Advanced Simulation Techniques Drive Powertrain Design
Commercial Vehicle Designers are Using A Variety of Simulation and Validation Tools…
…as they attempt to find new ways to improve many aspects of vehicle design. Engineers are working with a growing number of tools and physical parameters as they attempt to add features and functions that often require close interaction between systems.
Engine makers do a lot of simulation and validation to better understand the trade-offs in powertrain design. Cummins’ new structural B6.7 engine for agricultural tractors is shown. (image: Cummins)
Design software tools allow developers to do more with models, letting them try a range of options before beginning to work with hardware and prototypes. This ability to simulate using virtual components and systems is critical for design teams trying to improve safety and functionality while cutting fuel consumption and emissions.
As vehicles and subsystems get more complex, improvements often come when engineers can analyze many factors using a range of tools. Multiphysics software is becoming increasingly important. Computational fluid dynamics, finite element analysis, and model-based simulations are among the tools being used.
“Advanced simulation techniques continue to drive the design process in both the on- and off-highway industries,” said Kiran Govindswamy, Vice President, NVH, and Vehicle Engineering at FEV. “This includes the use of hybrid-methodologies which may include the linking of multiple simulation toolchains, like CFD/FEA and MBS/FEA or a judicious combination of test and CAE-based data. As an example, test data for vehicle noise transfer functions can be combined with simulated powertrain/driveline vibration and noise to simulate the customer’s experience at the driver’s ear location, well before physical prototypes become available.”
In areas like engines, it’s difficult to further improve fuel economy while meeting emissions requirements. Minute changes in one area often have unexpected consequences, forcing engineers to process a number of design iterations to understand how tweaks of one parameter impact other facets of the design.
“There’s a lot of complexity, so we need to do a lot of validation,” said Jonathon White, Executive Director of Cummins Engine Business. “From a powertrain perspective, we need to understand how we go about making trade-offs.”
