Increase Innovation Through Simulation - Guillaume Mesplont, Renault Nissan

RNTBCI is a key player in Renault-Nissan CAE landscape. By merging the teams and organizing upper body CAE development by domains, Indian engineers are now able to support remote activities for both OEMs. Not only for performance validation, we are now challenged to support innovation activities, propose countermeasure that deals with performance trade-off and reduce the lead time.

In this context, a partnership has been built with Altair in India. Altair India is giving local expertise to help RNTBCI develop and support local as well as remote activities in 3 main domains: Automation, Optimization and Innovation.

Partnering with Altair enabled us to propose significant reduction in the lead time and the validation of performance in the openings and body structure area. Metier automation scripts were developed to enhance the development process.

In the optimization domain, we implemented MDO and Inspire. MDO was proposed to evaluate performance trade-off between Crash and NVH on a headlamp, and Inspire was used to support local upstream designs of localized parts in various domains.

Finally, Altair local expertize enabled our CAE team to support local innovation laboratory to evaluate new concepts for the future line-up.

Transcript

1. CAE1| 15 July 2015 “Partnering with Altair to Improve Efficiency and Increase Innovation through Simulation Driven Design” 1st October, 2015 Guillaume Mesplont Renault CAE Account Manager Renault Nissan Technology & Business Center India
2. 2 Confidential | Agenda  About Renault-Nissan in India  Challenges in vehicle development  Partnering with Altair  Examples  Innovation  Automation  Inspire  MDO
3. 3 Confidential | Agenda  About Renault-Nissan in India  Challenges in vehicle development  Partnering with Altair  Examples  Innovation  Automation  Inspire  MDO
4. 4 Confidential | CHENNAI  Renault Nissan Technology & Business Center India Pvt. Ltd.,  Strategically located at Chennai About RNTBCI… Airport National Highway No.5 (Kolkatta Highway) National Highway No.4( Bangalore Highway ) Chennai Port Ennore Port   Hyundai National Highway No.45(GST Road) Mahindra World City – Saint Gobain Flextronics Nokia Ford Visteon NMIPL – Nissan , Marketing , Sales RNAIPL Oragadam Plant RNTBCI Center RIPL – Renault , Marketing , Sales NAT RIP
5. 5 Confidential | Operational from April 08 Operational from March 09 Phase 1 Phase 2 • R & AE • Vehicle & P/Train • Global Engg. Support • Process Engineering • Cost Estimation • IS/IT • Purchase • BPO • SSC (Shared Service Center) Business Technology Renault Nissan Technology & Business Centre India ENGG. IS/IT Purchase BPO SSC  Joint Venture of Renault and Nissan.
6. 6 Confidential |  Providing Innovative Automotive Solutions to India Renault Nissan Fleet in India
7. 7 Confidential | Agenda  About Renault-Nissan in India  Challenges in vehicle development  Partnering with Altair  Examples  Automation  Innovation  Inspire  MDO
8. 8 Confidential | Model Setup Report CM & Optimization 80 % of time 20 % of time Model Setup CM & Optimization Reduce Time Report Value added Task Today’s Challenges  Optimum design in the concept phase  Optimizing the design for Multi domain
9. 9 Confidential | Agenda  About Renault-Nissan in India  Challenges in vehicle development  Partnering with Altair  Examples  Innovation  Automation  Inspire  MDO
10. 10 Confidential | Why partnering with Altair in India? Chennai Bangalore RNTBCI  Alliance CAE center  >300 HC  Remote and local projects upstream and Development Altair Technical Center Bangalore  >500 Developers  ESG team  Huge force of development in Altair Technical center Bangalore  Only 50mn flight
11. 11 Confidential | Automation Local design innovation support [Radioss] Upstream Optimization [Inspire] Multi domain Optimization [MDO] Altair Partnership main Areas
12. 12 Confidential | Agenda  About Renault-Nissan in India  Challenges in vehicle development  Partnering with Altair  Examples  Automation  Innovation  Inspire  MDO
13. 13 Confidential | 1. Automation  Example : front door static stiffness evaluation  Over 40 different load cases  Each time have to setup the model, launch calculation, post process and make the report Average 13 hrs
14. 14 Confidential |
15. 15 Confidential |  Benefits & Perspectives 1. Automation  625 man days (3 engineers) of manual work saved  This workforce can be used for value added tasks such as Optimization and Counter-measures.  Opportunity to deploy automation for other Openings calculations
16. 16 Confidential | 2. Innovation : Using Radioss for Airbag Deployment Simulation Methods • UP : Uniform Pressure – Pressure is constant anywhere within the airbag volume – Gas property, injector, vent holes, and jetting effect can be setup on the monitored volume – Multiple chambers can be defined • CEL : Coupled Euler Lagrange – Airbag set into a « cube » of air (Euler/ALE 3-D hexa) – Airbag fabric (Lagrange 2-D shell) coupled with a specific CEL fluid/structure interface (TYPE18) – Gas flow computed using ALE (Arbitrary Lagrange-Euler) method • FVM : Finite Volume Method * – Air inside the bag automatically/transparently meshed and re- meshed during the computation – Airbag input almost same as in Uniform Pressure input card – Gas flow computed using ALE method  LOCAL LCI in India – Collaborative innovation laboratory – is developing inflating parts. Need to simulate inflation and deflation time
17. 17 Confidential | 3. Inspire • Turn table • Seat • Chassis
18. 18 Confidential | Inspire Example #1 - TurnTable Filling the design space and applying boundaries  Rotating table concept
19. 19 Confidential | Inspire Example #2 – 3rd Row seat base bracket Pivot points Seat Base mountings Base Bracket Details  3rd row seat base bracket design optimization
20. 20 Confidential | Inspire Example #3 - Chassis Cas 1 Fx = +xxxN (effort centre roue) Fy = +xxxN (effort pied de roue) Fz = -xxxN (centre ressort) Cas 2 Fx = -xxxN (effort centre roue) Fy = -xxxN (effort pied de roue) Fz = -xxxN (centre ressort) Pied de roue Centre roue Centre ressort  Local project chassis part mass reduction
21. 21 Confidential | Head lamp mounting brackets are considered as the design variable to meet crash performance and NVH performance of the head lamp assembly 4. MDO – Case study  Headlamp support Bracket combined NVH/Crash Optimization
22. 22 Confidential | Target responses: Crash Requirement: The contact force should be less than 3500 N NVH Requirement : The first Natural Frequency should be more than 30 Hz Min / Max Thickness allowable: Min Thickness Allowable is 0.8mm Max Thickness Allowable is 1.8mm 4. MDO – Benefit  Thickness is optimized to reach both NVH and Crash targets at the same time
23. 23 Confidential | Conclusion Partnering with Altair in India main benefits:  Help reduce the lead time with automation  allow more time for added value tasks  Support for new technologies development and competencies ramp-up  Leverage latest technology innovation  Enhance capabilities for C/M studies on project development  simulation driven design
24. 24 Confidential |