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Basics of Product Data Management in Automotive Engineering

Conference Paper · April 2009

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 Institute of Automotive Engineering

Basics of
Product Data Management in
Automotive Engineering

Name of institute

Mario Hirz
Institute of Automotive Engineering
Graz University of Technology
M. Hirz 2009
 Institute of Automotive Engineering

What is PDM ?

PDM (Product Data Management) includes all organization based tasks for
the identification, the supply and the archival storage of product related data
during the product development.
Nomenclature:

EDM … Engineering Data Management, former notation of PDM

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Development of PLM-technologies

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Development of PLM-technologies

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Why PDM ?
Change of products

Volkswagen
Beetle 1939

VW model
range 2009
Nowadays:
Big number of car variants
Manifold drive train & chassis configurations
Manifold supplementary equipment

Source: VW

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Why PDM ? - Summary

PDM helps to organize the data and information flow throughout the
development process.

The management of the entire flow of data, processes and documents

during the development or modification of products across the products
lifecycle states the basis for an efficient virtual product generation.

Complex product structures or product variations create numerous product

parameter and information. A powerful PDM system supports the interaction
of the data transfer between different phases of the development.

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Simultaneous engineering
Conventional procedure
Project start

Production
Definition of Concept 3D/2D Optimization Production
requirements phase design planning

Procedure with simultaneous engineering Time

saving
Project start

Definition of
requirements Concept

Production
phase 3D/2D
design Optimization
Production
planning
Integrated virtual
product model

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Challenges

Product development in the automotive industry presents several

challenges in the area of PDM, including:

• Insufficient transmission of knowledge gained in process and knowledge

management to product data management
• Systematic approach to the design and development of PDM processes
and systems (functional strategy, roadmap)
• Few use cases for operative and project-oriented application of PDM
• The implementation of PLM approaches involves some difficulties,
especially in larger companies with complex structures
• Data management activities can lack a process orientation
• Excessive orientation towards systems and software in PDM designs

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Main functionalities of PDM

File management
Product oriented

Product structure management

Data archive
functions

Documentation & scripts

Configuration management Data network

Product versions / releases
Product classification
Lifecycle management

PDM System
Status management
Process oriented

Change management
Process interfaces
functions

Process management
Release management
Workflow management
Rights & communication
Project management
Lifecycle management

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Main functionalities of PDM

Workflow
Product structure management
management Project
management

Relations
PersonsProcessesPartDocumentFile

Management of Classification -
documents Variants
A1 A2
Module 1
B1 B2
Part x
C1 C2

acording to Müller, N.

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Product Data
- Product defining data in view of technical requirements
(target specification data)
- Product describing data in view of technical product documentation
(article code, article attributes, releases …  BOM)
- Geometry data
Characteristics of data
- Process data
- Data quality
- Product configuration data
- Data age, maturity
- Meta data
- Project progress
- Documents
- Data status
-…
- Data format
- Utilization and validity, …

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Management of documents

- Provision of data and documents

- Documents
- Target requirements, technical product specifications
- Standards, job instructions
- Drawings
- Documentations
- Test reports
- Offers, contracts
- Documents of change management
- Manuals, scripts
- Data archiving
- Document control
- Document distribution

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Workflow management
- Control of document (modification, verification)
- Integration of customer & supplier
- Distribution of documents
- CAD data management Change management
- DMU / CAx workflow - Problem identification
(detection, registration and tracking)
- Change management
- Modification proposal (assessment of
adaptation variants, synchronization of
involved parties, result definition)
- Modification order (start of product correction)
- Modification verification (model check)
- Release management (update of data manage-
ment system, customer and supplier)

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PDM system architecture

Graphical user interface

Functional modules
Application related functions Application
- Product data management
independent
- Document management functions

Interfaces
- Product structure & configuration management
- Classification management - External
- Management of product configurations functions
- Workflow management - Collaborative
- User management functions
- Project data management -…

Administration
Data base system Configuration
Settings

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Relationship between CAD, CAE, CAT and CAM

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Criteria for the integration of CAD-systems

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Examples of application for CAx - process workflows

DMU (Digital Mock Up)

FEM (Finite Element Method)

CFD (Computational Fluid Dynamics)

MBS (Multi Body System)

CAD VR (Virtual Reality)

TPD (Technical Product Documentation)

RPT (Rapid Prototyping)

NC/RC/MC
(Numerical Control / Robot Control / Measure Control)

PPC (Production Planning & Control)

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Process workflow: CAD - DMU

• Digital Mock Ups are digital dummies, which include a simplified

representation of a product.
• DMUs contain information of:
- Product geometry (volumes and / or surfaces)
- Product structure
• DMU – processes are used for packaging studies, clash detection,
mounting & assembling simulations, and others.
• Basis for the DMU – processes are converted (simplified) 3D-CAD data
from a virtual product model (master model).
• Based on the simplification, the accuracy of a DMU model is lower than
those of the 3D-CAD master model (DMU  tessellated geometry).
• In the DMU process, a direct modification of geometry data is not
possible.

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Process workflow: CAD - DMU

Example:
Vehicle packaging study

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Process workflow: CAD - DMU

Support of frontloading - approaches by:

• Handling of large data structures through the product development
• Localizing and elimination of problems in complex assemblies
• Target oriented and early assembling based optimization

Trends:
• Geometrical freeze in early sections of the development cycle
• Integration of functional investigations into the DMU process
• Integration of data from supplier and external engineering partners
• Integration of DMU software functionalities into 3D-CAD software
packages

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DMU - process

3D-CAD design
DMU model
Master model: Data transfer
CAD - native data Simplified model:
including history & Tessellated geometry
Common data formats:
structure CAD native, STEP,
data & model structure
IGES, VDA, …

DMU investigations
Information back flow - Packaging
- Clash detection
- Assembling simulation
- Kinematics
-…

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Process workflow: CAD - FEM

• The Finite Element Method (FEM) is used for the calculation of stress,
deformation, thermal load and natural frequency.
• The FEM calculation process is based on an approximated geometry, witch
is derived from the 3D-CAD model. Depending on the type of geometry
and on the target of simulation, different types of approximation are used.
• The data transfer from the 3D-CAD model into the FE – program is
performed by a discretization process.
• Boundary conditions of loads (forces, momentums, …), restraints (fixed
components, bearings, ...), material characteristics, temperatures, etc. are
defined in the FE – program.
• After the simulation process, the results have to be evaluated and lead to
an optimization of the master geometry in the 3D-CAD program. A direct
modification in the FEM – software is not possible.

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Process workflow: CAD - FEM

stress according to Mises

FEM simulation of a
1-cylinder engine crank train

conrod

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Example of application:
natural frequency

Torsional oscillation Bending oscillation

f = 226 Hz
f = 406 Hz

f = 880 Hz f = 413 Hz

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FEM - process

3D-CAD design FEM model

Master model: Data transfer Geometry approxi-
CAD - native data mated by finite basis
including history & Common data formats: elements
structure CAD native, STEP,
IGES, VDA, …
Information back flow

Analysis & FEM calculation

evaluation
- Boundary conditions
Stress - Load definition
- Deformation - Material characteristics
- Natural frequencies - Rules & functions
-… -…

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Process workflow: CAD - CFD

• CFD (Computational Fluid Dynamics) - simulation enable the calculation

and optimization of gaseous and liquid flow processes.
• Similar to the FEM calculation process, the CFD - model is based on a
approximated geometry, the CFD - mesh.
• The data transfer from the 3D-CAD model into the CFD - program is
performed by neutral standard data formats (STEP, IGES, …).
• Boundary conditions of the calculations are defined in the CFD -
program directly.
• After the simulation process, the results have to be evaluated and lead to
an optimization of the master geometry in the 3D-CAD program. A direct
modification in the CFD - software is not possible.

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Example of application:
CFD simulation of a water jacket

T
,T
V

DMU including cylinder Convection heat transfer

and cylinder head of a coefficiency at the water
1-cyl. engine jacket

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Process workflow: CAD - MBS

• Multi Body Simulation (MBS) is used for kinematical based calculation and
optimization of assembled (movable) products.
• The MBS - model is based on the CAD - product structure, whereas bodies,
links and joints are considered as rigid in principle.
• Boundary conditions (forces, momentums, masses, degrees of freedom in
movement) are defined in the MBS program.
• The MBS model often consists of simplified geometrical elements, which
are equipped with relevant data for the kinematical calculation.
• After the simulation process, the results have to be evaluated and lead to
an optimization of the master geometry in the 3D-CAD program. A direct
modification in the MBS - software is not possible.

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Example of application:
MBS simulation of an automotive suspension

Simulation of suspension characteristics under

different road conditions

source: ADAMS

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Process workflow: CAD - VR

• VR (Virtual Reality) describes a computer - generated virtual environment,

which works as user interface.
• VR based studies include the user into the virtual environment.
• Real time interactions of geometries and / or functionalities support an
assessment of the model.
• An imagination of manipulability objects gives a near to real life feeling of
the virtual product.
• The VRML - data format (Virtual Reality Modeling Language, 1994) was
designed to display 3D - models and to integrate user based interactions.
• VRML - data, which are generated from a 3D-CAD master model, include
simplified geometry information without history data.

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Examples of application

sources: VRVis, Audi

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Process workflow: CAD - TPD

• The Technical Product Documentation (TPD) enables a derivation of

technical drawings, bill of material, spare part lists, prospects, and others
directly from the 3D-CAD model.
• The CAD master model has to include all the required information (product
structure, geometry, tolerances, material, production related data, etc.).
• TPD – formats are: Text based (PDF), 2D - vector & pixel graphics (DXF,
TIFF, GIF), hypermedia formats (HTML, XML), or 3D-documentation
software based formats (3D-PDF, WRL)
• TPD processes are always linked to standardization regulations and
guidelines (ISO, DIN, company defined standards).

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Examples of application

2
1
1… piston
2… piston pin
3… piston pin bearing
3
4
4… con rod
5… lower con rod bearing
6… crank pin
6
7… crank webs

3D – exploded view
Part list and 2D – workshop drawings

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Process workflow: CAD - RPT

• Rapid Prototyping (RPT) is used to generate hardware models from virtual

geometry data during the product development phase.
• The early available prototype enables real life studies, test bench
optimization or customer discussions.
• RPT is used for concept models, design- or ergonomic studies or functional
tests and optimization.
• Rapid prototypes are generated from a tessellated geometry, which is
derived from a 3D-CAD master model. The most usual file format is STL
(Structural Triangle Language). STL geometries are based on triangulated
surfaces without any history or product structure information.
• Productions techniques are Laser Sintering, Stereo Lithographic, 3D-
Printing, etc.

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Process workflow: CAD - RPT

Virtual product

Physical rapid
prototype

source: Bluming

Physical product
source: ZCorp

source: rapid MFG

source: Ducati

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Process workflow: CAD - NC/RC/MC

• CAD - NC/RC/MC (Numerical Control / Robot Control / Measure Control)

processes take over geometry data of a product from a 3D-CAD master
model into a manufacturing specific environment (language).
• Beside the geometry information, the master model includes all production
relevant data (tolerances, surface treatment, material characteristics, etc.).
• A NC - data model contains machine-specific information of applied tools,
model fixation, cutting speed, and others.
• RC - data enclose handling and / or assembling relevant data of the
product in the manufacturing process.
• MC - data define prescribed measurement procedures for the analysis of
the manufacturing process, deviation of tolerances or abrasion parameters.

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Example of application:
Stamp milling simulation

sources: predator CNC

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Process workflow: CAD - PPC

• PPC (Production Planning & Control) includes the administration and

organization of manufacturing relevant data and procedures.
• Only released product data are transformed into the production planning
process.
• PPS data base on the 3D-CAD geometry, 2D- drawings and additional
manufacturing relevant information.

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Process workflow: CAD - PPC

Bill of Material (BOM), working schedule, manufacturing recourses

CAD / CAM: PPC:

Basically technical functions Basically economical / operational functions

CAE/CAD/CAP
- Product concept - Customer order

Production
planning
- Design / simulation - Project calculation

planning
- Process planning - Requirements planning
- Material logistics - Material logistics
- C - programming - Production capacity calculation
- Order release

- Control of NC - machines
CAM / CAQ

Production
- Transportation control - Production management & control
control

control
- Storage management - Operating data logging
- Assembling control - Controlling (time, quantity, costs)
- Maintenance management - Shipment management
- Quality management

according to Scheer

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Abbreviations
BOM ...… Bill of Material
CAD …... Computer Aided Design
CAE ….. Computer Aided Engineering
CNC ….. Computer Numerical Control
CFD …... Computational Fluid Dynamics
DIN …… Deutsches Institut für Normung (German Institute of Standardization)
DMU ….. Digital Mock Up
DXF …... Drawing EXchange Format
FEM …... Finite Elements Method
GIF ……. Graphics Interchange Format
HTML … HyperText Markup Language
IGES ….. Initial Graphics Exchange Specification
ISO …… International Organization for Standardization
MC ……. Measure Control
MBS ….. Multi Body System
MPV ..… Multi Purpose Vehicle
NC ……. Numerical Control
PDF …... Portable Document Format
PDM ….. Product Data Management
PLC …… Product Lifecycle Collaboration
PLM …... Product Lifecycle Management
RC ……. Robot Control
RPT …... Rapid Prototyping
STEP …. Standard for the Exchange of Product data
SUV …... Sport Utility Vehicle
TIFF …... Tagged Image File Format
TPD …... Technical Product Documentation
VDA …... Verband Der Automobilindustrie, DIN - standard for data exchange
VR …….. Virtual Reality
WRL ….. Web Rule Language
XML …... Extensible Markup Language
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Further literature:

ISBN-13: 978-3642119392
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Thanks for
your attention

M. Hirz
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