Accelerated Load Data Analysis with LMS TecWare - Download ...

Accelerated Load Data Analysis with LMS TecWare 

Launching LMS TecWare Rev 3 

LMS User Conference 2006 

Dominiek Coppens – Product Line Manager

Agenda 

1 Durability challenges 

2 The durability engineering process 

3 LMS TecWare value proposition 

4 LMS TecWare tips and tricks 

5 Conclusions 

2 LMS User Conference 2006

3 LMS User Conference 2006 

Durability challenges

Industry Challenges 

Challenging market 

requirements… 

Resulting in… 

While competition requires 

rethinking processes… 

! Avoid product recall 

! Superior quality 

! But not over designed 

! Lower price 

! Enormous variety of choices 

! Innovative designs 

! Light weight materials 

! Compact structures 

! More variants 

! On fewer platforms 

! Shorten design cycles 

! Test-based fatigue takes too long 

! Increase productivity of product 

development 

! Gain full insight into durability 

! Improve relationship 

OEM / supplier 


The durability 

engineering process 


Durability engineering process – “As-is” process 

Build – test – redesign – no longer practical 

Strength only ! 

Unrealistic loading 

Time consuming -> overdesign 

Very late in the development process 

Costly 


LMS TecWare 

value proposition 


LMS durability engineering process – “To be” process 

Optimizing for durability performance 

VALUE 2 

Realistic simulation 

through 

representative 

loading conditions 

VALUE 1 

Assess durability 

performance earlier 

VALUE 3 

Accelerate durability 

testing 


The durability engineering process 

LMS’ durability solutions – products and services 

Upfront 

engineering 

Detailed 

engineering 

Refinement 

engineering 

Design Performance simulation 

Test 

CATIA V5 

LMS Test Mobile 

LMS Virtual.Lab 

Designer Fatigue 

LMS Virtual.Lab 

Durability 

The Durability 

Alliance 


Load data processing 


LMS durability solution value proposition - Value 1 

Assess durability performance earlier in development 

“LMS Lifetime prediction software 

identifies and fixes fatigue problems 

in a few days versus several weeks of 

physical testing.“ 

BMW Group 

“LMS durability simulation enabled Fiat 

Research Center to save an estimated 200,000 

dollars on the durability development of a Case 

New Holland tractor and to compress the 

development time with at least six months.” 


! Extends stress analysis by taking into account 

damage accumulation 

! Identify and fix fatigue problems in a few days vs 

several weeks of physical testing 

! Enables what-if studies and results in a refined 

analysis 

! Delivers clear recommendations for guiding major 

design choices 

! Results in fewer iteration studies in testing 

Dr. Kamel Bel Knani, Head of the Structural Durability 

Team at FIAT-CRF

LMS durability solution value proposition – Value 2 

Representative loading conditions – real-life simulation 

Efficiently process huge amounts of data 

“Using LMS TecWare the measurement data processing has been 

completely automated. The graphical interface allows to easily create and 

debug the different steps in the process.” 

DaimlerChrysler 

Manage durability load data 

“Collaborative web-based solution manages durability-specific test 

workflows and knowledge base.” 

Volkswagen 

Predict loads earlier in development 

“To assess the durability performance of our designs in the early development 

stages, we require accurate loading information. Through the implementation 

of LMS Virtual.Lab Motion, our engineering teams generate system loads 

even before they can be measured on physical prototypes of new vehicles. “ 

Bruno Hazet, PSA 


LMS durability solution value proposition – Value 3 

Accelerate durability testing 

! Design and optimize durability test scenarios 

! More accurate and more efficient rig testing 

“LMS will help Ford cut 

months from our 

development cycle and save 

hundreds of thousands of 

dollars.” 

Dr. Weiss, Ford Cologne. 

100 

“Through more accurate 

and efficient rig testing, 

LMS solutions contribute 

to higher product quality 

and lower engineering 

and component costs.” 

ZF Lemforder 

Fahrwerktechnik 

test time [days] 

10 

60 

9 

1 

100% 

From 60 to 10 days ! 

8 

7 

6 

95% 90% 85% 80% 

75% 

“The resulting proving ground and 

rig testing scenarios accurately 

replicated the excitation of the 

actual road in one-hundredth of the 

time that would have been required 

for road testing.” 

Ford Otosan 

rel. damage sum 


Intelligent load data processing using LMS TecWare 

To design representative durability test schedules 

To efficiently process raw data 

To accelerate test scenarios 

To correlate data from 

test track, test rig, CAE 

To efficiently manage 

durability data 



To efficiently process huge amounts of data 

Successful durability engineering requires intelligent load data processing. 

! Processing of raw data into loads for virtual and 

physical tests 

! Automatic detection of : 

! Measurement failures, outliners, etc. 

! Test track segments 

! Streamlines the process from 

! data import, 

! consolidation, 

! reduction, 

! documenting, 

! comparison 

• Fast load data processing 

• Easy for non-experts 

• Customizable to your process 

• Helps to standardize on corporate proced 

“Using LMS TecWare the measurement data processing has been completely automated 

and the resulting reports deliver a maximum of engineering insight. The graphical 

interface allows to easily create and debug the different steps in the process” 



To correlate data from test track, test rig, CAE 

Correlation of results 

Predict loads earlier in development 

“To assess the durability performance of our designs in the early 

development stages, we require accurate loading information. 

Through the implementation of LMS Virtual.Lab Motion, our 

engineering teams generate system loads even before they can be 

measured on physical prototypes of new vehicles. “ 

Bruno Hazet, PSA 


Application case 

BMW using virtual test rigs for loads cascading 

BMW axle test rig for 

non-driven front-suspensions 

BMW Virtual Axle test rig model 

Measurement Initial MBS model Optimized MBS model 

Loads cascading 

! “Numerically measure” interface 

component forces using a virtual test rig 

model 

! Adapt existing ride and handling multibody 

models for durability loads 

cascading 

! Use of LMS TecWare for correlating test 

and simulation 

! Avoid physical prototyping 

! Earlier in the design process 

“Having used LMS durability technologies for load data analysis and numerical 

fatigue life predictions for several years, we are able to improve our durability 

engineering process substantially (...) and reduce the time and costs of the 

development process.” 

Dr. Martin Brune, Manager Predevelopment, Methods, Calculation, BMW Group 



To efficiently manage durability data 

Efficiently search and retrieve 

durability data across departments 

Durability Data Management 

! Web-enabled 

! Data annotation 

! Process management (instrumentation, test 

rig preparation, ...) 

! Data search and download (“Google”) 

! Durability data displays 

! Durability engineering data drivers 

! Remote launching of batch jobs 

The Durability Data Management system controls the different steps in the 

testing process. It allows efficient organization and creation of tasks and 

allows us to find back any data from any measurement campaign in a very 

efficient manner. 



To design representative scenarios 

Damage based on strain gage signals, full truck 

1 

• Condensed test schedules 

• Design customer correlated test schedules 

Accelerated durability testing cycles 

! Meeting 1.2 million km durability 

requirement 

! Real tests would take 3 years 

! Large-scale customer data collection 

! 5000 km Turkish public road data 

! Ford Lommel proving ground 

! Development of accelerated rig test 

! Target setting 

! Test schedule definition 

! Resulting test schedule 8 weeks 

! Test acceleration of factor 100 

LMS engineers performed dedicated data collection, applied extensive load 

data processing techniques and developed a 6- to 8-week test track sequence 

and 4-week accelerated rig test scenario that matched the fatigue damage 

generated by 1.2 million km of road driving. 



To accelerate durability test scenarios 

Reduce transmission time by 85% 

! Reduced testing time 

! Customer correlated 

! No loose of fatigue content 

! Dedicated data reduction methods 

! Process integration 

Load data reduction for rotating components 

! Multi-axial time at level 

! Rotating moment histogram 

! Rotating rainflow counting 

Using hybrid engineering technologies of the LMS durability products we were 

able to improve durability testing procedures for gearboxes and transmission 

system drastically. Certain subsystem tests could be shortened from previously 

several weeks to now less than one day.” 

Dr. Wolfram Weiß, Powertrain development, Ford Köln 



Tips and Tricks 


Durability load data processing 

using LMS TecWare – Tips and Tricks 

Design 

Performance 

simulation 

Test 

Load data processing 

Durability data management 

Streamline 

Load 

data 

Consolidate 

Interpret Document Compare 


data 

Test 

schedule 

definition 


data 


LMS Tec.Manager 

Tip 1. Organize data. 

Rev 3 

Intuitive search 

! Similar to Altavista® or Google® 

! Template-based search 

Analyze search results using 

! Tree navigation 

! Excel style view on attributes 

Full text search 

! Support of all common ‘Office’ files 

! Support of all text files 

Facilitate use of data throughout 

the entire development process 


LMS TecWare Tips and Tricks 

Tip 2. Standardize processes 



Tip 2. Standardize processes 

Rev 3 

! A drastical reduction in the time 

required to process time data 

! Automating tasks - less errors, reduces 

user dependency 

! Easier for non-experts to master - no 

programming skills required 

! Faster creation of sequences of load data 

processing tasks 

! Quicker process flow debugging 

! Helps to standardize on corporate 

procedures 

! Protects investments - supports all LMS 

TecWare methods 



Tip 3 - Reduce vast amount of data 

! Benefits 

! Open to most common file formats 

Can be used for 

Part of 

• Read and write 

• On PC and UNIX platforms 

! No file conversion, hence no time nor disk 

space wasted as data is directly accessed 


File interfaces 

Read 

Write 

Product 

ASCII " " LMS TecWare Kernel 

LMS TecWare IF " " LMS TecWare Kernel 

IST LabSite " " LMS TecWare Kernel 

IST RigSys " " LMS TecWare Kernel 

LMS CADA-X TDF " " LMS TecWare Kernel 

LMS Test.Lab TDF " " LMS TecWare Kernel 

LMS Roadrunner (SKALAR 20) " LMS TecWare Kernel 

LMS Pimento (SKALAR 20) " LMS TecWare Kernel 

LMS Virtual.Lab Time series interface " " LMS TecWare Kernel 

MH E.D.A.S. " LMS TecWare MH EDAS File Interface 

MH E.D.A.S.WIN " LMS TecWare MH EDAS File Interface 

MSC.ADAMS (/Car) Durability interface " " LMS TecWare MTS RPC III File Interface 

MTS RPC-III " " LMS TecWare MTS RPC III File Interface 

nCode DAC " LMS TecWare nCode DAC File Interface 

NI DIAdem " " LMS TecWare NI DIAdem File Interface 

IMC µMUSYCS FAMOS " LMS TecWare IMC µMusycs FAMOS File Interface 

Aditec EDT " LMS TecWare Universal Binary File Interface 

Aditec PBK/PK2 " LMS TecWare Universal Binary File Interface 

HEAD acoustics " LMS TecWare Universal Binary File Interface 

I-DEAS BUF(binary universal file) " LMS TecWare Universal Binary File Interface 

Inhouse data formats via LMS Universal Binary " LMS TecWare Universal Binary File Interface 



Why rainflow counting 

• Basic damage event : closed hysteresis loop 

Interpret 

• Rainflow counting = counting of closed hysteresis loops in time signal 

Rainflow 

counting 

1 

0 

9 

8 

7 

6 

5 

4 

3 

2 

1 

Load history 

from 

load 

level 

1 

2 

3 

4 

5 

6 

7 

8 

9 

1 

0 

to load level 

1 2 3 4 5 6 7 8 9 

10 

Damage 

calculation 

Closed hysteresis 

loop 

Classification 

into bins 

Rainflow Matrix: 

at any from-to cell: entry 

for the numbers of cycles 

to 

(Pseudo-) 

Damage 

from 

constant amplitude 

constant mean 

Lines of constant mean 

and constant amplitude 

in a rainflow matrix 

standing 

hystereses 

hanging 

hystereses 



Accurate Load Data Processing 

Accuracy 

! Features 

! Rainflow counting taking 

residue into account 

! Increased accuracy 

! Increased accuracy for : 

• extrapolation of rainflow matrices, 

• reconstruction to time signals, especially 

for shorter events 

! Multi-axial rainflow counting 

! Increased accuracy for multi-axial loading 

! Rotating rainflow matrix 

! Increased accuracy for rotating 

components 

! CombiTrack : partial 

optimization to design correlated 

test schedule 

! Increased accuracy : closer match 

between durability target and actual test 

schedule 


LMS TecWare Reporting 

! Benefit 

!Efficiently publish, share and compare 

load data 

! Features 

!Creation of template-based reports 

• MS Word 

• MS Excel 

• HTML 

• ASCII csv 

!Multi-page reports 

!Fit for massive amounts of data 

!Full axis labeling 

!Automatic table of contents 

and page numbering 



Tip 4 – Optimize existing test schedules 

Optimized existing test schedules 

! Different methods included for creating damage equivalent 

reduced-length tests 

! Pre-configured batch programs encapsulating input signal 

definition, parameter setting, processing and report generation 

! Methods working in time or rainflow domain, uni-axial or multi-axial 

Accelerate physical and virtual testing 



Conclusion



Streamline 

Everything you need for durability load data processing. 

Successful durability engineering requires intelligent load 

data processing. 

Document 

! Processing of raw data into loading histories for virtual and 

physical tests 

! Streamlines the process from data import, over consolidation, 

reduction, documenting, reporting and comparison 

! Optimizing existing test schedules for physical and virtual tests 

! Define customer correlated test schedules 

! Integrated load data management (via LMS Tec.Manager) 

Streamlining load data processing 

in all stages of the development process 

Consolidate

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