Numerische Simulation in der Automobilindustrie: Big Data in der industriellen Praxis

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1 Numerische Simulation in der Automobilindustrie: Big Data in der industriellen Praxis Clemens-August Thole

2 SIDACT Fraunhofer Spin-Off starting January 1st, 2013 FEMZIP Compression of simulation results DIFFCRASH Robust Design: Identification of areas in geometry causing scatter of simulation results SDMZIP Compression of sets of simulation results Marketing, support, new application areas 5 full time, 4 students

3 HPC Systeme und Archive DWD Cores 3 PByte ECMWF Cores 40 PByte DKFZ Cores 20 PByte Automobilhersteller Cores ~1 (6) PByte Viele keine unabhängige Systeme 32 (Crash) 512 (CFD) cores pro Berechnung, max. 1 Nacht pro Simulation Die meiste Rechenzeit für Crash und CFD 4 40 GByte pro Simulationsergebnis (Akustik auch mehrere Tbyte) Ergebnisse werden meist nach ein paar Monaten gelöscht

4 Anwendungsbereiche numerischer Simulation Strukturmechanik Fahrdynamik Innenströmungen Außenströmungen Crashsimulation Steifigkeit, Vibrationen, Wärmeübertragung Komfort, Kühlung, Verbrennung Kühlung im Motorraum, Luftwiderstand, Verschmutzung von Heckscheibe, Funktion Scheibenwaschanlage Simulation von Produktionsprozessen Umformen, Walzen, Beschneiden, Gießen Prozessketten Elektrische Schaltkreis Simulation Elektromagnetische Kompatibilität Kopplung verschiedener Disziplinen

5 Marktbedeutung von Numerischer Simulation Zum Vergleich IBM: $19,600 Mitarbeiter: Based on CIMdata estimates, the Mainstream PLM market grew 12.6% in 2012 to $21.1 billion. Once again, simulation and analysis (S&A) was the fastest growing segment, showing the increasing importance of S&A across the product development life cycle.

6 Softwarehersteller CAD Gittergenerierung Numerische Software Postprocessing Dassault Systems (F) CATIA Siemens Pro-E (D, USA) Beta (GR) Ansa ANSYS (USA, GB), MSC (USA), ESI (F), CD-Adapco (USA, GB), Simulia (F, USA), LSTC (USA), MAGMASOFT(D), Intes (D) GNS (D), Altair (USA), Beta (GR)

7 FEMZIP - mp3 for simulation results CRASH FEMZIP-L for LS-DYNA FEMZIP-P FEMZIP-R FEMZIP-ERFH5 FEMZIP-a4db for PAM-CRASH for Radioss Explicit for PAM-CRASH new format (beta) for GNS Animator4 database CFD (FEMZIP-ENSG for EnSight Case Gold) (FEMZIP-CCM FEMZIP-OF for StarCD (.ccm data format)) for OPENFOAM (beta, incremental and distributed data handling) NVH FEMZIP-N for OP2 (NASTRAN / Radioss Implicit)

8 Data Compression Floating-point data cannot be efficiently compressed losslessly:» A compression factor of only 1.2 is obtained» The solution is FEMZIP Airflow simulation around a car: 6 variables, 43 million elements, 21 time steps

9 Lossy Data Compression Quantization Floating point data is rounded to a given precision and mapped into the integer domain. Prediction A bijective transformation is performed to prepare those integers for encoding purposes (reduce entropy). Encoding Afterwards an entropy encoding method is used which removes redundant bits. 32/64-Bit float 13534, » FEMZIP achieves compression factors of about 10!

10 Result of ensemble forecast Simulation Analysis 10% probability bounds

11 Initial position of singular vectors in winter 92/93

12 Buckling Knickstab Tubes Buckling mode as result of linear structural analysis

13 DIFFCRASH : Stability analysis Postprocessing tool Statistical Analysis of full simulation models Basic analysis methods Correlation based methods PCA based methods

14 Difference PCA (Patent beantragt) State 0 State 8 State 34

15 Thank you for your attention! Clemens-August Thole