Automotive Benchmarking using High Energy X-Ray Scan Technology

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Imogen Hart
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rela'onships between Careso< Global and its customers.

1 Automotive Benchmarking using High Energy X-Ray Scan Technology Copyright Informa0on: 2019 Careso9 Global. This document may contain confiden'al informa'on pertaining to strategic plans, data and business rela'onships between Careso< Global and its customers. This document is provided only for the intended recipients. Please do not distribute or copy the content in any form without a wri@en authoriza'on from Careso< Global.

2 Disclaimer This document is for the intended recipient(s) and the organization employing the recipient(s) ( Organization ) only. No part of this document in whole or in part shall be shared with any third-party apart from the recipient(s) and the Organization. Caresoft Global Inc. and all its operating units, subsidiaries, and its authorised representatives claim no responsibilities and/or obligations of any kind against any harm or perceived harm caused to the recipient and the Organisation by sharing this document in whole or in-part to parties other than the intended recipient(s). Caresoft Global Inc. and all its operating units, subsidiaries acknowledge the rights of all the registered trademarks and names used in this document. Caresoft Global Inc. and all its operating units do not claim affiliation or arrangements of any kind with the OEM of the vehicles referred in this document. By reading the contents of this document, storing, and distributing this document, the intended recipient is understood to have agreed to the terms in this disclaimer. 2

3 Agenda q Who we are q Automotive Benchmarking (Current Methodology) q How has Caresoft Changed the Game? q Beyond Commercialization: Educational Mission q Q&A 3

4 Caresoft Global Who we are?

About Us Founded in 2007 and headquartered in USA A global engineering

citizens in various geographies ISO 9001, ISO 27001 ITAR certified

conglomerate Sakthi Automotive Manufacturer of Chassis & Drivetrain

Engineers graduating every year) and 12 schools (all non-profit) Social

5 About Us Founded in 2007 and headquartered in USA A global engineering services and software company 1,700+ global resources with 75% local citizens in various geographies ISO 9001, ISO ITAR certified Affiliated with the Sakthi Group in Detroit a $2 billion global conglomerate Sakthi Automotive Manufacturer of Chassis & Drivetrain components Groups Educational Institution 9 Technical Institutions (2000+ Engineers graduating every year) and 12 schools (all non-profit) Social responsibility Food shelters, hospitals, schools, orphanages and old age homes in North America, Belgium, Italy and India 5

6 Our Global Presence North Dakota Iowa Illinois Querétaro Michigan Wisconsin Pennsylvania Georgia UK Germany Belgium Austria France Hungary Italy Portugal New Delhi Pune Bangalore Chennai Coimbatore Pollachi Shanghai Changsha Japan Sete Lagoas Belo Horizonte Curi'ba 6

7 Awards For Our Innovative Technology Ford Smart Pillar World Excellence Award, 2018 Automo've News All-Stars Award 2018 Automo've News Pace Award,

8 Automotive Benchmarking Current Methodology

9 Traditional Benchmarking Process Vehicle Picture Package Optical Scanning PRE-TEARDOWN Vehicle Measurements Weighing Traditional Way Pre-Teardown Document Optical Scan Teardown Teardown Photos of Systems Optical Scan Key Systems Manufacturer Information Material Information TEARDOWN 9

elementary optical scan data sets No notes on strategic choices made by OEMs Non

10 Limitations of Traditional Benchmarking Traditional way Traditional way No actionable intelligence Data limited only to photographs, Bill of materials and elementary optical scan data sets No notes on strategic choices made by OEMs Non existent advance engineering data CAD and Analysis OEMs cannot decipher costing data 10

11 How has Caresoft Changed the Game?

Benchmarking using High Energy X-Ray Scan Technology Non-destructive method of automotive benchmarking using high energy scan technology 3D data of an entire vehicle with an accuracy of ~100-750

12 Benchmarking using High Energy X-Ray Scan Technology Non-destructive method of automotive benchmarking using high energy scan technology 3D data of an entire vehicle with an accuracy of ~ microns (0.1mm 0.75 mm) Technology Benefits of High Energy Scan Ability to understand the design intent of the components and assemblies Electrical Topology, Architecture, Connector and EDS Digital mock-up view 3D assembly view with parametric Precise internal and external geometries, opening a new frontier of scientific competitive assessment 12

13 High Energy X-Ray Scan Technology Density Variation Complete Vehicle All Density Components Medium Density Components High Density Components The Tesla Model 3 is fully operational after the high energy scan 13

14 High Energy X-Ray Scan Technology The vehicles are fully operational after the high energy scan 14

15 High Energy X-Ray Scan Technology Internal Layout 15

16 High Energy X-Ray Scan Technology Door Harness Routing 16

17 High Energy X-Ray Scan Technology Battery Layout 17

18 Scan to 3D CAD: Electric Powertrain 18

19 Electric Powertrain Detailed CAD Model All the components are captured & modeled to greater detail and higher accuracy 19

20 Scan to 3D CAD (Vehicle Architecture) 20

21 Engineering Insights from High Energy Scan Technology High Energy CT Scan Detailed 3D CAD Mesh models CFD and other analysis..and a lot more Electrical systems routing and should costing Vehicle packaging and VR 21

Caresoft s Innovation Vs Industry Full Vehicle Selected Sections 3D

(STEP files) Optical Scan Point cloud data will only be provided with

22 Caresoft s Innovation Vs Industry Full Vehicle Selected Sections 3D CAD Data (STEP files) Optical Scan Careso< Compe'tors 3D CAD Data (STEP files) Optical Scan Point cloud data will only be provided with outer boundary whereas our deliverable will include internal part details. Accuracy of the assembled point cloud data from competition is approximately 5 mm whereas Caresoft CAD accuracy is approximately 0.35 mm. 22

23 Body and Structures

24 BIW 3D CAD Model X-Ray Scan Input 3D CAD Model 24

25 BIW 3D CAD Model X-Ray Scan Input 25

26 BIW 3D CAD Model All internal reinforcements on A pillar, B pillar etc. are available in CAD B pillar Exploded View 26

27 BIW 3D CAD Model Shell with Battery Section Section with Weld Details Adhesive /Glue/Sealant/Foam in 3D CAD Weld Details ü ü ü ü ü Weld, Adhesive and sealant details in 3D CAD Infinite sections from CAD to study the design intent Higher Analysis co-relation % (using 3D CAD data) Better understanding on manufacturability and tooling Detailed study of the assembly sequences (Using 3D assembly) can be performed 27

28 BIW CAD Model (with component type) Stamping parts Castings parts Extrusion parts 28

29 BIW CAD Model (with reinforcement) Sill Cross Sec'on 29

30 FE Model Joining Techniques and Material Properties BIW - MESH SPOT WELD & RIVETS HEXA WITH CONTACT BOLTS RIGID-BEAM-RIGID COMP1-SOLID-COMP2 2T 3T 4T e.g RgdBody-BEAM-RgdBody MATERIAL PROPERTIES Stress Strain ξ σ (MPa) Example: STRESS STRAIN DETAILS WELD (Seam, Fillet, Laser, etc.) - RIGIDS ADHESIVE HEXA WITH CONTACT 30

31 Analysis and Simulations TORSIONAL STIFFNESS ANALYSIS BENDING STIFFNESS ANALYSIS Front Suspension Tower Rear Suspension Tower Front Suspension Tower Rear Suspension Tower TORSION MODE MODAL ANALYSIS BENDING MODE FREQUENCY Hz FREQUENCY Hz 31

32 Full Vehicle FE Model ü AXLE SYSTEM ü BATTERY ASSEMBLY ü BIW ASSEMBLY ü BRAKE ASSEMBLY ü CENTER CONSOLE ü CLOSURES ASSEMBLY ü COOLING ASSEMBLY ü E-DRIVE ASSEMBLY ü EXTERIOR TRIMS ü FRAME ASSEMBLY ü GLASS ASSEMBLY ü HVAC ASSEMBLY ü INSTRUMENT PANEL ASSEMBLY ü INTERIOR TRIMS ü LAMP ASSEMBLY ü NHL ASSEMBLY ü PEDAL ASSEMBLY ü SEATING ASSEMBLY ü STEERING ASSEMBLY ü SUSPENSION ASSEMBLY ü TRIMS CLOSURES ü WHEELS ASSEMBLY 32

33 Full Vehicle Frontal Crash Simulation FRONTAL CRASH FMVSS msec 50 msec 25 msec 50 msec 75 msec 100 msec 75 msec 100 msec 25 msec 50 msec 75 msec 100 msec 33

harness serviceability study Special routing and channel system Interface with

34 Full Vehicle Electrical and Electronics Architecture Separate Channel for Signal wires Separate Channel for Power wires Routing and fixation methodology Wire harness serviceability study Special routing and channel system Interface with other systems like BIW & Chassis Safety Strategy (HV Cables) Space claim strategy 34

35 Electrical Harness Routing Harness interconnection and component positioning studies Routing Strategy Routing fixation and space claim strategy 35

36 Electrical Harness Routing IP Harness Routing and Fixation Strategy 36

37 Electrical and Electronics Harness Drawings Harness Costing ü Splicing and crimping techniques ü EMI suppression techniques ü Wire size, materials used, multicore cables, special type of covering ü Wire table information (with connection information) ü Components (connector, terminal, etc.) and used for various applications ü Harness Layout & Length Information ü Harness Fixations information(cable tie, Fir tree & Support parts) ü Harness Manufacturing BOM information ü Wire table information (From and to end of wire) ü Harness cost analysis 37

38 Manufacturing Process Analysis - Instrument Panel Findings at a glance Course of assembly Key Findings ProKon units from assembly steps Assembly Sequence Tool List 38

39 Manufacturing Process Analysis - Powertrain 39

40 Engineering Data in Virtual Reality 40

41 Other Applications of HE Scan

42 Automated Inspection Reference Frame Reference Region of Interest Reference Frame Reference Region of Interest Reference Frame Reference Region of Interest Skip Porosity Undercut Defect Frame Defect Detec0on Defect Frame Chassis Frame Welds Defect Detec0on Defect Frame Defect Detec0on Engine Head - Shrinkage Engine Head - Broken Core 42

43 Engine Head Analysis Engine Head Engine Head CT Scan Automated Defect Enhancement Steel Inserts with Details Minimized Beam Hardening Improved Dimensional Accuracy Top Steel Inserts 43

44 Data Analytics Defect Detec'on, Classifica'on and Quan'fica'on Automa0c Defect Enhancement Study of Gas Porosity Defects Knuckles 44

45 Benefits

46 Digitized Data Integrates Different Functions Vehicle Packaging and Digital Mock-up (3D CAD model of all systems in customer preferred CAD platform) Engineering teams Simulation and Analysis (CAE) Electrical Schematics and Harness Drawings (Full Vehicle) Electronics and CAN Analysis (when possible) Finance Manufacturing Product Validation Latest Technology and Innovation Costing Design for Manufacturing Assembly Analysis (DFA/EHPV) Capability Assessment - Performance Analysis Engineering Information (CAD) in PLM Allows global access for OEMs Extended Reality Simulation Motoview.com 46

47 Beyond Commercialization

48 Caresoft Benchmarking Data to Universities Caresoft has decided to graciously offer all of the work that they have done for the Tesla Model X for free to colleges and universities Caresoft has implemented their data sets in Michigan Technological University and are also working with a handful of universities in Europe, China, and Japan. Universities/Colleges under discussion for Caresoft benchmarking data implementation 1 Western Michigan University 2 Saginaw Valley State University 3 Eastern Michigan University 4 Lake Superior State University 5 University of Michigan Dearborn 6 Lawrence Tech University 7 Wayne State University 8 Michigan State University We believe our complete vehicle level engineering data can be of immense value to the students studying engineering and the professors for research purpose 48

49 Q & A 49

50 Thank you

COMPANY PRESENTATION. engine for life

COMPANY PRESENTATION. engine for life COMPANY PRESENTATION engine for life The MATADOR Group History Establishment of MATADOR Automotive Czech Republic Beginning of tire production in Púchov Acquisition of MATADOR Automotive Vráble Rubber