Day 1 | User Conference 8th October
Delivery mode:

Physical +Onl ine /Hybrid09:00 am – 09:15 am Welcome & introduction

Keynote Address
09:15 am – 10:00 am Increasing engineering efficiency by cyberphysical prototyping
Prof. Dr.-Ing. Guenther PROKOP | Chair of Automotive Engineering | TU Dresden
10:00 am – 10:30 am Green, sustainable technologies for automotive transmission validation
Mr. Hiral Kumar Patel | Deputy General Manager | Tata Motors Ltd.
10:30 am – 11:00 am Tea / coffee / bio breakUsers’ presentations
11:00 am – 11:30 am Multidisciplinary concurrent design for reusable launch vehicle & space craft
to realize future missions with multi-physics modeling & simulation
Mr. Kaname Kawatsu | Associate Researcher R&D dept. | Japan Aerospace
Exploration Agency (JAXA) & NewtonWorks Corp. Japan
11:30 am – 12:00 pm Evaluation of low-frequency NVH phenomena in electric vehicles using a
modular drivetrain library in SimulationXMr. Martin Ebert | System Simulation Engineer | IAV GmbH
12:00 pm – 12:30 pm Enhancing sustainability in machinery with digital twins and systemsimulation
Mr. Sven Bätzing | Product Area New Business Virtual Engineering | Rexroth BRSL

12:30 pm – 01:00 pm Simulation-based analysis of system hydraulics in building energy supply: A
case study of a networked residential and industrial district
Mr. Pascal Jirschik| Project engineer | EA Systems GmbH
Continued…

Day 1 | User Conference 8th October
Delivery mode:

Physical +Onl ine /Hybrid

01:00 pm – 02:00 pm Networking lunch & breakUsers’ presentations
02:00 pm – 02:30 pm Gearshift simulation: shift feel perception using HIL method
Mr. Yogesh Tongaonkar | Sr. Manager Transmission Development| Tata Motors Ltd.
02:30 pm – 03:00 pm Multibody systems models of trucks for digital twin development
Mr. Roktim Bruder | Simulation engineer | Daimler Truck AG
03:00 pm – 03:30 pm Simulation models as the core of a digital twin for a copper ore mine

Dr. Torsten Hellmuth | Sr. Key Expert – Product Management Mining | INNOMOTICS
GmbH
03:30 pm – 04:00 pm Utilizing SimulationX to assess and redesign jackleg hammer drill
Ms. Srividya Kuppa| Researcher, Department Of Systems Design Engineering |University Of Waterloo, Canada
04:00 pm – 04:15 pm Tea / coffee / bio break

SimulationX news
04:15 pm – 05:00 pm Key updates, news & announcements

Wrap up & Dinner
05:00 pm – 05:30 pm Closing remarks, summary & take-aways
06:30 pm onwards

Team building & dinnerContinued…

Day 2 | Tutorial Day 9th October
Delivery mode:

Online•09:30 am – 10:00 am Introduction & gearing up•

10:00 am – 12:30 pm: Scripting in SimulationX with Python
REQUIREMENT / Pre-requisites: Python 3.12 installed & virtual environment for SX set up

Setting up the Python environment and introduction to Jupiter Notebooks, SimulationX tools•

and the Workflow Automation library•

Preprocessing and postprocessing data by means of Python•

Reducing a detailed physical model structure into a map-based type to improve computationtime•

Utilize advance analysis methods by using Python to speed up your analysis•

Easier handling of big models by automation•

12:30 pm – 01:30 pm: Lunch break•

01:30 pm – 03:30 pm: Recommended tips & tricks to improve efficiency & experience•

Learn how to set up a convenient simulation environment for different use cases and how
efficient workflows can improve your experience in SimulationX••

Configuration of SimulationX•

Configuration of result windows•

Efficient workflows

Inside .isx – short introduction to the structure of an SimulationX project file and how to

attach additional data•

Advanced modelling methods for easier modelling•

Using the inner and outer declarations for e.g. easier distribution of parameters•

Use initial equations to define boundary conditions at simulation start easily•

03:30 pm – 04:00 pm: Q&A with tea/coffee•

04:00 pm – 05:30 pm: Special use case – Inverse kinematics•

Identify actuator movements and forces or torques to follow a predefined trajectory in a system with multiple
degrees of freedom to derive the necessary operation range and size of drives in this kinematics

Transcripts of all theconference presentation
abstracts

All Abstracts

Increasing engineering efficiency by cyberphysical prototyping
Prof. Dr.-Ing. Guenther PROKOP | Chair of Automotive Engineering | TU Dresden
Today's development cycles must be cost-effective, fast, flexible, and resilient. Thereby product complexity andrequirements on safety, sustainability, and performance are ever increasing. The V-model is thus supplemented by agile
methods, which impacts how test and simulation methods have to be combined efficiently. Cyberphysical methods aredesigned to support this change in system engineering methods:
1. Cyberphysical prototyping: the vehicle is divided into subsystems, each of which can be developed using respective
testrigs and/or simulation models. Testrigs and simulation models can be coupled in real time to form cyberphysical fullvehicle prototypes. Digital twins of testrigs and highly advanced control concepts are required.
2. Human centered attribute development: cyberphysical prototypes can be experienced subjectively at every
development stage, if coupled with a highly immersive driving simulator. Moreover, driver experience and driver
behavior can be understood and predicted by feeding measured driver behavior into driver models.
3. Smart test environments for automation and connectivity: the cyberphysical prototype has to be considered incontext to its environment (road space, informational radio connections). The appropriate test environment is tocombine physical vehicles with simulators for several traffic participants.
Prototypes for these instruments are being developed at TU Dresden. Their role in modern development isdemonstrated in the presentation.

Green, sustainable technologies for automotive transmission validation
Mr. Hiral Kumar Patel | Deputy General Manager | Tata Motors Ltd.
With the increase in car emissions, several developing & developed countries are implementing strict regulations tominimize the environmental impact of the automotive industry. Sustainable product development and ensure minimal
CO2 emission are prime concern for automotive industry. Undoubtedly, moving towards a clean /greener, more
ecological solution presents an ideal business move for automobile manufacturers, offering significant potential to drivea more sustainable future. Automotive OEMs target Net-Zero-CO2 between 2030-2040. As a result, companies areactively focussing on development & launch Electric and Hybrid powertrain vehicle in the market. Recent statistics
highlight the transformative impact of green energy on the automotive industry, with electric vehicle (EV) sales
witnessing
remarkable
growth
withmultipleOEMs
andstartups
entering
inthisfield.
Another pivotal aspect of this transformation is the front loading of development activities through digital validation
process for robust product development catering to need for faster launch of new products. Road load data acquisition
and accurate duty cycle generation for target market is need of hour as huge cost and resource gets engaged in thisactivity at early product development stage. Accuracy of this data determine success of the product in the market.
Simulation tools available now-a-days can be used for this application. Range anxiety is another area where simulation
tools can help to derive optimal drivetrain strategy.

Evaluation of low-frequency NVH phenomena in electric vehicles using a modular drivetrain libraryin SimulationXMr. Martin Ebert | System Simulation Engineer | IAV GmbH
A very important aspect for the development of electric vehicles is the early analysis of vibration phenomena of the edrive axles in their mounts, which lead to high dynamic loads on the drivetrain and high mount forces when the
excitation is taken into account. The presentation will introduce an efficient simulation method using a modular model
library in the software SimulationX - starting from the excitation source at the wheel-ground contact, to the vehicle
model. Furthermore, the influence of the model detailing of the wheel-ground contact and thechassis on the accuracy of the simulation results is examined. These models can be used, for example, for an initialassessment of low-frequency vibration phenomena during different driving maneuvers, such as ABS braking on badroad surfaces or driving over uneven surfaces with one side (full-load approach and full braking). The presentation also
shows mathematical optimization possibilities for the arrangement of the aggregate mount components based on thesemodels. In addition, the partial model exchange with other simulation programs via the FMI interface is described.

Continued…

All Abstracts

Multidisciplinary concurrent design for reusable launch vehicle & space craft to realize future
missions with multi-physics modeling & simulation
Mr. Kaname Kawatsu | Associate Researcher R&D dept. | Japan Aerospace Exploration Agency
In collaboration with NewtonWorks Corp. Japan
In order to realize future space missions that are unprecedented and difficult, such as landing of reusable rockets andautomatic docking of spacecraft, it is important to determine feasibility and technical risks at an early stage.
Furthermore, there are issues with the reproducibility of the actual operating environment and the costs involved inground tests, making comprehensive evaluation difficult. Therefore, in addition to ground tests using conventional
hardware, efficient model-based evaluation is required. Therefore, JAXA had introduced multidisciplinary concurrent
approach for mission feasibility and safety evaluation by focusing on the interaction of complex physical domains andusing models that integrate multiple elements (mechanisms, control, propulsion systems, etc.) to realize future space
missions.
Reusable launch vehicles of the future are expected to drastically reduce space transportation costs. Realizing a radical
reduction in cost for space transportation requires not only reusable design efforts for longer life but also technologies
that will improve reusable launch vehicle readiness, reliability and safety. In evaluating system feasibility during concept
studies, it is necessary to identify important characteristics and bottle-neck technologies that contribute significantly tocapacity and mass regarding design specifications and operational conditions. Furthermore, from the perspective ofrobustness against weather conditions during operation, it is necessary to evaluate sensitivity and understand
optimization trends through parametric study. During attitude control or landing phase, both vehicle reorientation anddrag from atmospheric flight incite large amplitude propellant slosh that may affect vehicle stability. Landing mechanicalload transfer to the vehicle body is key of structure design and stability is important. Each phenomenon needs to beevaluated certainly and has strong interaction through such as vehicle attitude, position, and velocity during landing
phase. Therefore, achieving optimized design require a multi-physics system-level evaluation with affordable evaluation
cost which enables parametric study considering vehicle specification, constraint, and variation of condition.
Rendezvous docking (RVD) is a key technique for space activities and missions, including in-orbit servicing and planetary
exploration missions. This technology is gaining importance because it makes a wide range of space activities andmissions possible. These activities include orbital supply and replacement services, and assembly of large spacestructures that cannot be launched as a whole. In fact, the RVD is one of the crucial technologies in the International
Space Station (ISS) program to provide physical connection for the crew and resources. One of the planned missions of
the HTV-X, successor to the HTV, is a demonstration of automatic docking system. After transporting cargoes andleaving the ISS, the HTV-X can be used as a platform for technical demonstration. The docking system needs to achieve ahigh level of reliability and safety. However, there are many scenarios for safety measures of the time-variant actuatorstates on both the vehicle and the docking mechanism. The HTV-X vehicle must integrate the attitude control systemand the automatic docking system during design evaluation and safety assessment. For safe autonomous docking withthe target spacecraft, it is essential to evaluate the interaction of the host vehicle and the automated docking
mechanism regarding failures and other off-nominal events to ensure that the system is trustworthy. However, it isdifficult to comprehensively evaluate and verify the system only by ground testing because of the difficulty of
reproducing the operating conditions in space. Therefore, this study applied a model-based approach to the design
evaluation and risk assessment of the automatic docking system, aiming to simulate normal and off-nominal scenarios
under accidents or failures accurately.

Continued…

All Abstracts

Enhancing sustainability in machinery with digital twins and system simulation
Mr. Sven Bätzing | Product Area New Business Virtual Engineering | Rexroth BRSL
Co-Authors: Dr.-Ing. Nils Menager, Mr. Rüdiger Kampfmann
Sustainability has been gaining in importance in all areas of society for several years. Therefore, OEMs, machine
operators, government and society expect extensive activities from machinery suppliers. Bosch Rexroth has taken thischallenge and pursues a holistic approach from cradle to grave. This means that the whole life cycle of a product isconsidered, i.e., from raw material mining up to recycling.
In the industrial sector, the operating phase of a machine is of particular importance, as it has a massive impact on theCO2 emissions, whereas in the sector of consumer goods, it is often the manufacturing phase that is more significant.
Hence, the power consumption of machines used in industrial production should be already considered and minimized
during development. This applies especially to hydraulic machines such as presses and injection molding machines,
which often have a high energy consumption.
However, a component-based approach alone is not meaningful. Instead, the interaction of the entire machinery must
be considered, and the energy consumption is strongly dependent on the used cycle. Without the usage of digital twins
and Virtual Engineering methods, the energy consumption can hardly be calculated before commissioning, especiallysince norm cycles are not always defined. Simulation usage makes it also easy to compare different machine concepts,
including analyses regarding energy efficiency and power consumption, and thus to find an optimal setup.
Bosch Rexroth has recognized this demand and provides digital twins in form of the Modelica library Rexroth BRSL. The
BRSL is a 1D system simulation library with a focus on hydraulic and electric drive technology. It provides everythingfrom a single source that is needed to create a representation of the static, dynamic and kinematic properties of an
entire machine or system in the form of a digital twin. Finally, this digital twin can be used both for well-known andestablished use cases like the validation of the dynamic systembehavior already in early phases of the development cycle, but also for future-relevant topics like the energy analyses
mentioned above.
The library contains a huge variety of generic components, but also fully parameterized and validated models of Bosch
Rexroth components. The generic models have to be parameterized manually, e.g. on the basis of data sheets, and cantherefore be used in a versatile and flexible manner. This allows usage of these models to represent the behavior of
products from many different manufacturers. The also available pre-parameterized models, however, require no further
parameterization. All parameters including the required efficiency tables for energy analyses are already stored inside
the component model, so that the models are ready-to-use as soon as they are placed on the modeling area. On the
one hand, this avoids possible errors during parameterization, on the other hand, the time required for modeling can besignificantly reduced. Every Rexroth component has a unique type key that specifies it. A Rexroth component model canbe easily integrated into the Modelica model by selecting its type key from a dropdown menu inside the parameter
dialog of the Rexroth base component model. This allows a well-organized representation of the huge amount ofavailable type keys and makes it easy for the user to insert special Rexroth components into his system model.
In this contribution it is shown how Virtual Engineering based on BRSL can contribute to a future-proof engineering.
First, an overview of the BRSL and its content is given and the possibilities of how BRSL models can be used together
with components from other libraries within SimulationX are presented. Afterwards, the use of the library specifically forsustainability use cases is presented using an industry-relevant example.

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All Abstracts

Simulation-based analysis of system hydraulics in building energy supply: A case study of a
networked residential and industrial district
Mr. Pascal Jirschik| Project engineer | EA Systems GmbHFor carbon-neutral and efficient design of energy systems, the complexity of the system hydraulics is increasing.
Simulation-based analysis of system hydraulics is important for a better understanding of the planned energy system,
especially when integrating renewable energy sources and other generation systems in parallel. For this reason, thesimulation-based analysis and optimization of system hydraulics in the building energy supply will be investigated on
the basis of a networked residential and industrial district.
The redevelopment of several commercial/office and cultural buildings will be supplied with heating and cooling. In
addition to district heating, reversible heat pumps will be used to utilize waste heat from the cooling process for heating.
A large ice storage system is planned for peak shaving. A cooling system with a downstream air heat pump for de-icing
is planned to provide residual heat and cold from the environment. In addition to the dimensional analysis of theindividual components, the comprehensive control of all components and their interactions represents a significant
challenge.
Due to the dynamic characteristics of such a complex system, this presentation will analyze the possibilities and resultsof a model-based dynamic simulation with SimulationX and our in-house simulation library GreenCity.

Gearshift simulation: shift feel perception using HIL method
Mr. Yogesh Tongaonkar | Senior Manager Transmission Development| Tata Motors Ltd.
Gearshift feel is one of the basic customer touchpoint with which the customer makes an impression about therefinement and robustness of vehicle build quality. Current practice of evaluation of the gearshift quality involves
measurement on vehicle and processing of this data to arrive at objective parameters quantifying the results. This
process requires presence of physical components assembled in the vehicle making it a time consuming and costly
process. In addition to this, to arrive at desired shift feel, might require multiple design iterations further delaying thefinal product. The process being discussed in the presentation involves HIL method using gearshift simulator. Gearshift
simulator is basically a dynamic servo actuator capable of simulating a gear shift with real time inputs from the driver.
Design parameters of the transmission are given as input to the controller and based on the driver inputs the controller
provides real time feedback on the shift lever of the simulator which is perceived as gear shift event. Any design
iteration can be readily accommodated in the model and its perceived shift quality can be evaluated quickly thereby
reducing cost and time of the activity.

Multibody systems models of trucks for digital twin development
Mr. Roktim Bruder | Simulation engineer | Daimler Truck AG
Co-Authors: Sven Dronka, Christoph Schramm (ESI Group)
In the past years, software-in-the-loop (SiL) simulation models have become more and more relevant for thedevelopment of ECUs (Electronic Control Unit) and the virtual validation of vehicles. Due to the increasing complexity of
ECU functions and their interaction with different physical subsystems of the vehicle, SiL simulation is a powerful andresource-saving tool for the development of intelligent, sustainable, and safe vehicles.
Therefore, Daimler Truck develops a modular framework, which allows the rapid modeling of a Digital Interdisciplinary
Vehicle (DIVe) with its mechatronic interactions between virtualized ECUs (vECU) and the physical models of the vehicle.
The modularity of the framework allows experts of different fields of work to contribute to a pool of modules.
For many years already, SimulationX contributes different modules into the DIVe module pool for the generation of theDigital Twin. To increase the efficiency of the module generation process, the transformation of the SimulationX model
into a DIVe conform module was fully automated. With this approach, various models of vehicle subsystems can be
integrated quickly into the DIVe framework.
In the past, SimulationX provided various models of the conventional or electrified drivetrain or the pneumatic andhydraulic braking system. Recently, Daimler Truck utilized SimulationX to model the multibody dynamics of trucks toaccurately simulate their vehicle dynamics. This multibody model was extended with models for the steering and tire
subsystems to ensure that the Digital Twin represents the handling of the real truck as realistically as required.
Various applications of the Digital Twin models are already an integral part of the development process at Daimler Truckand save time and costs as well as provide options that cannot be covered by testing. The co-simulation of a multi body
vehicle model with multiple control modules for the development of autonomous trucks and active safety systems ispresented.

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All Abstracts

Simulation models as the core of a digital twin for a copper ore mine
Dr. Torsten Hellmuth | Senior Key Expert – Product Management Mining | INNOMOTICS GmbHThe transport line of a copper ore mine is about 13km long and consists of 12 belt conveyors. Each belt conveyor wasmodeled in SimulationX. The models run 24/7 in parallel with the real system and provide various data which, combinedwith the measured values of the belt conveyors, provide essential information and KPI ́s on the technical condition of
the system as well as on the process quality.
The models are continuously scaled automatically to minimize possible deviations between the real belt conveyor andthe model due to wear or temperature influences.
The digital twin, in particular the belt conveyor models and the scaling function developed together with ESI, are thesubject of this presentation.

Utilizing SimulationX to assess and redesign jackleg hammer drill
Ms. Srividya Kuppa| Researcher, Department Of Systems Design Engineering | University Of Waterloo,
CanadaThe project “Assessing and Redesigning Jackleg Hammer Drill for Mining Operation” aims to reduce the vibrations
reaching the user’s hands and the weight of the Jackleg pneumatic drill through comprehensive vibration analysis andperformance simulation. Using SimulationX software’s capabilities, we will simulate the Jackleg drill’s working mechanics
and vibrational behavior under load, no-load, and different rock hardness operating conditions. Critical factors
contributing to the vibration from the model, mapping vibration intensity and propagation across the device will beidentified, and a design modification will be proposed.
SimulationX's dynamic analysis will enable us to create a comprehensive model of the Jackleg Drill. Physicalcharacteristics and the operating parameters will be replicated as per the original design of the drill. By conducting
vibration analysis within the simulated environment, we can pinpoint the sources of excessive vibration, predict theirpropagation route, and assess the overall performance. Proposed modifications may include redesigning specific partsof the device or selecting other materials. The effect of redesign and material replacements will be modeled against the
mapped vibration across the device.
To validate the simulation results, experimental vibration measurements of the drill will be conducted by instrumenting
the drill with accelerometers. The experimental data points will be compared against the simulation results to verify themodel and design iteration.
The outcomes of this project will provide actionable insights into design insights, potentially leading to a redesigned
Jackleg drill with lesser vibrations at the user’s end and reduced weight.