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Automotive Product Finder Magazine | Body design has a major structural function
Body design has a major structural function
Car body: Designing for perfection
BorgWarner expands electric motor series with HVH 146
…says Shree Harsha, Director (Marketing, India) of DASSAULT SYSTEMES, as he explains usage of latest technologies in fastening the body designing process in automotive industry.
What are the difficulties in before automakers while car body designing?
As automotive companies strive to bring decisions earlier in the development cycle where the cost of change is lower, they need to increase their understanding about early concepts through virtual performance assessment. Further, utilising simulation-based multidiscipline optimisation, engineers can deal with competing requirements simultaneously during design evolution, identify risks and drive improvements to achieve better concept designs.
Low cost and high quality is now a new question for every automotive center to meet the fast growing market’s requirement. For body in white (BIW) development, we need to minimise BIW mass based on the performance requirements. During the BIW concept developing phase, some key design variables, such as rails and pillars width and position, shell thickness, etc, and multi-attribute responses from safety, NVH, and durability are considered to explore the design space. Design of experiment (DOE) is used to assess the impact of the variables on the objectives, and this helps the engineer to better understand the design space and give design recommendation. Approximations component is used sequentially to create fast-running surrogate models to replace the real CAE simulations.
Finally, the optimisation tool is used to perform a trade-off study. This helps engineer to know what is the minimum cost for the design to meet all design targets, or when the BIW weight is fixed, what is the potential maximum design performance.
How is Dassault Systèmes helping car makers to solve body design challenges?
For the concept body development today we can showcase a hybrid approach (established products and 3DEXPERIENCE Apps) utilising the power of SFE-CONCEPT for concept modelling, Abaqus as unified solver for multidiscipline simulations and platform native apps for process and data management, optimisation and results analytics. The 3DEXPERIENCE Platform addresses critical challenges of concept engineering process by providing strong connection between design and simulation, common reference for data from requirements up to results, collaborative environment to facilitate process build and decision making.
Heading towards unified user experience, 3DEXPERIENCE is becoming an ideal framework to implement and use more efficiently multidisciplinary optimisation in vehicle concept development phase, enabling companies to gain more knowledge upfront about their products before investing in details.
How can latest technologies fasten the body designing process in EV?
New electric vehicle innovators and global OEMs have many challenges in common. Competition has never been greater to converge new EV concepts, support early feasibility, engineer highest performance, and accelerate innovative vehicles to market, all while optimising costs, quality and customer experience.
The modern automotive body is expected to serve many purposes from being a critical structural member and reducing noise and vibration for occupant comfort, to protecting occupants in the event of a crash. Today, many organisations treat these different disciplines as isolated “silos” based on unique tools usage within each discipline. The overhead resulting from multiple tools and models taxes engineering organisations and limits productivity.
With EV there are new technological challenges as you have an opportunity to minimise weight so as to improve battery range characteristics but it has its own packaging implications which are direct bearing on vehicle architecture. Also, the impact of vehicle dynamics due to low center of gravity has to be considered but this brings up new opportunities in huge potential for modularisation (battery modules, motors by axles or at wheels). Safety requirements associated with battery thermal and ageing requirements has to be considered which has a direct impact on HVAC and electric harness systems of EV. In summary, it’s a large multi scale, multi physics problem to be solved with contradictory requirements/constraints.
HVAC And Electric Harness Systems
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