduction
reduction
Planning
Planning CAE
CAE has
has big
big opportunities
opportunities for
for parts
parts cost
cost reduction
reduction
Plan Digital Test Physical Test
Drawing
Target Setting Confirm Targets release
Test Validation Test
Vehicle
CAE
Package
CAE
Planning Component
CAE CAE
CAE
Test Test
Parts
Design Optimizasion Mainly Development
⇒Parts Cost Reduction Cost Reduction
Parts Design
⇒V-3P Main Scope 11CAE value definition and current status
V3P has 3 digital lots
All performance should be validated till Data Release
Styling Chosen Model Freeze
~1996 plan
concept
detail design test , production preparation
design
digital study
proto proto data release
physical SOP
study
CAE is reference information ① process management
② CAE accuracy, application, improved
2004~V3P concept
plan design detail design test , production preparation
digital study Data Release
physical proto fastest
SOP
validation
CAE replaces physical test SOP new platform
12CAE value definition and current status
The Result of Performance CAE
Up to 2004 : Expanded the scope of analysis application
approximately twice as well as improved the analysis accuracy
Proto-type 1st test OK rate reached record high of 95%.
Components of OK Rate of Trial Production Vehicle
Performance Evaluation on “NOTE” and “Wingroad”
FY00 FY01 FY02
13CAE value definition and current status
Example : Crash CAE
Injury Prediction CAE technology for
test reduction
14CAE value definition and current status
Example of Key technology of Crash safety
Representation of Air-bag deployment : gas flow
Accurate airbag CAE is achieved with FPM to represent gas flow.
Test CAE
G(m/s2) Impact test
200
150
Test
CAE
100
50
0
0 20 40 60 80 100
-50
around gas generator T (msec) 15Current status of CAE cover range and value
Example of Key technology of Crash safety
Representation of Air-bag deployment : bag folding
Sim-folder is quite effective to fold air-bag model.
16Current status of CAE cover range and value
Side Impact : this technology applied to 7 regulations
IIHS POLE_AM50
US-NCAP POLE_AF05
17Current status of CAE cover range and value
Side Impact : Injury value prediction accuracy become
enough to validate the design
⇒by this technology, test
Verification reduced
between test and CAE
CAE
Deflection CAE
TEST
Load
TEST
IIHS US-NCAP IIHS US-NCAP
Deflection [mm]
Load [KN]
Upper Mid Lower Upper Lower Upper Mid Lower Ilium Acetabulum APF PSPF
Shoulder Combined
Rib Chest Rib Abdomen Rib Chest Rib
Pelvis
18Agenda
CAE History of NISSAN
CAE value definition and current status
ー related with Process innovation as Nissan V-3P ー
CAE cover range and its expansion plan
ー with reference of R&D technology strategyー
Summary
19Nissan’s Four Strategic technology Fields (2006~)
Nissan’s Core Technology Values:
Trusted Driving Pleasure
For each field, technology development will
be achieved based on a defined target
(Vision 2015) and detailed roadmap
Trusted ① Safety Life on Board ④
② Environment
DP (Dynamic Performance) ③
⑤ Q
u a l it y
・C ost Driving Pleasure
・V-3P
Proce
ss
CAE contribution domain
20Nissan’s Four Strategic technology Fields (2006~)
Nissan’s Core Technology Values:
Trusted Driving Pleasure
For each field, technology development will
be achieved based on a defined target
(Vision 2015) and detailed roadmap
Safety Life on Board
Environment
DP (Dynamic Performance)
Quali
ty・Co
st・V-3
P Proce
ss
21CAE cover range and expansion plan -Safety-
Safety Shield Concept “The Vehicle That Helps Protect People”
The vehicle activates various barriers to help the driver, passengers and other
road users avoid danger from normal driving conditions through post accident
conditions.
Risk has not yet appeared
ex) Adaptive Front-Lighting System
（AFS)
Risk has appeared
ex)Lane Departure Prevention （LDP）
Crash may occur
ex) Vehicle dynamics control （VDC）
Crash is unavoidable
ex)Intelligent Brake assist , Pre-crash Seatbelt
Crash
ex) Zone Body ,
Pop-up Engine Hood 22CAE cover range and expansion plan -Safety-
Reduce fatalities/serious injuries
Safety involving nissan vehicles to half of
1995 rate by 2015
fatalities/serious injuries per 10k vehicles
achieved at FY09
fatalities per 10k vehicles
will be achieved at 2010
fatalities/serious injuries per 10k vehicles
(incl. UK) achieved at 2006
23CAE cover range and expansion plan -Safety-
Passive Safety CAE technology
Already expanded to Injury Value Prediction
MDB Velocity：50km/h
TEST
CAE
24CAE cover range and expansion plan -Safety-
Active Safety CAE technology : ESC regulation
Should be expanded to “Active Safety with Control Technology”
like followings ; SILS,MILS,HILS...
US：FMVSS126, E/J：ECE R13H, Australia：ADR31-02 based
on gtr No.8(Grobal Technical Regulation)
CAE can select worst case to test
Test CAE
25Nissan’s Four Strategic technology Fields (2006~)
Nissan’s Core Technology Values:
Trusted Driving Pleasure
For each field, technology development will
be achieved based on a defined target
(Vision 2015) and detailed roadmap
Safety Life on Board
Environment
DP (Dynamic Performance)
Quali
ty・Co
st・V-3
P Proce
ss
26CAE cover range and expansion plan -Environment-
Start of Sales : 2010 December (JPN,US)
2011 (EUR)
Capacity 5 persons Max. SPEED 140kph over
LAMINATED Li-ion
DRIVE FWD BATTERY
BATTERY (AESC)
High Response BATTERY
MOTOR
Synchronous AC MOTOR CAPACITY/ 24kWh/90kW over
(O/P・Torque)
(80kW・280Nm) POWER
RANGE 160km over (US LA4) OTHER Dedicated IT System
27 27
Nissan Strictly Confidential Restricted 27CAE cover range and expansion plan -Environment-
November,2nd
Nissan original Hybrid : Light weight / Conpact
・No torque converter.
・1Motor for both drive and electric generator.
Clutch control is quite difficult (drivability/fuel
efficiency...). But test based development ⇒ Infiniti M HV : 5.26L/100km
Many design changes had done.
SILS for PT/Chassis control should be developed.
Inverter Clutch 1 Li-ion battery
Motor
Clutch 2
28
V6 3.5L engine 7 speed automatic transmission 28Agenda
CAE History of NISSAN
CAE value definition and current status
ー related with Process innovation as Nissan V-3P ー
CAE cover range and its expansion plan
ー with reference of R&D technology strategyー
Summary
29Summary
CAE is constituted in vehicle development process and
contributed to reduction of “development cost”, “part cost”,
“development term”, and “quality & performance improvement”.
Furthermore we expand CAE coverage and CAE quality to
achieve practical value, especially in EV/HV domain.
30
ＣＡＥ technology development road-map 30LEAF
Thank
Thank you
you for
for your
your Attention
Attention
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