Towards more intelligent realism in simulation tools

In a scenario of unstoppable implementation of technologies in constant renewal, the simulation of automotive processes, a standard in the design, development and manufacture of vehicles and components, cannot lose its pace as a vector of competitiveness. Three renowned specialists offer their vision to AutoRevista.

The most outstanding advances in AutoForm's activity, the benchmark in software solutions for sheet metal forming and body assembly processes, are focused on the continuous improvement of simulation accuracy and realism. "The integration of technologies such as assembly simulation or the prediction of process repeatability taking into account production factors already at an early stage of engineering allows a more accurate modelling of process behaviour in various situations. In addition, the optimisation of algorithms and improved processing capacity are bridging the gap between virtual reality and physics, allowing simulations that are ever more faithful to real conditions," Mª Pilar Carruesco, Country Manager of AutoForm Engineering Spain, points out.

New challenges are emerging, such as the simulation of new assemblies, such as battery boxes, which need to be both light and strong. Also the increasing use of aluminium, which implies changes compared to steel (Mª Pilar Carruesco, AutoForm)

Carruesco stresses that "the transition from combustion engine vehicles to electric and electrified models is significantly influencing our activity. New challenges are appearing, such as, for example, the simulation of new assemblies, such as the battery box, assemblies that must be light and at the same time resistant. Also the increased use of aluminium, which implies changes in the manufacturing process compared to steel. And all this is linked to the common strategy of manufacturers to shorten the time to launch a new model at a competitive price in the market".

AutoForm is working closely with OEMs, Tier 1 and Tier 2 companies, technology centres and universities to drive more innovative and efficient developments in simulation software. These partnerships allow us to access additional expertise and resources, as well as to participate in joint research projects to address emerging challenges in the automotive industry". AutoForm’s Country Manager emphasises that "simulation software plays a crucial role in improving sustainability in the automotive industry. It enables the optimisation of designs and processes, which translates into reduced emissions, efficient use of materials and improved fuel efficiency. Furthermore, it contributes to the validation of technologies and strategies that support the transition towards cleaner and more sustainable mobility”.

Currently, AutoForm is working on projects including advanced battery box simulation and body assembly. "Additionally, it is important to note that collaboration and knowledge sharing are key to addressing the evolving challenges of the automotive industry, and we are committed to continue contributing to the advancement of simulation in this dynamic context.", Mª Pilar Carruesco concludes.

Synchronising the supply chain

Elena Madera, Head of Manufacturing and Automotive d T-Systems Iberia, considers that "Solutions such as the digital twin, combined with AI and other technologies, make it possible to generate a more efficient and sustainable production chain, reduce or detect bottlenecks and anticipate component shortages, among other benefits for the industry. At T-Systems, we contribute to the promotion of the entire mobility value chain; on the one hand, mobility as a service, with platforms equipped with standardised software modules, or solutions that facilitate OTA (Over the Air) updates, so that vehicles no longer need to go to the workshop for them".

"On the other hand, we have designed platforms such as GIMM, an MES solution created to synchronise the supply chain by offering a specific response for Just in Time, Just in Sequence, Traceability, Production Control and Warehouse Management, integrated with Machine Learning and Artificial Intelligence, to guarantee a more agile, flexible and profitable industrial production, thanks to the early detection and prediction of possible failures in the production process; and solutions such as Digital Supply Chain from J-EDI Digital Solutions, which ensure traceability of the supply chain thanks to AI-based algorithms 

supply chain thanks to AI-based algorithms, enabling transport optimisation. These solutions are implemented and are a successful reality today in various automotive manufacturers and suppliers".

Regarding the emergence of electric vehicles, in parallel with connectivity, autonomous driving and infotainment technologies, Elena Madera argues that "OEMs are looking for new ways to manage software more efficiently, develop innovative functions faster, ensure scalability and reduce costs through more efficient development processes. From our experience in technology development, we have solutions for safety and software integration related to control equipment, ADAS systems, or I/O integration and testing for OEMs. We ensure the efficiency of the design and creation processes of new vehicles through the digitalisation of factory processes".

Vehicle manufacturers are looking for new ways to manage software more efficiently, develop innovative functions faster, ensure scalability and reduce costs through more efficient development processes (Elena Madera, T-Systems)

Together with seven other leading automotive companies such as BMW, Mercedes-Benz and Volkswagen, T-Systems has helped to form Cofinity-X, "an entity that promotes the efficient and secure exchange of data between automotive industry players in Europe, with the boost of the Catena X and Gaia X project. This initiative seeks to increase the efficiency of the supply chain by ensuring full data sovereignty in an open, trusted, collaborative and secure environment for the parties sharing the information. Also in the data economy, a field in which we are conducting in-depth research through the Chair in Data Engineering, created together with Google and the University of Granada, we are also working in the field of data economics and with the participation of the IA Foundation of Granada".

Regarding sustainability, the T-Systems representative states that "Digital Twin's solutions provide us with virtual and individual representations of a vehicle and its behaviour to facilitate services. Digital Twin's solutions offer us virtual and individual representations of a vehicle and its behaviour to facilitate services; but it also manages to increase efficiency in production operations, improve management, logistics and transport operations, which helps to reduce energy expenditure, and the consequent improvement for the environment. In addition, solutions such as Road Test Predictor, based on an Artificial Intelligence algorithm, help to reduce time, costs and CO2 emissions in on-road vehicle testing, while maintaining the same level of quality".

Elena Madera underlines that "at T-Systems we are proud of our support to international customers to drive innovation in the automotive industry. Earlier this year, we renewed our partnership with Volkswagen Autoeuropa, for the promotion of the cloud in the production plant located in the Portuguese town of Palmela, ensuring the interoperability of local applications to improve production management.It is currently one of 100 production plants worldwide that operate with T-Systems' GIMM suite for production and logistics control. Integrated with Machine Learning and Artificial Intelligence technologies, GIMM facilitates the digitalisation of industrial companies through its three main modules: LINCS: Controls and ensures the correct Just in Time and Just in Sequence synchronisation between automotive manufacturers, component suppliers and logistics operators; PROCS (MES): which carries out production traceability and compliance, assisting line operators in validating each step of the process and ensuring the quality of each part produced; and STOCS (Warehouse Management), which integrates the management of warehouse inventory, space, material handling and transport resources in real time and ensures timely and error-free delivery of materials. Volkswagen Autoeuropa was also the first to implement the Road Test Predictor".

"In addition, internationally, we are partnering with a German automotive manufacturer with the NVIDIA Omniverse solution, powering the migration and management of the secure, sovereign European cloud platform.With Omniverse, companies can unify their tools and 3D data with the OpenUSD standard, enabling teams to collaborate remotely through photorealistic visualisations and simulations of, for example, production lines and industrial facilities.

Digital test tracks

Peter Larsson, Head of Industry & Partnerships at ESI Group, says “In the realm of Virtual Performance Testing, ESI envisions a future where digital test tracks offer an eco-friendly alternative to extensive physical testing. By creating fully operational digital vehicle prototypes and subjecting them to rigorous virtual testing on a simulated automotive test track, automakers can certify new designs in a cost-effective manner, reducing testing mileage and minimizing environmental impact. Whether predicting the performance of vehicle structures in crash scenarios, enhancing the strength of car designs through dynamic testing or ensuring a quiet in-cabin experience through acoustic simulations”.

“From stamping process validation to simulating body casting processes and ensuring strong spot weld structures, ESI’s simulation software plays a crucial role in optimizing manufacturing processes. In addition, ESI is pioneering Collaborative Virtual Workflows in the Industrial Metaverse”.

According to Larsson, “the imperative to reduce weight wherever possible has prompted distinct considerations in structural design, thereby escalating the need to evaluate diverse crash and safety scenarios. Innovations in materials, designed to counter the loss in vehicle mass, necessitate fresh testing approaches to swiftly establish the strength and safety of these materials for vehicle production. A similar challenge is presented by the swiftly evolving field of battery technologies, which remains a relatively unknown territory compared to the wealth of knowledge amassed by automotive OEMs over decades of internal combustion engine (ICE) development”.

“In envisioning the future of mobility safety testing, ESI sees a shift towards 100% digital, smart, and artificially intelligent methodologies. This paradigm aims to empower engineers with speed, precision, and confidence in designing vehicles with optimal safety features. Smart machine learning technology creates a parametric model of the design space requiring fewer high-fidelity simulation runs. Such advancements enable both skilled and non-skilled engineers to efficiently grasp variable effects, pinpoint significant combinations, and prioritize load cases and design parameters for in-depth examination. This fast parametric design space exploration proves invaluable for optimizing virtual crash test results, ensuring vehicle safety, weight, and cost are carefully balanced within a limited timeframe”, says Larsson.

Intelligent machine learning technology creates a parametric model of the design space that requires fewer high-fidelity simulations. These advances enable engineers, both skilled and unskilled (Peter Larsson, ESI Group)

As one of the founding members of the ExcelCar association, ESI is working closely with Stellantis to align innovation initiatives for future simulation solutions with the dedicated needs of this industry. “OEMs have to consider reliability, safety, and energy efficiency early in development, contributing to reduced waste and emissions. Embracing this approach helps manufacturers efficiently navigate complexity, make early trade-offs, and align with decarbonization plans for a cleaner, safer, and more sustainable future. Our IC.IDO Weave, an immersive virtual prototyping solution, facilitates cross-functional collaboration for designing and validating product designs in industries such as automotive and aerospace. The collaboration between SEAT S.A. Technical Center and ESI Group on the development of the CUPRA Formentor, achieving a 5-star safety rating while significantly reducing physical tests, exemplifies the transformative power of simulation software in the automotive sector”.

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Article published in AutoRevista 2.386