1 Introduction

Copyright PIDOTECH Inc. All Rights Reserved.
v v PIDO Technology v Applications
2
)%(ECNEULFNI
70% 20% 5% 5%
30% OVERHEAD 15% LABOR 50% MATERIAL 5% PRODUCT DESIGN
5% 70%
4
Design Requirements: Product Performances Manufacturability (DFM) Assembly (DFA) Design Variables: Shape and Size Topology Material
Design Requirements: Production without Defects Design Variables: Process Parameters (Variables)
5
Design Problem Formulation Design Requirements Design Variables
Analysis Procedure Establishment CAE Experiments
Design Procedure Establishment Conventional Design Advanced Design (e.g. Optimization)
6
Select an initial design
Evaluate the performance using CAE/Experiment
Are design requirements satisfied ?
No
Change design variables
Yes
Know-How Adequate Design Experience Intuition
7
Ladder Type Frame - , - Ladder Type Frame - -
Frame Type Carbody System
Ladder Type Frame , Carryover 10kg Spec. ?

Priority #1
Minimize Weight
Priority #2
Lower Limit 1th Torsional Freq.
Priority #3
Lower Limit 2nd Bending Freq.
Priority #4
Lower Limit 3rd Lateral Freq.
(9)
(6)
st1
st2
st3
ct1
ct2
ct3
ct4
ct5
ct6
h1
h2
h3
w1
w2 h2
w3
*
Design Problem
Design Variables (15)
(9) (6)
Objective Function (1)

Minimize Weight
Constraints (3)
Lower Limit 1th Torsional Freq. Lower Limit 2nd Bending Freq. Lower Limit 3rd Lateral Freq.
Select an initial design
Automatic Process Using PIDO technology
Evaluate the performance using CAE/Experiment
Are design requirements satisfied ?
No
Modify design variables
Yes
Best Design Advanced Design Techniques
12
Multidisciplinary Design Optimization (MDO) : a field of engineering that uses optimization methods to solve design problems incorporating a number of disciplines
13
Conventional Design : Sequential / Hierarchical Procedure

DOF of Design l Discipline1: Safety l Discipline2: NVH l Discipline3: Durability Performance DOF of Design Performance DOF of Design Performance
x1 x12 x13 x123 x2 x23 x3
x1 x12 x13 x123 x2 x23 x3 x1 x12 x13 x123 x2 x23 x3
x1 x12 x13 x123 x2 x23 x3 x1 x12 x13 x123 x2 x23 x3 x1 x12 x13 x123 x2 x23 x3
Safety
NVH
Durability
MDO : Concurrent / Simultaneous Procedure

DOF of Design Performance
NVH
l Discipline1: Safety l Discipline2: NVH l Discipline3: Durability
x1 x12 x13 x123 x2 x23 x3 x1 x12 x13 x123 x2 x23 x3 x1 x12 x13 x123 x2 x23 x3
Safety
Durability
x={xL, xS} xL={x1, x2, x3} : Local Design Variables xS={x12, x13, x23, x123} : Shared Design Variables
quoted from M.J. Kiemele, Air Academy Associates, 2003

15
Long development time

High cost Unsatisfactory quality due to design change difficulty
Physical Prototype
Shifting from Physical Prototype to Virtual Prototype
Virtual Prototype
Fast delivery Low cost High quality assurance in the early stage
In order to enhance the value of Virtual Prototype , PIDO (Process Integration and Design Optimization) technology is a necessity.
Integration of CAE tools Automation of complex analysis and design procedures Optimization of product/process designs 17
A PIDO tool that can produce the best design solution by integrating CAE tools in a distributed computing environment automating complex analysis and design procedures using Engine applying appropriate design tools including DOE and optimizers
Visual Modeling UI Framework Design Data Manager Workflow Engine Design Process Manager
What-If Study Parametric Study Reliability Analysis Design Of Experiments Approximation Design Optimization Sequential Approximate Optimization Reliability-Based Design Optimization
Analysis Component Layer
Design Component Layer
CAE Tools
PIAnO Engine
Interface Engine Execution Manager Job Scheduling Manager
Message Broker (Socket)
TCP/IP
Architecture of PIAnO Developed by PIDOTECH Inc.
18
Decision Making
CAE Solver
Process
19
Decision Making
CAE Solver
Process Process
20
. .
What-If Study Parametric Study Reliability Analysis
1-D Parametric Study Kriging Model Vector Parametric Study Radial Basis Function Model FORM Monte Carlo Sampling Latin Hypercube Sampling enhanced Dimension Reduction Method (eDR)
Meta-modeling
Response Surface Model Radial Basis Function Regression Model
Design Optimization
Sequential Two-point Diagonal Quadratic Approximate Opt.
Progressive Quadratic Response Surface Method Micro Genetic Algorithm Evolutionary Algorithm
Design of Experiments
Full Factorial Design Orthogonal Array Central Composite Design (CCD/ICCD/FCCD) Plackett-Burman Design Box-BehnKen Design LHD/OLHD Augmented LHD Inherited LHD Hybrid Optimization Algorithm (v3.x) Metamodel-Based Sequential Approximate Opt. (v3.x)
Reliability-Based Design Optimization
Advanced Single Loop Single Vector Enhanced Reliability-Based design Optimization with Smart Initiation Approach (ERBOSIA v3.x) eDR-Based Robust Design Optimization (v3.x)
Taguchi Method (v3.x)

21
(A )
(Manual, ) Design Time

= 6 * 3 * 160/ =
2,880
PIAnO Design Time

= 2 * 3 * 64/ =
384
80% ! (ex. 1 3 )
! (ex. 33% )
1 20 12
(2880-384)
)(
)(
3 = 1
22
PIAnO I
[] Hardpoint & Bush (ADAMS/Car) [] Hardpoint & Bush RBDO (ADAMS/Car) [] (CarSim, Simulink) [] (ADAMS, CarSIm) [] Bush (ADAMS) [] (In-house Code) [] Torsion Beam Axle (Hypermesh, MSC.Nastran, ADAMS/Car, MSC.Fatigue) [] / (Hypermesh, Hyperview, MSC.Patran/Nastran/ADAMS/Fatigue) [] / CTBA (Hypermesh, In-house Code) [] Front (Hypermesh, MSC.Nastran, ABAQUS, ADAMS/Car, FEMFAT) [] ABS Controller Parameter Calibration (CarSim, Simulink) [] Fuel Tank (Experiments)
( )
[] Fuel System Vent Valve (Experiments) [] Isolator (Hypermesh, ABAQUS, MSC.Patran, MSC.Fatigue, Matlab) [] Engine Mount (MSC.Nastran) [] SUV Ladder Type Frame (Hypermesh, MSC.Nastran) [] Frame Layout (NX, Hypermesh, LS-Dyna, In-house Code) [HEV] Parallel HEV Control Strategy (Simulink) [P/T] Fuel Rail (ADINA) [P/T] Dual CVVT Valve Timing (GT-Power) [P/T] Variable Induction System Runner Length (GT-Power) [P/T] Intake Manifold EGR Port (GT-Power, STAR-CD) [P/T] SUV (GT-Power, GT-Drive) [P/T] Turbocharger Resonator (GT-Power)
PIAnO II
[] Switched Reluctance Motor (In-house Code) [] ODD Spindle Motor (Flux3D) [] HDD Spindle Motor (Flux3D) [] Projection Optical System (Code-V) [] Lens (Code-V) [] Lens (Code-V) [] LCD RBDO (Hypermesh, LS-Dyna) [] LCD BLU (SPEOS, In-house Code) [] HDD RBDO (CML-Static) [] HDD Reduced Basis (CML-Static) [] DTR (CML-Dynamic, CML-Static) [] Cleaning Blade (Hypermesh, ABAQUS)
(/ )
[] Heat Sink (FLOTHERM) [] LED Heat Sink (FLOTHERM) [] / (Hypermesh, MSC.Nastran, MSC.Fatigue) [] Plate-Fin Multi-Objective (STAR-CD) [] (DADS, ANSYS) [] Balancer (Experiments)
PIAnO III
//
[] Tracked Vehicle (In-house Code) [] K2 Offset Strip Fin (FLUENT) [] Lightweight Torpedo Structure (MSC.Nastran) [] (Gambit, Tgrid, FLUENT, Vorstab) [] Compound Helicopter MDO (GTPDP, RDFD, CLBAR) [] Rotorcraft MDO (15 In-house Codes)
( )
//
[] Heat Sink (FLUENT) [] (SolidWorks, COSMOSWorks) [] Wireless Sensor Node Leaping (RecurDyn) [] Thin Glass Transport System (Experiments) [] Chip Breaker (DAFUL)
[] Stage (ANSYS)
///
[] LNG (ANSYS) [] Propeller (In-house Code) [] SONAR (ANSYS) [] (CAESAR II) [] RC (MIDAS-Gen) [] High-Rise Truss (ABAQUS) [] Composite Blade (SAMCEF)
/
[] Blank Sheet (Hypermesh, ABAQUS) [] Front Bumper (MoldFlow) [] Motor Bracket Gate (MAPS3D) [] CD Gate (MAPS3D) [] Instrument Panel (MAPS3D) [] Fog Blank Cover (MAPS3D) [] Balancer Case (MAPS3D)
Design Problem
(9) (6)
Objective Function (1)

Minimize Weight
Constraints (3)
Lower Limit 1th Torsional Freq. Lower Limit 2nd Bending Freq. Lower Limit 3rd Lateral Freq.
CAE Tools
Hypermesh: Morphing MSC.Nastran: Modal Analysis
Design Tools
PIAnO: What-If Study, Parametric Study, Design Optimization
What-If Study
Hypermesh

Parametric Study DOE Approximation Reliability Analysis Design Optimization RBDO
PIAnO
MSC.Nastran
Applied CAE Tools
Embedded Design Tools

Used for
: Initial : Optimal
12kg ()
Weight(-) 1st Torsional Frequency
: Infeasible Region
2nd Bending Frequency
3rd Lateral Frequency
12kg Frame 20%

30

st1 st2 st3 ct1 ct2 ct3 ct4 ct5 ct6 st1 st2 st3

: Initial : Optimal
w1 h1 w2 h2 w3 h3
ct1
ct2
ct3
ct4
ct5
ct6
31
Torsion Beam Axle (TBA) is widely used due to a lightweight and a simple configuration
Rear suspension
Rear Suspension TBA K&C ?
Maximize Fatigue Life Cycle
Roll Center Height Upper Limit
Minimize Weight
Total Roll Rate Lower Limit
W/C Lateral Stiffness Lower Limit
34
TBA Thickness
Trailing Arm Thickness
Inflection Angle
Position of Transition Region
35
Design Variables (4) Shape Parameters Using Morphing (Inflection Angle, Transition Position) TBA Thickness Trailing Arm Thickness
Inflection Angle
Objective Function (1) Maximize Fatigue Life Cycle
Position of Transition Region
Trailing Arm Thickness
Constraints (4) Roll Center Height Upper Limit Weight Upper Limit Total Roll Rate Lower Limit W/C Lateral Stiffness Lower Limit
TBA Thickness
36
Elapsed Time for 1 simulation
@ 28 min
Hypermesh 7.0
Mass
MD.Nastran 2006r2 (Modal Analysis)

Modal Neutral File
MSC.ADAMS 2005r2 (Roll Mode Analysis)
Hot Spots Max. Stress/Strain
Time Load History Data Fatigue Input
MSC.Fatigue 2005r2
Fatigue Life Cycle Most Damaged Node
MSC.ADAMS 2005r2 (K&C Analysis)
K&C Characteristics
37
CAE Tools
Hypermesh: Morphing MSC.Nastran: Modal Analysis ADAMS/Car: Multibody Dynamics MSC.Fatigue: Fatigue Analysis
Design Tools
PIAnO: Parametric Study, Design Optimization
What-If Study
Hypermesh
PIAnO
MSC.Nastran
ADAMS/Car
MSC.Fatigue
Applied CAE Tools

Used for
Fatigue Life Cycle 56.2%
80% 56.2% K&C
Initial
Optimal
Roll Center Height Upper Limit
Weight Upper Limit
Total Roll Rate
W/C Lateral Stiff.
Feasible
Feasible
Lower Limit
Lower Limit
Initial Optimal
Initial
Optimal
Initial
Optimal
Initial
Optimal
39
(a) TBA Thickness 1.00 (b) TA Thickness 1.00 (c) Inflection Angle 2.45 2.70 4.00 2.60 2.74 4.00
-8.00 -7.00
0.00
11.00
: Initial
(d) Position of Transition Region -35.00 -6.60 0.00 35.00
: Optimum
40
Minimize the maximum vertical acceleration at the CG of the hull !

Tracked Vehicle
Tracked Vehicle , Hydro-pneumatic Suspension Unit (HSU) ?

42
Tracked Vehicle
Loading Condition
Tracked vehicle runs over a semi-circular bump of 0.36 m radius with a velocity of 35 km/h.
Wheel_1
Wheel_6 Wheel_1
Hull
C.G.
0.36 m (14 inch)
v(9) : Charging pressures of the 1st, 2nd, 5th and 6th HSUs (4),
Length of gas chambers (1), Pre-load for Belleville springs (1), Choking flow rate (1), Inner diameter of an orifice (1), Static track tension (1) v(1) : Minimize Vertical acceleration at CG of the hull v(15): Wheel travels during jounce (6), Equally distributed static forces on the wheels (6), Track tension (1), Charging pressures of the 3rd and 4th HSUs (2)
43
CAE Tools
Inhouse-Code: Multibody Dynamics
Design Tools
PIAnO: Design Optimization
What-If Study
Inhouse-Code
PIAnO
(PQRSM)
Applied CAE Tools

Used for
44

2.00 1.80 1.60 1.40 1.20 1.00 0.80 0.60 0.40 0.20
Initial Optimal
Acceleration at CG of the hull
0.00
X(1)
X(2)
X(3)
X(4)
X(5)
X(6)
X(7)
X(8)
X(9)
40% 15
45
Optimized Acceleration at Seat
Optimized Wheel Travel
46
Design Path
ABS Controller Calibration
ABS Controller ?
48

ABS Controller Switch Threshold
v Initial/Operating Conditions
Initial Speed: 120km/h Spike Braking of 15mPa @ 0.2s Split Mu (0.2L/0.5R) @ 3m
ABS Controller ABS Controller ABS Controller ABS Controller
FRT On Switch Value FRT Off Switch Value RR On Switch Value RR Off Switch Value
v
Minimize Square Sum of Yaw Minimize Station
Brake Actuator Gain LR & RR

v(6): Brake Actuator Gain LR & RR (1), ABS Controller FRT On & Off Switch Values (2), ABS Controller RR On & Off Switch Values (2), ABS Controller Switch Threshold (1) v(1): Square Sum of Yaw & Station Copyright PIDOTECH Inc. All Rights Reserved.
49
CAE Tools
CarSim: Vehicle Dynamic Simulation Simulink: Simulation System Modeling
Design Tools
PIAnO: Design Optimization
What-If Study
CarSim
PIAnO
Simulink
Applied CAE Tools

Used for
Initial Design
Optimal Design
6 () ABS Controller , Yaw Angle Station

(L/D)
53
(CL) 0.4 (CD)

0.0400
Cn_dynamic
1.6E-02 1.4E-02
0.0380
1.2E-02 1.0E-02
0.0360
Cn_dynamic
-20 0.2000 0.4000 0.6000 0.8000
CD
8.0E-03 6.0E-03 4.0E-03 2.0E-03 0.0E+00
0.0340
0.0320
0.0300 0.0000
-2.0E-03 -4.0E-03
20
40
60
Infeasible
CL
Angle of attack
54
Main Wing
Twist Angle (deg) Taper Ratio (-)
L2 Definition L1 -10.0 -10.0 Lower Bound 0.3 -5.0 4.1 L2/L1
Tail wing
Dihedral (deg) Height (m)
0.0 0.0 Midpoint
0.55
0.0
4.6
10.0 10.0 Upper Bound
0.8
5.0
5.1
55
Find Twist angle, Taper ratio, Dihedral, Tail height at (CL=0.4)
to minimize CD subject to
Cn_dynamic() > 0, where =[-7, 50]

Design variables
Lower Initial Upper
Twist angle Taper ratio Dihedral Tail height
-10.00 0.30 -5.00 4.1
-3.00 0.58 0.00 4.6
10.00 0.80 5.0 5.1 56
CAE TOOLS
Gambit Tgrid Fluent Vorstab Mesh PIAnO
DESIGN TOOL
DOE Approximation Design Optimization
CD
Cnb _ dynamic
What-If Study
Gambit
Parametric Study DOE
(OLHD) (RBF)
Tgrid
Approximation Reliability Analysis
Fluent
Design Optimization RBDO
(EA)
Vorstab
Applied CAE Tools

Used for 57
(CL) 0.4 (CD)
Cn_dynamic
0.03328 0.03227
1.6E-02 1.4E-02 1.2E-02
Cn_dynamic
-20
10 count (3.1%)
1.0E-02 8.0E-03 6.0E-03 4.0E-03 2.0E-03 0.0E+00 -2.0E-03 -4.0E-03 0 20 40 60
Infeasible
Initial
Optimum
Angle of attack
58
Optimum Design
Initial Design
Design Variables
Twist Angle Taper Ratio Dihedral Tail height
: Initial : Optimal
59
Air Conditioner ()
Discharge pipe
Suction pipe
Compressor Grommet (3)
?
61

, (1 ~ 3 )
60Hz : 55~60, 110~120 , 165~180 Hz

, , 190MPa
: 7.0 mm : 7.5 mm
Pipe

(PSD) 1.5
62
U-tube ,
Design variables (unit: mm)

Lower X1 X2 X3 X4 X5 L1 L2 L3 L4 L5 -56.0 -100.0 -20.0 -60.0 -22.0 Initial 0 0 0 0 0 Upper +50.0 +50.0 +10.0 +15.0 +20.0 PIPE Discharge Discharge Suction Suction Suction
63
Find
Change in pipe length, X=[X1, X2, X3, X4, X5]T Pipe mass Penalty value, P 0.5
Minimize Subject to
Maximum stress (x) 190MPa Maximum stress (y) 190MPa Maximum stress (z) 190MPa Fatigue life (discharge) 1.5 hours Fatigue life (suction) 1.5 hours -56 -100 -20 -60 -22 X1 X2 X3 X4 X5 50 50 10 15 20
64
Change in pipe length
X1~X5
Parametric FE modeling
Multidisciplinary Analysis 1 Pre-processor & 4 Analyzers : 1 4 (core2-duo 2.4GHz CPU and 2G RAM)
HyperMesh FE model
( )
Normal modes analysis
Unit static analysis
MSC.Nastran
Static force calculation
3.7
Frequency Response analysis
MSC.Nastran
Mass calculation P value calculation
VB script
Linear static analysis
MSC.Nastran
Fatigue life analysis
HyperMesh
In-house code
MSC.Nastran
MSC.Fatigue
Pipe mass
Penalty value, P
Maximum stress
Fatigue life
65
PIAnO
Parametric FE modeling
Mass calculation
Normal modes Analysis
Static Analysis
Fatigue Analysis
66
CAE Tools
HyperMesh: Morphing MSC.Nastran: Static, Modal, & Freq. Response Analysis MSC.Fatigue: Vibration Fatigue Analysis In-house Code: Data Calculations
Design Tools
PIAnO: Parametric Study, Design Optimization
What-If Study
HyperMesh
PIAnO
MSC.Nastran
MSC.Fatigue
In-house Code
Applied CAE Tools

Used for

Initial Optimal
18%
Lower limit : 1.5 hours
X1 X2
Upper limit : 190MPa
: 55~60, 110~120, 165~180 Hz
X3 X4 X5
18%
68
Heat Sink
?
70
#1
#2
12 junction .
5 10
9 7 8
Driver TR(12) Main TR(11)
3 4
2
71
Lower Bounds 20 20 6 6 -35.0 6 3 3
Design Variables
RF Block heat sink , HR Digital Block heat sink , HD RF Block base , BR Digital Block base, Transition Position BD Sunshield heat-sink , G Digital Block heat sink , tD RF Block heat sink , tR
Upper Bounds 40
RF Block
40
10 10 35.0 12 4 4
Digital Block
72

Heat sink Height of the RF block, HR Heat sink Height of the Digital block, HD Base Thickness of the RF block, BR Base Thickness of the Digital block, BD Gap of the Sun-shield to heat sink, G Heat sink thickness of the Digital block, tD Heat sink thickness of the RF block, tR
Objective Function (1) Minimize (HR + BR)+(HD + BD )
Constraints (12) Ti Tiallow 0 i=1,2,,12
73
Analysis conditions
1. 2. 3. 4. ( ) Ambient Temp. : 50C Altitude : 1800m Solar Load - : 753W/m2 5. Air property - Conductivity : 0.02839 (w/mk ) - Density : 0.9059 (kg/m3) 6. ALDC 12 property - Conductivity : 98 (w/mk ) 7. FR4 property - Conductivity : Kx=Ky=35W/m.K, Kz=0.33 W/m.K ( : Telcordia GR-63-CORE )
Simulation Tool : Flotherm v7.0 Grid information : (Global + Local Grid) 799557 EA
74
CAE Tools
FLOTHERM: Thermal Analysis for Electronic Equipment
Design Tools
PIAnO: DOE, Approximation, Design Optimization
What-If Study Parametric Study DOE Approximation Reliability Analysis Design Optimization RBDO
PIAnO
FLOTHERM
Applied CAE Tools

Used for
75

20

40
41.9 %
HR HD
6 10
BR BD
6 12
G
Feasible
tD tR
41.9% !

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Copyright PIDOTECH Inc. All Rights Reserved.

v v PIDO Technology v Applications

Copyright PIDOTECH Inc. All Rights Reserved.

30% OVERHEAD 15% LABOR 50% MATERIAL 5% PRODUCT DESIGN

Design Problem Formulation Design Requirements Design Variables

Analysis Procedure Establishment CAE Experiments

Design Procedure Establishment Conventional Design Advanced Design (e.g. Optimization)

Select an initial design

Evaluate the performance using CAE/Experiment

Are design requirements satisfied ?

Change design variables

Ladder Type Frame - , - Ladder Type Frame - -

Frame Type Carbody System

Ladder Type Frame , Carryover 10kg Spec. ?

Lower Limit 1th Torsional Freq.

Lower Limit 2nd Bending Freq.

Lower Limit 3rd Lateral Freq.

Copyright PIDOTECH Inc. All Rights Reserved.

Objective Function (1)

Copyright PIDOTECH Inc. All Rights Reserved.

Select an initial design

Automatic Process Using PIDO technology

Evaluate the performance using CAE/Experiment

Are design requirements satisfied ?

Modify design variables

Conventional Design : Sequential / Hierarchical Procedure

x1 x12 x13 x123 x2 x23 x3

x1 x12 x13 x123 x2 x23 x3 x1 x12 x13 x123 x2 x23 x3

MDO : Concurrent / Simultaneous Procedure

l Discipline1: Safety l Discipline2: NVH l Discipline3: Durability

quoted from M.J. Kiemele, Air Academy Associates, 2003

Copyright PIDOTECH Inc. All Rights Reserved.

Long development time

Shifting from Physical Prototype to Virtual Prototype

Analysis Component Layer

Design Component Layer

Message Broker (Socket)

Architecture of PIAnO Developed by PIDOTECH Inc.

Response Surface Model Radial Basis Function Regression Model

Sequential Two-point Diagonal Quadratic Approximate Opt.

Reliability-Based Design Optimization

Taguchi Method (v3.x)

(Manual, ) Design Time

PIAnO Design Time

Copyright PIDOTECH Inc. All Rights Reserved.

Copyright PIDOTECH Inc. All Rights Reserved.

Copyright PIDOTECH Inc. All Rights Reserved.

Objective Function (1)

Copyright PIDOTECH Inc. All Rights Reserved.

Applied CAE Tools

Embedded Design Tools

2nd Bending Frequency

3rd Lateral Frequency

12kg Frame 20%

Copyright PIDOTECH Inc. All Rights Reserved.

Rear Suspension TBA K&C ?

Copyright PIDOTECH Inc. All Rights Reserved.

Maximize Fatigue Life Cycle

Roll Center Height Upper Limit