Vehicle developers often need to reconcile conflicting requirements in their conceptual designs to optimum effect. Such conflicting requirements may include lightweight design versus alternative drive systems, safety versus comfort or costs versus tailored solutions for the customer. A major role is also played by the increasing number of materials and processing methods which need to be taken into account when developing new concepts.
An integral approach is required for computer-assisted development methods to complete such tasks. The quality and feasibility of design concepts should be verified and enhanced at the earliest stage possible. This calls for two areas to be examined simultaneously: the simulation processes for demonstrating structural integrity, which includes crash scenarios, statics and dynamics, and the calculation methods for producibility using processes such as deep-drawing, casting, welding and application of surface finishes.
TECOSIM explains new process solution for faster virtual vehicle development
Under TECOSIM’s leadership, a consortium of medium-sized companies have developed a method which can be used to create a fully parametrised concept geometry in CATIA (computer-aided, three-dimensional, interactive application) and implement multi-disciplinary structure optimisation using an extensive range of simulation programs. Among other things, this method makes computer-assisted optimisation and robustness assessment possible as a basis for finding a new vehicle body concept or improving an existing vehicle body structure in an automated analysis process.
Inadequacies in current optimisation solutions are remedied in TEC|CONCEPT thanks to an integral approach and full, bi-directional integration in CATIA V5.
In the first case, a large number of variants need to be tested due to the many design variables and restrictions. Simulations with very long coputing times are thus only used for mature concepts. During the concept stage, quickly performed analyses can help determine the scope available for design more fully, thus identifying better solutions.
In the second case, the calculation project starts with a reference structure for which weight minimisation potential needs to be evaluated, for example. This is why we also refer to the required analysis potential analysis or the resultant geometry as the potential vehicle or potential model.
The software solution consists of the three key components FCM, TEC|ODM and optiSLang plus other state-of-the-art CAE tools to carry out tasks such as production process simulation or structure qualification. While these software solutions were being compiled, special attention was paid to ensuring that the customers' existing simulation tools were used as far as possible and were modified through adjustments to integrate the TEC|CONCEPT potential vehicle method into the overall process.
The TEC|CONCEPT process establishes and takes into account objectives regarding aspects such as weight, noise, safety, manufacture and costs.
In TEC|CONCEPT, TECOSIM offers
The advantages of TEC|CONCEPT at a glance
You will find more about the potential vehicle method TEC|CONCEPT and members of the consortium in the description of the research project in the attachment. You can also contact us in person for more information.