SIMPACK

Automotive
Content

Page 04 SIMPACK Automotive

06 Suspension Design

07 Virtual Component Test Rigs

08 Handling and Driving Dynamics

10 Powertrain and Driveline

12 Ride, Noise/Vibration/Harshness (NVH) and Durability

14 Software-in-the-Loop (SIL)

15 Real-time Applications/Hardware-in-the-Loop (HIL)

16 Specialised Multibody Simulation (MBS) Modelling

Elements

17 MBS Data Handling

18 SIMPACK Engine

19 SIMPACK Interfaces

20 Customers working with SIMPACK Automotive

22 SIMPACK Compatibility


SIMPACK Automotive

The SIMPACK Automotive product family is way up to high frequency durability studies.
used for the dynamic analysis, prediction and SIMPACK also has an optimum connectivity
optimisation of all automotive mechanical to control software and can even export entire
and mechatronic components and vehicles. models as code for SIL and HIL applications.

SIMPACK’s ability to simulate high-frequency The versatility and range of analyses with
vibration and harsh shock contact, in both the SIMPACK Automotive are virtually limitless,
frequency and time domain, makes SIMPACK which translates directly to a huge potential
Automotive the number one choice of leading for reducing development costs. Consequently,
automobile manufacturers for ride and comfort an ever-increasing number of automotive
analyses. Due to SIMPACK’s powerful solver manufacturers and component suppliers are
and use of relative kinematics, extremely fast turning to SIMPACK Automotive as their
and accurate calculations can be carried out, preferred choice for multibody simulation.
from low frequency dynamic handling all the

The versatility and range of analyses

with SIMPACK Automotive are virtually
limitless.


SIMPACK Automotive Application Areas

Plastic Deformation, Abuse, Crash

Amplitude

large Dynamic Loads, Durability

Quasi- Handling, Primary Ride Secondary Ride Comfort, NVH Acoustics

Statics HIL, SIL (e.g. Oscillations
(e.g. (e.g. (e.g. of Engine, (e.g. (e.g.
Suspension Global Chassis Oscillations of Transmission, Steering, Exhaust Brakes, Hydraulics)
Kin. and Movement) Suspensions) Driveline, System)
Elastokin.) Subframes)
small

Vehicle low high Frequency

Oscillations


Suspension Design

Using predefined templates of parameterised – Single sided contacts (bump stops)

standard suspensions enables users to quickly – Friction, stick-slip and hysteresis effects
and easily achieve standard single suspen- – Non-linear, frequency dependent
sion analysis results, for both kinematics and bushings
elastokinematics. Not only can quasi-static – Flexible components (leaf springs,
characteristics like camber, toe, etc. be calcu- twist beam suspension, flexible damper
lated during jounce/rebound and steering, but rods, etc.)
also additional results like natural frequencies, – User specific routines
mode shapes, transfer function, etc. Standard
models can always be further enhanced with
more detailed modelling and specialised ele-
ments like:

A SIMPACK user can always further

enhance standard models with more
detailed modelling and specialised
elements.

Virtual Component Test Rigs

Seat Rail Vertical

Due to SIMPACK‘s transparent and simple

modelling structure, any type of single auto­
motive component and virtual test rig can be
set up by the user. Easy comparison and
validation (using virtual test rigs with real mea­
surements), enables users to carry out further
optimisation, with confidence, on well verified
virtual components. With SIMPACK substruc-
ture techniques, these verified components can
easily be used within more complex complete
system models, without additional modelling – Oil pump velocity sweep
and verification effort. Application examples of – Chassis mechanisms
general automotive components within virtual – Steering shimmy test rig
test rigs include: – Single suspension transfer function
– Engine bearing test rig
– Exhaust system transfer function
– Truck cabin excitation test rig
– Driveline roller test rig
– Hydropulse test rig

All components and vehicles can be easily

investigated in SIMPACK using virtual
test rigs.


Handling and Driving Dynamics

Complete vehicle models are set up very ef-

fectively, efficiently and clearly using SIMPACK
Autmotive predefined and parameterised com-
ponent models. With substructure techniques
all components can be exchanged easily with
user defined components in order to refine the
level of model detail. Standard open and closed
loop handling and driving dynamic simula-
tion scenario definitions (e.g. constant radius
cornering, lane change, sinusodial steering,
braking while cornering) are also available with
predefined substructures.

Various vehicle configurations and

manoeuvres may be easily set up in
SIMPACK for the simulation of handling
and driving dynamics.

 Result Comparison of Driving Dynamics Manoeuvres

In order to adapt complete vehicle models and

associated simulation scenarios many SIMPACK
Automotive specific modelling elements are
available:

– Various tire models

– Tire characteristic test plots
– Track (road) definition
– Curve superelevations
– Road height plan
– Single obstacles
– Deterministic road irregularities
– Longitudinal and lateral vehicle
controller (driver model)


Powertrain and Driveline

SIMPACK Automotive offers a detailed library

of specialised powertrain and driveline com-
ponents. Therefore, complete, detailed vehicle
models can be set up in order to study the
complex 3D behaviour during engine-power-
train-driveline-vehicle interactions.

All associated modelling components are com-

patible and communicate with the SIMPACK
time domain solver in order to optimise solver
stability, accuracy and performance for such
complete and complex full vehicle models.
SIMPACK Powertrain and Driveline component
examples are:

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 Pull Away and Gear Shift

– Kinematic and elastic gear boxes with

non-linear stiffness and clearance
(manual gear box, planetary gearbox,
differential gearbox)
– Detailed gear wheel force element with
position dependent stiffness (parameter
excitation)
– Gear shift during simulation
– Gear wheel synchroniser element with
contacts and friction
– Universal and constant velocity joints
– Flexible driveline shafts
– Engine torque or gas force based drive-
line excitations
– Driveline roller test rigs

For powertrain and driveline components,

SIMPACK offers a comprehensive element
library and extensive functionalities.

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Ride, NVH and Durability

Correspondence of Measured Data

SIMPACK’s solver is not only ideal for handling

high frequency analyses (even into the acoustic
range) but also for investigations involving
extreme non-linear manoeuvres and harsh
shock contact, such as “idiot-starts” (sudden
clutch release), curb strikes, bridge jumping,
etc. With the additional SIMPACK NVH (Noise/
Vibration/Harshness) module, users may also
benefit from the powerful, time saving, linear
system analysis. Because SIMPACK enables easy
comparisons between linear and non-linear
methods, a user can always be assured of the
suitability of the chosen method.

Extreme non-linear manoeuvres and harsh

shock contact such as “idiot start“ and
bridge jumps are easily simulated using
SIMPACK‘s reliable solver.
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SIMPACK also enables fatigue life predictions
of virtual prototypes. The flexible components
may either be investigated as part of an entire
complex vehicle model or individually analysed
using virtual test rigs. Because the methods
using SIMPACK incorporate both the modal
coordinates and the time dependent reaction
forces, dynamic loading is also considered.
Using SIMPACK as the basis for durability
analysis (as opposed to a transient FE-analysis)
can save vast amounts of computation time
and resources.

Validation of Simulation Model

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Software-in-the-Loop (SIL)

A standard Inter Process Communication (IPC)

coupling enables SIMPACK users to easily
interface their models with other CAE soft-
ware or their own software code for advanced
mechatronic investigations. In addition to co-
simulation with MATLAB/Simulink®, users may
also take advantage of the MATLAB Real-Time
Workshop® and export entire parameterised
Simulink® models directly into SIMPACK. The
reverse approach may also be employed (de-
pending on the software emphasis) with entire
parameterised SIMPACK models exported as
S-functions directly into Simulink® or any other
simulation environment.

Complex Car Model in SIL Environment

Several methods of interfacing SIMPACK

to external programs enable users to
define “best practice“ processes for SIL
applications.
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Real-time Applications (MIL, HIL)

Code Export enables SIMPACK models to be SIMPACK offers the unique approach to use
exported to external platforms for SIL, MIL one common data source in order to para­
(Man-in-the-Loop) and HIL (Hardware-in-the- meterise offline and online (real-time) MBS
Loop) applications. Complex models created models simultaneously. This saves vast amounts
for dynamic, ride and durability investigations of modelling and verification time.
can also be used as the basis for real-time
applications. Therefore new SIMPACK elements
and methods have been specifically developed
for real-time applications in order to achieve
the required computation speeds.

Complex Truck Model in HIL Environment

Driving Simulator – Courtesy of DaimlerChrysler AG

Entire parameterised SIMPACK models can

be exported as code for MIL/HIL use.

15
Specialised MBS Modelling Elements

In order to simulate high-end 3D MBS models – Physical parameter based frequency and
(with frequency and amplitude dependent amplitude dependent force (bushing)
behaviours for example) numerous specialised elements
MBS modelling elements are available within – Measurement based (transfer function)
the SIMPACK Automotive product family. force element description
These include: – Stick Slip friction force elements
– High frequency comfort and durability
tire force elements
– Detailed air spring models
– Beam based leaf springs with contact
and friction
– User routines

An extensive range of modelling elements

in SIMPACK enables high-end simulation.

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MBS Data Handling

SIMPACK offers a data handling concept which

enables the user to organise and store MBS
model data in hierarchical, structured database
directories. By using model parameterisation
and substructures a clear separation of struc-
ture and parameterised data can be achieved.
In this way redundant data can be avoided and
development levels will be stored in terms of
associated parameter sets.

Whether carrying out analyses with highly

detailed models for ride investigations, or with
less complex models for HIL or SIL simulations,
common databases may be used.

Model Database

Model variants may be easily generated

and investigated by using the SIMPACK
database structure.

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SIMPACK Engine

The SIMPACK Engine product suite may crank shafts, hydro-dynamic bearing, etc.) may
also be easily used together with SIMPACK be easily incorporated. The use of SIMPACK
Automotive. parameterisation and substructures enables
efficient and secure model creation. Due to
SIMPACK Engine includes modelling elements SIMPACK‘s common database structure and
specifically implemented for detailed engine modelling elements all SIMPACK models, e.g.
simulations covering single component analysis Automotive or Engine models, are completely
to complete dynamically coupled engine compatible and therefore may be easily inter-
investigations. All engine components rang- connected and exchanged.
ing from valve trains (dynamic valve springs,
elastic contacts, etc.) and timing mechanisms For more detailed information please refer to
(chain, gearwheels, etc.) to crank trains (flexible the SIMPACK Engine brochure.

SIMPACK Crank Train SIMPACK Valve Train SIMPACK Chain Drive SIMPACK Engine

+ + =

SIMPACK Automotive functionalities may

be further enhanced by SIMPACK Engine
which enables the simulation of complete
coupled engines.
18
SIMPACK Interfaces

SIMPACK’s versatility and excellent interfaces

enable users to combine the core competence
of different software tools for optimum usage.
The strong interfaces also enable SIMPACK to
be easily integrated into a company‘s already
established and proven development processes. CAD

FEA
SIMPACK Interfaces to:
CAD, FEA, Durability, Control, Hydraulic, etc.

Durability

Control

Hydraulic

SIMPACK interfaces to CAD, FEA, durabil-

ity, control and hydraulic programs further
increase the range of SIMPACK‘s applica-
tion areas.
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Customers working with SIMPACK Automotive

SIMPACK is now the world leading multibody “SIMPACK has enabled us to rapidly
simulation software for commercial vehicles enhance our dynamic simulation
and the number one choice of leading auto- capabilities with a level of versatility
which enables the use of fewer
mobile manufacturers for ride and comfort
core models. This, in turn, leads to
analyses.
a more efficient design support
process and reduced response time
for track support tasks.“

Richard Frith, Midland F1 Racing Ltd.,

United Kingdom

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“For almost ten years, SIMPACK has “Over the past few years, SIMPACK “MAN has been using SIMPACK since
been used at BMW Acoustics and has become an important tool in the very first version. Since then
Vibrations Development. A modu- the development process of our SIMPACK has matured into an indis-
l­arised database has been achieved, Mercedes-Benz vans and trucks. pensable tool for handling, NVH,
which includes the whole range of With SIMPACK, we have the ability active control, and durability investi-
vehicles with all the different sub- to design vehicle models based on a gations of both trucks and buses.
systems, e.g. engines, powertrains master model database for different
and suspensions. The SIMPACK vehi- applications, for example for vehicle We consider both INTEC‘s nearby
cle model is part of the virtual car driving dynamics, ride comfort, drive location and its outstanding com-
process for design and evaluation of train vibrations, durability, braking petence in simulation technology to
vibration characteristics, such as ride system layout, and the layout of be invaluable for productive coopera-
comfort, powertrain, chassis and active systems.“ tion.“
body vibrations.“
Thomas Ille, MAN Nutzfahrzeuge AG,
Joachim Pressel, DaimlerChrysler Germany
Andreas Raith, BMW Group,
Commercial Vehicles Division,
Germany
Germany

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SIMPACK Compatibility

SIMPACK Automotive offers users the power From mounting configurations of single com-
and versatility to carry out an almost infinite ponents to entire mechatronic vehicle analyses,
range of analyses. Because all modules within from handling manoeuvres to high frequency
SIMPACK are 100% compatible, automotive durability studies, from linear system analysis to
users can also benefit from SIMPACK develop- non-linear shock contact, from co-simulation
ments originating out of other engineering to hardware-in-the-loop, SIMPACK Automotive
disciplines. offers the complete, harmonised solution.

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If you would like additional information or
brochures please contact us or visit our website
at www.simpack.com.
INTEC GmbH
Argelsrieder Feld 13
82234 Wessling
Germany
Tel. +49 8153 9288-0
Fax +49 8153 9288-11
intec@simpack.de
www.simpack.com