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Fenyes4/14/04
Multidisciplinary Analysis and Optimization of Vehicle Architectures
Peter A. FenyesGeneral Motors R&D and Planning
Vehicle Development Research Laboratory
Presented at MIT 4/14/04 for
16.888/ESD.77JMultidisciplinary System Design Optimization
(MSDO)Prof. Olivier de Weck and Prof. Karen Willcox
Fenyes4/14/04
…. Designing Great GM Cars and Trucks !
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Fenyes4/14/04
Multidisciplinary Analysis and Optimization of Vehicle Architetctures
Outline
• The vehicle design process– Early stage vehicle design– Vehicle architecture
• Parametric vehicle representation to support MAO• Multidisciplinary analysis and optimization
– Engineering, manufacturing, business
• Example vehicle design problem• MAO challenges
Fenyes4/14/04
General Motors R&Dhttp://www.gm.com/company/careers/career_paths/rnd/lab.html
Chemical & Environmental SciencesReaffirming GM's environmental principles
Electrical & Controls IntegrationEnabling electronics-based, driver-friendly, smart GM cars and trucks
Manufacturing Systems ResearchTransforming the enterprise through math-based processes and systems
Materials and ProcessesAdapting tomorrow's materials for
today's automobiles
Powertrain Systems ResearchDeveloping high-value, energy-efficient, high-
performance powerplants and drivetrains
Vehicle Development ResearchSpeeding and enhancing engineering
design and development
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Fenyes4/14/04
Vehicle Development Research Lab
• What do we work on?– Safety Systems– Lightweight Materials– Work Systems– CAE Methods– Vehicle Design– Virtual Reality– Mechametronics– Quality Methods
Fenyes4/14/04
Vehicle Design Design and Analysis Timeline
Des
ign
freed
om
Des
ign
deta
il (#
des
ign
para
met
ers)
Conceptual design Detail design
HIGH ARMS LANON-DRIVEN
STRUTSW/COILS
Componentselection
Topology design Parametric geometry
WBL
FO RO
GC
FH RH
LA
LF
LB
LR
LD
LH
h
b
Structures
Aerodynamics
Solar Load
OccupantDynamics
Ride & Handling
FuelEconomy
Crashworthiness
OtherAnalyses*
Representation
System Analysis
Time
Balance requirements
Detailed Analysis
Part design Manufacturing design
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Fenyes4/14/04
How Can MAO be Applied in Vehicle Design?
• Most effective application during early vehicle development– Vehicle “balance and integration”– This will be the focus of our discussion
• Can be applied in more detailed phases of design– Example: tradeoffs for aerodynamics and structure– Example: tradeoffs in component design
Fenyes4/14/04
Example: Architecture Selection Problem
New vehicle requirements
#1#2
#3#4
#5
Populated Databases- Architectures- Materials- Processes
0
1
2
3
4
Arch#1
Arch#3
Arch#5
Concept Description
- Fuel economy
- Wheelbase
- Interior volume
- Bending stiffness
…
Profit by ArchitectureDesign
Representation(Unigraphics)
Database(MS Access)
Multidisciplinary Optimization
(iSIGHT)
Structural Analysis
(NASTRAN)
Fuel Economy(EconoSTRAT)
Market Share(InSight)
Aerodynamics(ASD)
Interior Roominess
(Excel)
BIW Cost(IBIS)
Facilities Investment
(QuickStudy)
Profitability(Excel)
Summary of Results(Excel)
Design for profit
Considerations
• Multiple derivatives/multiple requirements
• Vehicle performance
• Material/process strategy
• Financial/marketing
ParametricArchitectures
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Fenyes4/14/04
Consider the Key Components of an MDO System
Elastic Structures
External Aerodynamics
Solar Load
Occupant Dynamics
Suspension Loads
Fuel Economy
Crashworthiness
Other Analyses*
ResultsDatabase
VehicleDatabase
Para
met
ric
Mod
eler
Dis
cipl
ine
M
odel
ers
Library Data
Library Data
TemplatesTemplates
User Input
Mul
tidis
cipl
inar
y
Opt
imiz
atio
n
Dis
cipl
ine
Ana
lysi
s &
S
ensi
tivity
Cal
cula
tions
Par
amet
ric R
epre
sent
atio
n
Fenyes4/14/04
Parametric Design Representation
• The shared common representation is used to generate analysis input for ALL disciplines
• Need a single consistent representation for architecture and derivatives• Combine UG geometry with non-geometric database
– UG parametric model– BOM data - available/allowable components– Marketing data
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Fenyes4/14/04
Consistent Parametric Design RepresentationThe shared common representation used to generate analysis input for ALL disciplines
• Geometric, non-geometric data
– Templates• Data to be varied parametrically
– Stored in parametric CAD system
– Library data• Data remains fixed (components) - location, orientation/location may change
– Parametric CAD system– Auxiliary database information
– User input• Selection and location of components, settings of dimensional parameters
HIGH ARMSLANON-DRIVEN
P=125
P=63
Fenyes4/14/04
Parametric Design Representation
• Combines– Parametric geometry (Unigraphics)– Non-geometric configuration data (MS Access)
• Many parameters available– High level architecture variables– Detail level component variables
WBL
FO RO
GC
FH RH
LA
LF
LB
LR
LD
LH
h
b
W
T
H
WR
BL
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Fenyes4/14/04
Parametric Geometry Driving Discipline Analysis
High level input parametersWheel baseOverhangsAxle positionsWidth...
Packaging Occupant, section dimensions, BOM items, …
MeasuresAreas, lengths, volumes, angles, …
Aerodynamics….
Resulting geometry used for:
Fenyes4/14/04
Parametric GeometryParametric Dimensions and Occupant Placement