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CAE

Passive safety

Crashworthiness: All kind of crash test procedures

Occupant protection:

  • Full restraint systems integration & validation
  • Whiplash simulation
    • Phase 1: Model construction
    • Subsystem tests for correlation
    • Whiplash test-CAE LOOP
  • FMVSS 201, Knee Mapping, OoP...

Pedestrian protection: Euro NCAP & ACEA test procedures

Particular studies: Bumper test, seatbelt anchorage, RCAR analysis

Road infrastructure:

  • Directive EN-1317 passenger cars, buses, trucks

Stiffness and fatigue analysis

Static stiffness

Dynamic stiffness

Fatigue analysis

  • Input forces from in-vehicle data acquisition
  • ADAMS (MultiBodySystem) model
  • Dang Van
  • Life prediction

Thermal analysis

  • Parcel shelf: Flexion at T=90º
  • Creep analysis
  • Interior trimming: Thermal expansion 90º
  • Thermal clearance analysis

NVH

Frequency and shape modes optimization

  • Body-in-White
  • Trimmed body

Correlation in prototype phases

  • Pretest: Definition of the wireframe
  • Simulation: Modal analysis

Calculation of the acoustic response

Analysis of sound pressure level:

  • Occupants position
  • Different car configurations
  • Different cases of excitations
  • Global noise simulation from test loads

Squeak & rattle

  • Important in the quality perception of the customer
  • Influence on the tiredness and nervousness of drivers
  • Methodology developed for detecting possible problems by simulation

Squeal noise

  • On-vehicle brake squeal characerisation on real conditions (speed, temperature, brake pressure)

    • Exterior noise recordings with microphones near the wheel
    • Interior noise recordings with microphones or Head-Acoustics
    • Vibration measurements on components
Squeal conditions
  • Main frequencies and noise amplitude
  • Squeal braking conditions: speed, temperature, brake pressure

CAE analysis

  • Diagnostic tool
  • Analyses based on test data
  • Countermeasures focused on disc and caliper

On-vehicle squeal validation

 Vehicle dynamics

IDIADA uses the latest CAE technology for simulating vehicle Ride, Handling and Durability performance. Many in house techniques have been developed that allow integrated functional teams to work together. Typical simulation activities include:

Chassis design & development

Tuning support and target establishment

Active safety & chassis control system development

Suspension optimisation studies

Ride comfort and durability analysis

Powertrain installation and driveline analysis

Tyre characterization & development

Fluid dynamics

External aerodynamics

  • LES turbulence model: detailed transient airflow
  • RANS turbulence model: efficient assessment
  • Styling phase: hat optimization
  • Engineering phase: body optimization

Aeroa-coustics

Defrost systems

Heating, Ventilation & Air Conditioning (HVAC)

Underhood thermal management: Workflow
  • 1D simulation: cooling system definition
  • 3D simulation: airflow & part temperatures
    •  Automated methodology for model set-up (1 month - 1 week)
    • All physical phenomena considered:
      • (Heat exchangers / evaporators, condensers / compressor, fans / convection / conduction / radiation)

Engine simulation activities

  • 1D simulation with Gt-Power; AMESIM

    • Performance
    • Emissions
    • Combustion
    • Functional:
      • (Air and fuel consumption / pressures / temperatures)
  • 3D simulation with AVL fire

    • Intake and exhaust
    • In-cylinder flow
    • Injection
    • Combustion prediction
    • In-cylinder pressure and temperature
    • Emissions

Optimitzation

 Automated optimitzation

  • Solver independent optimizer
  • Combination of multiple load-cases
  • Library of optimization algorithms
  • Optimization variables:
    • Weld-spots position
    • Stamped parts thicknesses
    • Material definition
  • Stochastic analysis
  • In-house developed methodology
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