Virtual Product Development at Case New Holland

Virtual Product Development at Case New Holland

VIRTUAL PRODUCT DEVELOPMENT
Case New Holland
Gennaro Monacelli
Agricultural & Construction Equipment
Design Analysis & Simulation Competence Centre
Design Analysis and Simulation Competence Centre
CNH Product Development Organization
AG Product
Development
Competence Centre
30 platforms
Tractor Platform
Equipment
Platform
Combine Platform
CE Product
Development
Product Development
common functions
•
•
•
•
•
6 platforms
Excavators and
Telehandler
Electrical & Electronics (Telematics, ..)
Driveline and Engine Installation
Hydraulics
Cab and external trim
Design Analysis and Simulation
Dozer and Wheel
Loader
Grader
Tractor Loader
Backhoe
- Styling (Fiat Group)
Forage and
Grape Harvester
Platform
Skid Steer Load
CTL
Wholegoods Platform
Vehicle Integration
Vehicle Integration
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
2
Goals of VPD
• Use advanced tools and methodologies (modeling and simulation) in
order to have a complete representation of the new product (geometry
and functions) in order to:
• reduce decisional risks
• minimize time and costs
• reduce the number of physical prototypes
• Increase quality
The approach is
• Complete digital representation of the Poduct (Digital Mock-Up)
and the Plant (Virtual Manufacturing)
• From Field to bench (mission identification and testing)
• From the bench to the math (mission simulation)
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
3
WW Digital Prototyping & Simulation in CNH
WW Design Analysis
and Simulation
FIAT Group
Intersectorial Projects
Design Analysis
Digital Prototyping & Simulation
Structural Analysis
CAD, DMU, VR, DMH
System Simulation
Transmission &
Fuel Efficiency
Thermo Fluid Dynamics
NVH Simulation
Vehicle Dynamics
Dynamic Analysis
Particle Flow Modelling
Fatigue
Product & Process
Integration Simulation
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
4
Virtual Product Development Process
Robustness & Safety
Design & Optimization
Manufacturing
Marketing & Sales
Vehicle System Perfomance
DMU
Concept
Development
Service
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
5
Target setting approach in Product Development
Methods/Tools for target setting, deployment and achieving
PERFORMANCE OBJECTIVE
MEASUREMENTS
CARRY-OVER
CONSTRAINTS
TARGET
SETTING
(VTS)
Target Management
PRODUCT DEVELOPMENT
PROCEDURES
ARCHITECTURAL
ADVANCED
DESIGN
PHYSICAL
VALIDATION
TARGET
DEPLOYMENT
TARGET
ACHIEVING
Modeling &
Virtual Validation
Case New Holland: Design Analysis and Simulation
VIRTUAL
ANALYSIS
PRODUCT
TARGET
(TLR/CVP)
Gennaro Monacelli
6
Product Mission Simulation
CAE Standards
Design Procedures
Test Procedures
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
7
Digital Mock Up & Virtual Reality
Styling Reviews, Design Reviews, Commercial Publications, Tolerance
analysis, Ergonomics, Cab Visibility, Serviceability, Marketing & Sales, Human
Machine Interface
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
8
Linear Finite Element Analysis
Component structural analyses
Testing of components and products under
different working conditions and loads
Highest Principal Strain Component LC5a - Using a global load factor of 1.185
600
Lab Data
FEA
500
400
300
200
-200
-300
Good correlation with experimental data
and possibility to implement different
loading conditions
Case New Holland: Design Analysis and Simulation
-400
-500
-600
Gage
Gennaro Monacelli
9
60L
60R
59R
58L
58R
57L
-100
57R
55L
55R
54L
54R
53L
53R
52L
52R
11L
11R
9LB
9RB
9L
9R
8R
3
8L
0
1
Microstrain
100
ROPS and FOPS
Simulate and Evaluate cab behavior under shock load homologation test.
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
10
Virtual and Experimental Correlation
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
11
Topology Optimization
• Optimized structural configuration based on specified loads.
• Applied in the early stages of product development
The combine rear frame was designed using topology optimization.
The loading capacity was increased by 40% without cost increase.
Predicted Structural Shape
Case New Holland: Design Analysis and Simulation
Actual Resulting Design
Gennaro Monacelli
12
Fatigue life prediction - Bump Test
Comparison with on PMU field critical areas
Left strut - Outer side
Right strut - Outer side
Serial #1174018
3.387 hrs
Serial #1150302
3.720 hrs
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
13
Transmission and Fuel Efficiency
• Evaluate stress, strain and fatigue life of all transmission components, taking into
account the efficiency and power flows
• Predict gears fatigue life and simulate meshing loads and vibrations
Powertrain & Transmissions, Bearings
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
14
Vehicle Dynamics
Vehicle dynamics behavior simulation under
different working conditions and grounds,
including implements and cab.
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
15
Computational Fluid Dynamics
Underhood cooling, engine cooling,
Cabin HVAC, 3D hydraulics
Underhood Cooling
Forage Harvester
Compact Wheel Loader
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
16
NVH simulation
Exhaust
SPL (Sound Pressure Level)
CAB
SPL
total noise level registered
internally to the cabin due to the
combined action of all these
sources
Engine
Transmission of energy
from sources to driver
follows two paths:
Hydraulic
• Structure borne
Drive line
Front axle
• Airborne
Rear axle
Tyres
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
17
Factors of Noise Generation
Air-borne noise
[500 Hz  10KHz]
Factor of noise
generation
Countermeasures
Engine combustion noise
Mechanical noise
Addition of sound-insulating
sheet and sound absorbing
material
Laminated glasses
Suction and exhaust noise
Test tracks
Fan noise
Airflow noise
Noise emitting from panel
Structural-borne noise
[< 500 Hz]
Prevention of resonance,
dynamic stiffer, tuning by antivibration rubber mount
Deterministic
approach
BEM
SEA
FEM
0
300
Statistical approach
10000 Hz
500
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
18
Crop Modelling
Simulate crop, soil and seeds interactions
with the specific machine in order to
evaluate velocity and projection
36 Row Planter plenum
design
Applications: Hay and forage, Combines,
Cotton Picker, Grape harvester, Sugarcane
harvester, ripper, harrow/discer, Seeder,
Planter, Vertical Tillage
Crop Projection
Design of
Experiments of
elevator grain flow
for grape harvester
Crop Velocity
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
19
Crop Modelling
combine tailing system
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
20
Vehicle System Modelling
Simulate vehicle system performance
under different dynamics scenarios in
order to evaluate and improve our
products
Applications:
Design
Optimization,
Efficiency/Fuel Consumptions, Hydraulics
circuits, Transmission design, What-If
analysis
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
21
CAE Procedures and Standards
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
22
Why VPD is important?
 World wide organization
 Agricultural (EU, NA, LAR)
 5 lead Design Centers (2 NA, 2 EU, 1 South America)
 20 Plants (9 NA, 9 EU, 2 South America)
 50 Product lines (14 Tractors, 7 Harvesters, 16 Crop Production, 13 Hay
and Forage)
 Construction Equipment (EU, NA, LAR)
 3 lead Design Centers (1 NA, 2 EU)
 11 Plants (4 NA, 5 EU, 2 South America)
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
23
Conclusions
•
Virtual Product Development allows effective and quick “Design
Reviews”, including partners and suppliers also from remote
locations.
•
The communication process among all the actors involved in the
product development process becomes more effective
•
The product quality and project robustness are improved,
minimizing costs at the same time
Thank You!
For further information:
Gennaro Monacelli
AG & CE Competence Centre
Design Analysis and Simulation
CNH Italia S.p.A.
Viale delle Nazioni 55, San Matteo
41100 Modena - Italy
[email protected]
www.cnh.com
Case New Holland: Design Analysis and Simulation
Gennaro Monacelli
24