LMS_News_March_2010 by vecomtech

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									March 2010   LMSNEWS

         Advancing global
         aerospace projects
         Satellite integration and testing
         Aircraft-spacecraft development
         Virtual intelligent test rigs
         Optimized rocket engines
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LMSNEWS - March 2010

 04                          06                        12                        16                          18
 Insight                     Satellite testing         Modal analysis            GVT testing                 Aerospace
 Urbain Vandeurzen           Thales Alenia Space       LMS Test.Lab contributes DLR and ONERA                The Italian Aerospace
 and Jan Leuridan mark       standardized on           to better flutter analysis standardize on the         Research Centre CIRA
 their twenty-five-year      LMS systems at its        at Airbus                  LMS Test.Lab GVT           prepares for unmanned
 partnership with an         corporate-wide test                                  solution                   space travel
 insightful interview        centers

                                                       6                                                                   12
 Tough enough? Thales Alenia Space needs to know for                 Crunching the huge amounts of test data is a constant
 certain. Which is why Europe’s largest satellite manufacturer       challenge for any flight test engineer and most certainly
 counts on LMS systems to get 48 of the most complex, high-          the team working on the Airbus A380, the largest bird
 tech machines aloft in 2010.                                        in the sky.

 If you want a free subscription to LMSNEWS send us your details: editor@lmsintl.com

 Director of publication: Peter Vandeborne | Editor-in-chief: Jennifer Schlegel | Art Director: Werner Custers
 Contributing Editors: Tom Curry, Caroline Dothee, John Krouse and Stephen Vaughan| Contributing: Cindy Piskor,
 Kirsten Cabergs and Kurt Debille

 Although we make every effort to ensure the accuracy of LMS News, we cannot be held liable for incorrect information.

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22                          24                         28                           32                        38
Virtual test rig            Hybrid                     Engine                       1D design                 Full vehicle
                            engineering                development                  optimization              development
LMS Imagine.Lab             NPO Energomash uses        Revolutionary virtual test   Ground-breaking           Temsa and LMS team up
AMESim launches             test and simulation        bench cuts costs and         vehicle co-simulation     to put Turkish buses on
CERTIA into virtual test    tools to predict modal     improves overall engine      at Volvo Construction     the international map
rig modeling                vibration and dynamic      performance at DAF           Equipment

                                                       28                                                                    38
 The DAF in-house CAE-Engines team in Eindhoven created a              Producing 3000 buses annually, Temsa is a rising star
 revolutionary virtual test bench using LMS Virtual.Lab to put         in the bus world. A behind the scenes look at this Turkish
 the next-generation MX engine through its cost-cutting paces.         vehicle development success story.

 Front cover image: Earth

 Other images courtesy of:
 Airbus, Belga, CERTIA, CIRA, DAF, LMS International, NPO Energomash,
 Temsa, Thales Alenia Space and Volvo Construction Equipment
 © LMS International 2010

                                                                                                              LMSNEWS - March 2010 |   3|
A solid and global approach to business and, of course, the pioneering, mission critical
technology. Dr. Urbain Vandeurzen and Dr. Jan Leuridan mark their twenty-five-year partnership
with an insightful interview into their success in the aerospace and ground vehicle sectors.

LMS News: How did LMS fare in 2009?

Dr. Urbain Vandeurzen: Without question 2009 was a very
difficult year. Many of our customers saw a 25%-35% drop-off in
business – especially those in the automotive and auto-related
sectors. The truck industry suffered even more. But we’ve
managed to navigate very well through the crisis.

LMS News: How?

UV: Simply three reasons: the strength of our customer
relationships. We are key strategic partners to many leading
companies in the mechanical manufacturing industries. Secondly,       Dr. Urbain Vandeurzen
the strength of our business model. Third, the spread of our          Chairman & Chief Executive Officer
business globally. Our worldwide presence is a critical factor to
our success. It is thanks to this combination that we ended the
year on a profitable upswing.
                                                                     equipment. If you look at that cumulative 5 years, we have
LMS News: What is the strength of the LMS business model?            equipped practically 80% of the market. The success stories in
                                                                     high-end test speak for themselves.
UV: Our market-leading, mission-critical technology. You can’t
forget that we are the pioneers of high-end structural and NVH       LMS News: Recently, LMS was in the news with ONERA-DLR
testing, the inventors of hybrid engineering, and the provider of    selecting the LMS solutions for GVT. Why did they opt for LMS?
a number of leading and patented technologies for test-based
engineering and virtual simulation. And we continue to invest        JL: The GVT (Ground Vibration Test) test is a very critical test
in the future of the industry with our LMS Next vision for a         in any aircraft development program. For the large aircraft
smarter and more sustainable planet. On top of that, we have a       programs in Europe, this testing has been done by ONERA and
strong global presence with over 30 LMS offices world-wide. Our      DLR. Their expertise with GVT testing has been built up over 50
revenue streams not only come from Europe, Japan and North           years on programs such as the Concorde, the Airbus A300, and
America, but also increasingly from the new growth BRIC regions.     more recently, the Airbus A380. Following extensive benchmarks,
                                                                     when the time came to replace their current systems, they
LMS News: Over the past years, LMS has branched outside of           jointly selected LMS as their GVT solution partner. The LMS
the automotive sector. Why is this strategically successful?         GVT solution provided the most complete standard platform,
                                                                     easily configurable and customizable to integrate both DLR’s
UV: We are well known historically in the automotive market.         and ONERA’s specific know-how and methods for GVT testing.
But one of our key strengths is that our technology is applicable    Additionally, both systems can easily be combined into a single
outside the automotive sector. We have seen tremendous growth        1000+ channel unit required for testing very large aircraft, such
in aerospace, the broader ground vehicle industry as well as         as the upcoming Airbus XWB350.
other high-tech mechanical and process-oriented industries.
                                                                     LMS News: What sets us above the others in this area?
LMS News: Worldwide, LMS has become the de facto standard
for environmental testing in satellite integration centers.          UV: What you can’t forget is that we not only have the testing
                                                                     systems and platforms, but also that our specialists in
Dr. Jan Leuridan: Absolutely. The article on Thales Alenia           Engineering Services have the hands-on experience to do live
Space highlights well the value our testing systems deliver to       GVT tests. We’ve worked successfully in the US and Europe
an industry where performance, reliability and compatibility         on a number of major GVT programs in recent years. Constant
are critical. Actually, every month over the last five years – and   feedback and hands-on know-how from the LMS Engineering
we’re talking all 60 months – we have won at least one deal          Services Division continues to enhance our GVT system.
with a satellite integration center to standardize on LMS test

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LMS News: LMS continues to innovate in the world of hybrid
engineering. What is notable in this issue?

UV: There is a very interesting story about the France-based test
rig provider CERTIA and how they design virtual intelligent test

JL: And I think another interesting story is the engineers at
Russian rocket engine supplier NPO Energomash. They use test
and simulation tools to accurately predict modal vibration and
dynamic loads in turbine rotors for next-generation international
launch vehicles. With the Soyuz rocket, physical testing is simply
not possible due to the extreme temperatures.
                                                                       Dr. Jan Leuridan
UV: In addition, there is the hybrid engineering durability success    Executive Vice-President & Chief Technical Officer
at the Turkish bus manufacturer Temsa. It is an excellent example
of how hybrid engineering can have real return on investment and
strategic impact.                                                     intensive analysis and post-processing. For acoustic engineers,
                                                                      it easily cuts the time needed for interior acoustic sound source
LMS News: Speaking of return on investment, Volvo cites a             localization by more than 50% while at the same time providing
65% reduction in physical testing development time. This is an        unprecedented insights. A tremendous gain in productivity and
enormous return on investment.                                        analysis precision.

UV: It is correct that ground vehicle manufacturers like Volvo        JL: LMS Virtual.Lab Rev 9 is getting great reviews. We really have
are shortening their development cycle with tremendous return         the most comprehensive, capable and versatile performance
on investment reducing the overall development process by a           simulation package on the market. And we continue to set the
third. DAF also speaks about using virtual simulation as a tool to    reference standard for acoustics. In one application, we have the
test four or five ideas and basically select the best concept for     fastest BEM and FEM-based solvers for stationary and transient
further detailed engineering. They can test many more concepts        acoustic analysis models up to several million elements covering
using virtual simulation and shorten their development process        low and high frequency analysis. Additionally, our unique new ray
as whole.                                                             tracing solver enables full audio acoustic analysis.

LMS News: The new releases are on the market. What type of            UV: And last but certainly not least, our big step forward in LMS
goodies can our customers expect?                                     Imagine.Lab can be found in vehicle energy management. In this
                                                                      release, we have built in the effect of start-stop systems. We have
JL: For LMS Test.Lab, the hot news is certainly in acoustics.         now a complete design platform for integration of hybrid-electric
In addition to our patented, operational TPA for fast and             powertrains, vehicle energy management and the integration
accurate transfer path analysis, we have exciting, new, patented      of energy recovery systems. With this solution, we are proving
technology for SSL (Sound Source Localization). With a high-tech      our commitment to work with the automotive OEMs and their
acoustic measurement head, where we combine video, laser              suppliers to develop the best possible solution for the future to
     and microphones in one integrated system, we can visualize       minimize fuel consumption and reduce CO2 emissions.
         the sound field in a photo-realistic manner to intuitively
            localize the sound sources in real-time, without labor-

                                                                                                                   LMSNEWS - March 2010 |   5|
                             Towards a wireless world
                             Nearing the end of operational life,
                             the entire Globalstar constellation of
                             48 telecommunications satellites will
                             be replaced by Thales Alenia Space –
                             Europe’s largest satellite manufacturer.

| 6 | LMSNEWS - March 2010
LMSNEWS - March 2010 |   7|
Telecommunications anywhere in the world                            constellation and ground network currently provide coverage
                                                                    to most inhabited places of the Earth, excluding only south-
A disaster response team in Florida calls for emergency aid         central Asia and central and southern Africa. Globalstar has
using a mobile phone, even though cell antennas and networks        plans to extend service to these areas in the coming years.
in the area have been destroyed by a hurricane. On the same
day, a soldier in a Mid-East war zone picks up a mobile phone
and talks to her daughter about her first day of school. Mobile
                                                                     Nearing the end of their operational life, the
communications in remote areas beyond cellular and landline
                                                                     original Globalstar satellites are scheduled to be
service take place around the world every day at petroleum
                                                                     replaced starting in the third quarter of 2010,
companies, mining operations, commercial fishing boats,
                                                                     when a three-stage Soyuz rocket will lift the first
construction sites, utilities, forestry services, government,
military and individual users hiking, mountain climbing or
                                                                     six second-generation satellites into orbit.
otherwise moving about in extremely remote locations.

Such voice calls – as well as Internet data connections –           These new satellites are designed with greater reliability,
are made on mobile telephones that connect to orbiting              increased power and a life expectancy of 15 years – double
satellites instead of terrestrial cell towers. A leader in this     that of the first-generation hardware. The new constellation and
rapidly evolving telecommunications field is Globalstar – the       the upgraded ground network that will follow are intended to
world’s largest provider of mobile satellite voice and data         provide more reliable service and faster data speeds required
services with over 375,000 subscribers in 120 countries             to support next-generation Internet-protocol-based services.
around the world. The company uses a constellation of 48
low-Earth-orbit satellites circling the globe about every           Satellite assembly, integration and test
90 minutes at an altitude of 1,414 km. Each satellite has
a set of solar panels for electrical power and two earth-           Prime contractor for this huge project is Thales Alenia
facing antenna arrays for two-way communications.                   Space, Europe’s largest satellite manufacturer. Being at
                                                                    the forefront of orbital infrastructures, Thales Alenia Space
Like small relay stations in the sky, the satellites receive        is a joint venture between Thales (67%) and Finmeccanica
signals, then amplify and transmit them back to gateway ground      (33%) and forms with Telespazio a Space Alliance. Thales
stations that process voice or data calls and distribute them to    Alenia Space is a worldwide reference in telecom, radar
local telephone networks or the Internet. Several satellites pick   and optical earth observation, defense and security as
up the same signal, preventing call interruption by handing off     well as navigation and science. Thales Alenia Space has 11
communication to one another through the Globalstar network         industrial sites in 4 European countries (France, Italy, Spain
when phone signals are blocked by buildings or terrain. The         and Belgium) with over 7,200 employees worldwide.

| 8 | LMSNEWS - March 2010
Thales Alenia Space has primary responsibility for the design,        and acoustic qualification tests are done in Cannes. Acoustic
manufacture, test and delivery of 48 second-generation                flight model tests performed just prior to satellite assembly and
satellites for the Globalstar constellation. The company              delivery to the launch pad are done in Rome. Verification testing
is also upgrading the Globalstar Satellite Operations                 on the antennas is done in Toulouse, France and L’Aquila, Italy.
and Control Center as well as Telemetry and Command
Units and In-Orbit Test hardware and software located in              Standardizing on LMS
Globalstar gateway ground stations around the world.
                                                                      Tests are conducted at all these facilities using state-
With Europe’s only integrated manufacturing and test center           of-the-art LMS SCADAS data acquisition hardware and
for satellite assembly and integration, Thales Alenia’s three         LMS Test.Lab control and data-reduction software.
Assembly, Integration and Test (AIT) Centers are located
in Rome, Italy, and in Cannes and Toulouse, France. The
multi-site capability is particularly well-suited for handling         With the addition of an expanded data acquisition
large satellite constellation projects, with specialized               system at Cannes, the 1,200+ total channel
capabilities for transporting sensitive hardware between               count for all three AITs ranks Thales Alenia
facilities and for delivering assembled satellites and related         among the most powerful distributed LMS
data acquisition systems directly to launch sites.                     test system for any company in the world.
One of the critical roles of these facilities is testing satellites
to ensure that highly sensitive components can withstand the
thunderous acoustics and jarring vibrations of vehicle launch.        The signal capacity, high speed, flexibility and versatility
Engineers focus on the thousands of individual parts and              of this LMS system are key to the success of the
subsystems that absolutely must remain intact, connected              company in these enormous satellite projects.
and fully operational – delicate structural components
deploying solar arrays and antennas, for example, as well as          Each center is autonomous, with vibration, acoustic and
highly sensitive and complex on-board electronic systems              other environmental test capabilities geared toward particular
with interconnected circuit boards, semiconductor chips,              applications. The Cannes center can accommodate major
signal processors, and other components. Such testing                 subsystems, large antennas and solar array, and satellites
is critical in the satellite business, since failure of any           up to 6 tons, while the Rome facility is limited to 3 tons and
one of these parts can jeopardize an entire mission.                  Toulouse is mainly targeted at testing components such as
                                                                      electronic equipment and antennas. LMS systems are also
All three AIT Centers perform various phases of these                 used for more specialized tests at these centers. At the Rome
environmental tests. For the Globalstar project, sine vibration       facility, for example, shock loading experienced by satellites

                                                                                                              LMSNEWS - March 2010 |   9|
Technicians work on the assembly line of
second-generation Globalstar satellites at
the Thales Alenia Space offices in Rome.
Globalstar is a low Earth orbit (LEO)
satellite constellation for satellite phone
and low-speed data communications.

due to separation of rocket stages is duplicated on a shaker      Well-choreographed concurrent engineering
table controlled by the LMS system, which also triggers a high-
speed camera recording structural response of the satellite.
                                                                   “For a project of this magnitude, testing must be a
AITs can perform tests for their own individual outside            chronological, concurrent engineering process. Our
contracts as well as work in concert with other Thales Alenia      site in Cannes can easily run two or three tests per
Space centers on major projects such as Globalstar and             day and deliver the results practically the moment
the Galileo and EGNOS navigation satellites, as well as the        the test is completed with our LMS solution.”
Herschel, Planck and Mars Express scientific missions.
                                                                   Mr. Hervé Ruzicska, manager mechanical test center
“Standardizing on LMS testing solutions is advantageous,”
said Jean-Charles Delambre, vibration and mechanical
testing expert at Thales Alenia Space Cannes Dynamic               “To meet these demands, we use a ‘technical island’ approach
Test Facility. “Our test systems are entirely compatible          where teams of people converge at the test site to get the
with those at our largest customer – ESA (European                job done as quickly as possible – technicians for set-up,
Space Agency) since they also use LMS extensively.                control, and data acquisition as well as facilities engineers,
                                                                  shaker specialists and instrumentation engineers.”
So we can readily ensure that our test procedures are done
according to their standards. And we can easily exchange          Daniele Tiani, Head of Mechanical Test Dept IU_AIT in
results data, technical information and best practices            Rome, noted that teams can run tests so quickly – push
related to the many satellite projects we work on for them.       the limits, so to speak – because of the confidence they
Also, our engineers can easily work at any of our three           have in the LMS system. As tests are being conducted,
sites thanks to the uniformity of the LMS technologies.           measurements are compared with prescribed limits and tests
                                                                  are automatically aborted via a control loop that triggers an
Their proficiency on the system easily transfers between          end-test command that gradually scales down vibration input.
the different Thales Alenia Space organizations – as well as
outside partners like ESA. This standardization really shows      “With tests controlled by the LMS system, we know that
its added-value when coordinating work and performing             fragile and expensive satellite components and subsystems
tests efficiently on large joint projects such as Globalstar.”    will be safe as the test sequence is performed exactly as

| 10 | LMSNEWS - March 2010
intended,” he noted. “With less reliable systems, tests         connecting, disconnecting and double-checking hundreds of
must proceed more deliberatively as engineers slowly            accelerometer cables as the satellite is moved from pre-test
ramp up test amplitudes to make sure there is no risk to        into the test area. This helps streamline the procedure of
the test specimen. This confidence in test control and          splitting up an extensive test into segments because not enough
reliability is a huge advantage of the LMS system.”             channels are available to run the test in its entirety. “With patch
                                                                panels pre-wired to route signals to appropriate slots of the
Time-saving capabilities                                        LMS SCADAS equipment by way of just a few master cables,
                                                                we can now reconfigure connections is just a few hours instead
 Another LMS capability that can compress                       of what used to take four days or more,” explained Mr. Tiani.
 test cycles is parallel processing to analyze
 measurement data in near real time, displaying                 Competitive value of proven capabilities
 results for critical channels as tests are
 being run and providing full results almost                    With these capabilities, Thales Alenia Space has become
 immediately after the conclusion of a test.                    a powerhouse in the worldwide space industry. “Clearly,
                                                                there is a competitive value for Thales Alenia Space to be
“By seeing results so fast, engineers can quickly spot any      standardized on test systems from LMS, which is recognized
inconsistencies and make immediate corrections – even in        for its technology and its outstanding customer service. In
the middle of a test run,” Mr. Tiani explained. “This saves     an industry such as satellite development and testing where
hours – and often days – of precious time that they would       performance, reliability and compatibility of digital systems are
otherwise have to spend waiting for results, only to discover   critical, the trend toward LMS as the de facto standard across
a problem that would mean re-running the entire test.”          the industry certainly makes sense. From each organization’s
                                                                perspective, there is just too much at stake to trust projects
Further time is saved through the use of the LMS patch panel    worth hundreds of millions of euros to anything less than
capability, which can avoid the time-consuming repetition of    the proven capabilities of LMS people and technology.”

                                                                  “Standardizing on LMS testing solutions
                                                                  is advantageous. Our test systems
                                                                  are entirely compatible with those
                                                                  at our largest customer - ESA. ”
                                                                  Jean-Charles Delambre, vibration and mechanical testing
                                                                  expert at Thales Alenia Space Cannes Dynamic Test Facility

                                                                                                       LMSNEWS - March 2010 |   11 |
Airbus discovers the right route to a
streamlined flutter analysis process
LMS Test.Lab contributes to better flutter analysis

Aeroelasticity, the interaction between inertial, elastic and aerodynamic forces, plays a vital
role in aircraft design. And as soon as you add four enormous engines and a significant
increase in size and flexibility, it is not surprising that aeroelastic behavior evolves becoming
more and more complex.

| 12 | LMSNEWS - March 2010
                                                                                  “We’ve been extremely impressed by the
                                                                                  way that the LMS Test.Lab software can
                                                                                  handle the immense amount of Airbus
                                                                                  A380 in-flight data.”
                                                                                  Jean Roubertier
                                                                                  Aeroelasticity expert at the Flight tests department - Airbus

Along with the aircraft characteristics,     similar mode shapes, both placed
modal identification methods used            in a low narrow frequency band.
during flutter testing have evolved to
assure correct parameter identification.     In terms of modal identification, these
Frequencies and damping value                new precise requirements called for
estimations have to be as accurate as        a better-defined and better-equipped
possible in order to define the aircraft     testing installation. This meant digging
fluttering margins used during those first   a bit to find the right kind of process.
mission-critical in-flight test campaigns.   Measured data needed to be recorded
                                             at enough locations with high enough
In a nutshell, flutter testing can be        quality to improve power spectra
broken into three segments: real-time;       and transfer function estimates and
near real-time and off-line. In-flight       avoid spatial aliasing when working         Edition du 09/03/07

real-time test campaigns acquire live        out aircraft deformed shapes. This
data during the test flight mostly as        required some innovative thinking
a safety check to continue the flight        and serious process validation in
envelope. Near real-time testing focuses     regards to current techniques.
on rapid modal estimation to determine
the overall safety of the flight and the     Building on EUREKA
flutter test program. Off-line deals with    FLITE projects
the finer analysis of the recorded flight
data and final report production.            Since 2001, Airbus France and LMS
                                             International have been cooperating
To validate data efficiently and             in regards to several EUREKA projects
effectively off-line, LMS Test.Lab Modal     called “FLITE” (Flight Test Easy). An
Analysis offers a full-featured package      intergovernmental initiative to support
with all the required functionality,         market-oriented European R&D, the
such as data pre-processing, modal           EUREKA FLITE projects focus on bringing
parameter estimation, mode shape             new and powerful tools to structural
animation and result validation.             engineers and aircraft designers,
                                             improving the quality and usefulness
Bigger airplanes.                            of data gathered during flight testing.
New flutter requirements.
                                             The FLITE consortium gathers world-
The Airbus flutter team in Toulouse,         ranking aircraft manufacturers and
France faced quite some challenges           technology providers from France,
working on the Airbus A380 campaign,         Belgium and Poland. The FLITE
but there were issues they had faced         projects offered a unique opportunity       XYZ sensors for elevator pulse analyses                      A380 msn
                                                                                                               A380 MSN001 was equipped with more than1
                                                                                                                                             EYTXGS                     Page:1
before with the Airbus A340 flutter          to confront new advanced algorithms         XYZ sensors for inner aileron pulse analyses
                                                                                         XYZ sensors for rudder pulse analyses                     FLUTTER &COMFORT
                                                                                                               100 measurement points uniformly ACELEROMETERS
campaign: high modal density and             with challenging real-life aircraft data.                         all over the primary aircraft structure.

                                                                                                                                        LMSNEWS - March 2010 |   13 |
                                                   The very clear LMS PolyMAX stabilization diagram allows an easy identification of the
                                                   many modes in the considered frequency band.

                                                Finding the right data                              and the post-processing completed in
                                                                                                    the design center in Airbus Germany. At
                                                In late 2007, LMS and Airbus agreed to              this stage, we are very pleased with the
                                                start a project to evaluate LMS PolyMAX,            results. LMS Test.Lab is able to provide
                                                an integrated part of the LMS                       us with the right type of results,” stated
                                                Test.Lab Structures suite as a key                  Jean Roubertier, Flight test department
                                                solution to achieve high-quality off-               aeroelasticity expert at Airbus.
                                                line in-flight data processing for flutter
                                                testing. The LMS Test.Lab Structures                Record-breaking
                                                suite is a complete solution for modal              data acquisition
                                                analysis, combining high-speed
                                                multichannel data acquisition with a
                                                suite of integrated testing, analysis, and            Considering that the 525-
                                                reporting tools. LMS is renowned for its              seat Airbus A380 is the
                                                modal testing experience and scalable                 largest commercial passenger
                                                solutions, from supporting impact testing             aircraft in the skies today, it
                                                on small structures up to large test                  isn’t surprising that simply
                                                campaigns using multiple shakers and                  due to its sheer size, the
                                                hundreds of measurement channels.                     acquired in-flight testing data
                                                                                                      is record-breaking as well.
                                                In the past, the Flight Test Departments
                                                of Airbus France performed data
                                                analysis using their in-house near real-            “With more than 100 sensors, this
                                                time analysis package and transferred               was one of the largest set-ups for an
                                                the results together with the raw                   in-flight flutter test campaign I have
                                                data to Airbus Germany where the                    ever seen. Also the amount of tests
                                                numerical flutter predictions were                  under different flight conditions is
                                                correlated with actual flight tests.                impressive. The resulting database
                                                However, Airbus France felt the need                is immense and efficient processing
                                                to carry out some more in-depth data                and report generation capabilities
                                                processing, so that they could transfer             are required,” stated Bart Peeters,
                                                more complete results to Germany.                   LMS Research Project Manager.
Measured mode shapes estimated from in-flight
sensor data. A wing bending mode (top) and a    “Clearly, we needed a solution that would           The Airbus Flutter team in Toulouse
fuselage bending mode are shown (bottom).       improve the alignment between on-line               performed a variety of excitations
                                                in-flight analysis occurring in Toulouse            including control surfaces sine sweeps

    | 14 | LMSNEWS - March 2010
and pulses. Pulses are currently used       Oliver Escandell. “This was thanks to       the project for a year. “And the validation
to assure crew and aircraft safety,         the amount of sensors we used and the       tools such as correlation levels, MAC
whereas sweeps are use to work              OMA capabilities of LMS Test.Lab.”          matrix, mode shape complexity (MPD and
out more accurate results allowing                                                      MPC criteria) are very complimentary
to update theoretical FE models.            De-noising the data                         in regards to real-time identifications
Thanks to integrating pulses into the                                                   performed during flutter tests.”
process, flutter flights duration time      Even with projects of this scale, there
has been considerably reduced.              is always noise in the data that needs      During the comparison testing, the
                                            to be managed. LMS Test.Lab paints          flutter team at Airbus used LMS
Technically speaking, the basic concept     a really clear picture with techniques      PolyMAX during sweep excitations of the
behind the project was to compare           that produce clear analysis results         aircraft. Results, using an exponential
classical experimental modal analysis       even from rather noisy data. This           window of 5% appear to be good,
(EMA) with LMS Test.Lab’s Operational       feature really offers clients like Airbus   supplying high synthesis correlations
Modal Analysis (OMA) technique. In          a true competitive advantage when it        (98% using just two references)
classical EMA, the control surface          comes to off-line test processing.          and clear stabilization diagrams.
excitation and aircraft response signals                                                “We’ve been extremely impressed by
are converted to Frequency Response         “We found that the exponential window,      the flutter analysis results and the way
Functions (FRFs). During the actual         which allowed for cross-correlation         that the LMS Test.Lab software can
flight, other excitation sources, such as   calculations, was a good de-noising tool    handle the challenges of processing
turbulence are present. Sometimes, this     for our in-flight data,” stated Miquel      the immense amount of Airbus A380
results in noisy FRFs. For example, an      Angel Oliver Escandell, a member of the     in-flight data during the off-line
aircraft tail response sensor receives a    Airbus Flutter team who was dedicated to    analysis,” concluded Jean Roubertier.
rather limited contribution from the wing
excitation. Therefore, the idea arose to
neglect the excitation signal and apply
OMA to the aircraft acceleration signals.

“We actually achieved better results         “With more than 100 sensors, this was one
using OMA than with classical EMA. We
found more modes. The synthesis was          of the largest set-ups for an in-flight flutter
better with higher correlation and fewer
errors. And the in-flight mode shapes
                                             test campaign I have ever seen.”
looked much nicer,” added Miquel Angel

                                                                                                      LMSNEWS - March 2010 |   15 |
DLR and ONERA standardize on LMS
Test.Lab GVT solution and select LMS as
Ground Vibration Testing partner

| 16 | LMSNEWS - March 2010
Supporting its leading position in Ground Vibration Testing (GVT)
solutions, LMS has entered into an agreement with DLR, the
German national research center for aeronautics and space,
and ONERA, the French national aerospace research center, to
deliver their next-generation GVT systems. DLR and ONERA each
ordered a 384-channel LMS Test.Lab GVT solution, which can be
combined to form a 768-channel test system.

With important GVT campaigns planned            GVT process,” stated Dr. Boeswald,          modal validation capabilities.
for the 2010-2011 timeframe, ONERA              Coordinator of DLR’s Ground Vibration
and DLR investigated various industrial         Test Facility in Goettingen, Germany. “In   “LMS truly understood our particular
players. Following successful GVT               addition, we also wanted to maintain the    situation and offered the solution
benchmarks, DLR and ONERA selected              possibility to combine our system with      we needed: a complete yet efficient
LMS and decided to base their new               ONERA’s system in France. Therefore,        GVT solution - easily customizable
GVT systems on the LMS Test.Lab GVT             we needed to align our decisions and        to fit our specific needs. LMS is an
solution. This solution already covers all      synchronize the evaluation effort.”         innovation-driven company, and LMS

      “DLR-ONERA’s decision in favor of LMS’ GVT
      solution confirms our position as the leading
      industrial partner for GVT testing.”
      Dr. Jan Leuridan, Executive Vice-President and CTO, LMS International

common GVT requirements, and could              “We are very pleased that DLR and           fully understands as well the need
easily be configured to fully manage DLR        ONERA have decided to standardize their     for high-level support of our research
and ONERA’s specific GVT methods and            GVT testing, methods and technology on      initiatives. By merging their leading GVT
practices.                                      the LMS Test.Lab GVT solution. Thanks       solution with our extensive 30 years of
                                                to its openness, we can work with DLR       GVT experience, we will be able to take
Additionally, the LMS Test.Lab GVT              and ONERA to customize our LMS GVT          our GVT testing practices to the next
solution proved to have the necessary           solution to efficiently meet all their      level, and meet the ever more stringent
openness to integrate customized                GVT process requirements,” stated Jan       deadlines of our customers,” stated Mr.
procedures to support DLR and ONERA’s           Debille, Aerospace Solutions Manager at     Pascal Lubrina, Manager of ONERA.’s
research initiatives.                           LMS International.                          Ground Vibration Test Facility.

“After the Airbus A380 GVT, we decided          The LMS Test.Lab GVT solution uses          “DLR-ONERA’s decision in favor of LMS’
to switch from LMS CADA-X modal                 the state-of-the-art LMS SCADAS III         GVT solution confirms our position as the
analysis software to Windows-based              networked data acquisition system, in       leading industrial partner for GVT testing.
LMS Test.Lab. To achieve that with              combination with the LMS Test.Lab data      Both DLR and ONERA have developed
our custom-built VXI data acquisition           acquisition applications for MIMO FRF       their know-how for GVT testing over
system, we had to link in-house data            acquisition under random, swept and         many years, and have a claim to fame
acquisition systems to the LMS Test.            stepped sine excitation conditions and      for GVT testing in the aviation industry.
Lab PolyMAX modal analysis solution.            a direct modal acquisition module for       At LMS, we look forward to contributing
For our next-generation solution, we            normal modes tuning. Key to maximal         to the advancement of the overall GVT
decided to combine data acquisition and         productivity, all acquisition modules are   methods and practices at these industry-
analysis in a common environment, and           seamlessly integrated with the world-       leading organizations,” stated Dr. Jan
selected the LMS Test.Lab GVT solution          class LMS Test.Lab modal analysis           Leuridan, Executive Vice-President and
as the platform to support the complete         software, PolyMAX, and its wealth of        CTO, LMS International.

                                                                                                           LMSNEWS - March 2010 |   17 |
| 18 | LMSNEWS - March 2010
It’s a ‘Go’ for the
Unmanned Space Vehicle at CIRA
The Italian Aerospace Research Centre
prepares for unmanned space travel with LMS

The Renaissance Italians gave us Machiavelli, Michelangelo, and Leonardo Da Vinci. So
it shouldn’t be surprising to discover that the 21st century Italians are also putting their
name on Europe’s aerospace renaissance. CIRA, the Italian Aerospace Research Centre, is
contributing valuable research and development know-how to numerous European projects.

One project where researchers are          associated with aerospace research.        that the winged USV-1 could withstand
harvesting know-how at CIRA is the         Eventually, the USV team at CIRA hopes     the scorching heat and Mach speeds
development of the Unmanned Space          to be able to offer the USV’s flight and   of the planned re-entry trajectory.
Vehicle (USV for short). Aimed to assist   lab space as a service to validate space
the international research community,      equipment to ESA or NASA standards.        On the big day, the 1250 kg USV
the in-development USV will be a multi-                                               with its 3.54m wingspan was airlifted
purpose, multi-mission flying laboratory   Castore: The first flight                  using a stratospheric balloon and
capable of atmospheric re-entry from                                                  released approximately 20 km above
low-earth orbit. Designed to act like      The first prototype USV-1 (named           the Earth. From this perilous point, the
a civil aircraft without human pilots,     Castore) took its maiden voyage above      USV cruised at a transonic speed of
the USV is actually a flying test bed      the sunny skies of Sardinia, Italy on      Mach 1.1 – powered solely by gravity.
where scientists can test materials,       March 24th, 2007. This first campaign      During the deceleration phase, a
verify structural and aerodynamic          addressed such space ‘basics’ like         three-stage parachute system acts
behavior, develop advanced guidance        aerodynamic performance and flight         like a set of Ferrari F1 space brakes,
and navigation and control functions       behavior during transonic flight. In       allowing the USV to plunge into the
as well as other typical technology        other words, the goal was to make sure     sea for recovery and re-use.

                                                                                                    LMSNEWS - March 2010 |   19 |
During the first flight, data was collected    This is known as the virtual GVT.           structural design for its first flight.
using a system of 500 sensors and relied
off ESA’s Artemis satellite to the Italian     To replicate the ideal world of numerical   “While performing the GVT on our CIRA
ground team. The data collected from           simulation as close as possible, a          Unmanned Space Vehicle, I was really
this first flight is currently being studied   dedicated suspension system was             amazed by the impressive performance
to improve the second planned USV              manufactured specifically for the test.     of the latest version of LMS Test.Lab.
prototype: Polluce, a vehicle that will be     During the actual GVT, the USV prototype
able to reach 82,000 feet (25km) altitude      itself was suspended by bungee cords         Not only were we confident
and travel at Mach 1.2 (1500km/hr).            in this dedicated suspension system.         that the LMS GVT solution
                                                                                            could provide us with the
Preparing for the big day                      To prepare for the actual tests to be        right type of results – an
                                               run on a 100-channel LMS SCADAS              accurate and reliable data set
Prior to the first flight, years of back       III system in combination with LMS           – it also runs on a standard
office work went into the USV project.         Test.Lab, the USV-1 was instrumented         Windows XP laptop.
One aspect was the ground vibration test       with 74 accelerometers and 4 shakers.
or GVT to confirm the vessel’s structural      MAC (Modal Assurance Criterion) was         This is much more streamlined compared
soundness under extreme aerodynamic            used to verify the quality of the modal     to the older version we used to run on
loads. This critical aerospace test was        results. This same MAC criterion was        a powerful yet bulky UNIX workstation.
in the hands of Vincenzo Quaranta,             used to correlate the test modes with       This new set-up is ideal for our lab at
PhD., Senior Scientist, Experimental           the ones predicted in the models.           CIRA. With a campus this size, we need
Vibro-acoustics Dean at CIRA. It                                                           a solution that can easily be packed
was his team’s task to make sure               The streamlined LMS solution                up and moved from test building to
that the “bird” could withstand the                                                        test building,” stated Dr. Quaranta.
extreme aeroelastic dynamic loads.             Using the LMS solution, Dr. Quaranta
                                               and his four-person team performed          He concluded, “LMS’ specialized
Designing a test strategy                      the GVT over several days. Both phase       team - especially the on-site team in
                                               separation and normal mode techniques       Novara, Italy really have helped us
Starting from the FE model, Dr. Quaranta       were used during the GVT to identify the    get the most out of the LMS Ground
and his team designed the test strategy        structural resonances in the respective     Vibration Testing solution which
and determined the optimal location for        frequencies and acquire FRFs (Frequency     combines LMS Test.Lab software and
sensors and shakers, using numerical           Response Functions) used to extract the     LMS SCADAS hardware. They not
modal data. LMS Virtual.Lab was used           modal parameters with the LMS Test.         only helped to customize our solution
to find the optimal location for sensors       Lab PolyMAX tool. From this information,    exactly to our needs – integrating
and an internal solution OFP (Optimal          Dr. Quaranta and his team could provide     our own code where we needed to
Force Pattern) was used to determine           the right data to predict the flutter       - they also were there to help find a
the number and location of the shakers.        parameters of the USV and approve the       solution to any issue that we had.”

| 20 | LMSNEWS - March 2010
Critical to any aerospace program, ground
vibration testing is necessary to validate
finite element models of the spacecraft,
                                                 LMS: a partner you can count on
adapt or modify the structure if necessary,      LMS News: LMS’ role in the USV’s GVT was a
and ultimately obtain a final ‘go for launch’.   minor but essential aspect of the entire first flight,
A step-by-step procedure, the GVT performed      but it isn’t the only role that LMS plays at CIRA?
by CIRA on the first USV prototype verified
the aero-elastic reliability and demonstrated    Dr. Mario L. Farioli, Support to the Board of
the absence of flutter-related instabilities     CIRA: Of course, we have worked together with
prior to the first flight.                       LMS for years. Besides the most recent work with
                                                 Vincenzo Quaranta on the USV and other vibration
                                                 and acoustic research, we have many other
                                                 projects including some cutting-edge optimization
                                                 work using LMS’ optimization software: NOESIS
                                                 Optimus. LMS is a well-appreciated partner of

                                                 LMS News: As a research center, what is your
                                                 biggest challenge?

                                                 Antonio Concilio, PhD, Head of the Smart
                                                 Structures and Vibroacoustics Lab at CIRA:
                                                 One of our biggest challenges is to provide
                                                 support for scientific research and services for
                                                 our commercial partners. When customers like the
                                                 Italian aerospace companies ask us to perform
                                                 GVT tests or vibro-acoustic characterization of
                                                 certain components, of course we help. We will
                                                 do the same for international research projects.
                                                 And the result should always be top-level. Because
                                                 LMS Test.Lab is so easy and quick to set-up, it is
                                                 really a performance enhancer and a quality insurer
                                                 – especially when we need to switch between
                                                 research and commercial activities.

                                                 LMS News: Why all the focus on GVT?

                                                 Vincenzo Quaranta, PhD, Senior Scientist,
                                                 Experimental Vibroacoustics Dean at CIRA: GVT
                                                 is a fundamental step in the development of a new
                                                 airplane. It validates and updates the numerical
                                                 model developed in the design phase. Only after a
                                                 GVT, the prototype is proclaimed first-flight ready.
                                                 For these reasons, it is crucial to carry out this task
                                                 with a system developed ‘ad hoc’ by a specialized
                                                 team like LMS.

                                                 Piergiovanni Renzoni, PhD, Head of the Flight
                                                 Technologies and Helicopter Systems at CIRA:
                                                 Especially in the aerospace field, continuity is
                                                 important. We need to maintain critical standards
                                                 and, especially for GVT, be compliant with various
                                                 standards. The LMS equipment lets us do this.

                                                                           LMSNEWS - March 2010 |   21 |
 Intelligent test rigs to
 tackle herculean aircraft design
 LMS Imagine.Lab AMESim launches
 CERTIA into virtual test rig modeling

 Building a new aircraft is a herculean task that takes years of intense effort and
 intricate development. The integration of complex mechatronics, multi-physical
 and control systems in the aircraft design as well as the actual manufacturing
 process is quite a formidable undertaking. Before a new aircraft is finally
 pronounced airworthy and ready for commercial production, it has undergone a
 myriad of vigorous certification tests at all levels in the manufacturing chain.

| 22 | LMSNEWS - March 2010
Ground-breaking virtual test benches
In order to perform all these different tests, actual physical     “LMS Imagine.Lab AMESim helped us
test benches are indispensable. The particular challenge for
                                                                   to reduce the test rig development
a test rig is to replicate the extreme conditions that aircraft
must to be able to withstand as well as create a specific          time by 25% and the availability
test set-up in which the material, component or assembly in
question can be put through these exceptional circumstances.       rate of the physical testing platform
                                                                   increased by approximately 60%.”
A specialist in the design and production of test rigs
is the Paris-based company CERTIA. Founded in 1987,
CERTIA is a test bench supplier for the aeronautical and           Achour Debiane, head of the automation department at CERTIA
automotive industries and counts Airbus France, the Safran
Group, Air France Industries, PSA Peugeot Citroën and
Renault among its customers. In recent years, CERTIA
has started using the LMS Imagine.Lab AMESim platform
to assist engineers in test rig development. The platform
helps developers choose the appropriate components                Besides shorter design cycles, another benefit of using 1D
to make sure the test bench functions properly.                   modeling in the concept phase is that it helps optimize the
                                                                  behavior and dynamic characteristics of the various test
“In the past, we had many problems with our test benches: what    rig components. The simulation results are vital for the
was especially difficult was to reproduce aeronautical loads      mechanical integration of the test rig and help validate the
and make sure that the test rigs would reach the projected        design by virtually verifying the stiffness, inertia and masses
performance. Because of these difficulties, it was clear that     of the test bench. Very early in the development cycle,
our test bench concept needed to change,” comments Achour         simulation determines the test rig viability and eliminates
Debiane, head of the automation department at CERTIA.             the need to change mechanical parts in the final stages.

Simulation innovation                                             Anticipating the future

CERTIA opted for the LMS Imagine.Lab AMESim                       “Having a virtual platform has become an absolute necessity.
platform because of its multi-physical simulation                 We have to be ready and anticipate requests from customers
capabilities and in particular for its hydraulic solutions.       like Airbus to do testing in a common virtual environment –
Using LMS Imagine.Lab has proven especially valuable              suppliers will need to be able to interface with OEMs. This will
in the early stages of the design process.                        be the way of working in the future,” asserts Mr. Debiane.

“During the feasibility studies of hydraulic systems, LMS         LMS has launched CERTIA into the world of simulation
Imagine.Lab has saved us a lot of time and programming            innovation and helps prepare the company for the virtual design
effort since it is no longer necessary to work on time-           of intelligent test rigs. Mechatronics engineering and intelligent
consuming equations. In the aeronautical field, planning          system simulation are sweeping the aeronautical industry and in
cycles are very short and since we are a supplier for a large     this virtual revolution, test bench design cannot stay behind.
organization, it is very important for us to do the feasibility
studies as quickly as possible,” states Mr. Debiane.

                                                                                                        LMSNEWS - March 2010 |   23 |
| 24 | LMSNEWS - March 2010
3, 2, 1…liftoff
Engineers at Russian rocket engine supplier NPO
Energomash use test and simulation tools to accurately
predict modal vibration and dynamic loads in turbine
rotors for next-generation international launch vehicles

                                                           LMSNEWS - March 2010 |   25 |
                                                                                           Producing 1.7 million pounds of thrust,
                                                                                           the RD-170 designed and manufactured
                                                                                           by NPO Energomash is one of the most
                                                                                           powerful and fuel efficient kerosene/liquid-
                                                                                           oxygen engines in the world.

With a heritage that dates back to the       Major engineering challenges                assessment and in subsequent durability
1940s, NPO Energomash is one of the                                                      and fatigue life estimates that rely
leading developers of liquid-fuel rocket     One of the major challenges in developing   solely on mathematical predictions.
engines. Their designs for kerosene/         such powerful engines is accurately
liquid-oxygen propulsion systems             determining vibrations and loads of         Correcting FE models for
are recognized as some of the most           critical components, such as the turbine    accurate predictions
efficient and powerful in the world.         rotor, one of the most dynamically
                                             stressed assemblies of the liquid-fuel
In recent years, these engines have          rocket engine. Knowing the amplitude         The accuracy of mathematical
been used in a wide range of spacecraft.     and frequency of these dynamic loads is      predictions can be increased
More than 1,500 launches have been           especially important in the development      appreciably through a
made with the Russian Federal Space          of reusable rocket engines, although         multidisciplinary approach using
Agency’s Soyuz rockets propelling            single-mission engines such as those for     experimental modal test results
both satellites into orbit as well as        the Atlas Evolved Expendable Launch          done in the lab to correct errors
people and equipment to and from             Vehicle (EELV) program generally are         in the finite-element model.
first the Soviet Mir space station and       designed for three or five flight cycles
now the International Space Station.         as an added margin of safety.

The Atlas III US orbital launch vehicle is   Directly measuring rotor loads during       At NPO Energomash, this type of model-
powered by NPO Energomash engines,           actual engine burn is impractical           correction approach was recently
as is the Atlas V: the newest and most       because of extreme temperatures, high       investigated using modal analysis
powerful of the family. Currently under      pressure levels, and poor access to         technology from LMS International.
development is the Angara series of          rapidly moving parts. On the other hand,
Russian launch vehicles intended to          mathematical models for methods such        Specifically, test and simulation tools
be the next-generation super-heavy-          as finite element analysis may deviate      were used for setting up the impact
lift workhorse. The heavy Angara             from real-world rotor behavior because      excitation experiment, measuring
series will be capable of putting            of variabilities in material properties,    structural vibrations, analyzing results,
payloads weighing as much as 28              damping properties of the assembly, part    identifying modal eigenfrequencies,
tons into orbit while the middle and         geometries, manufacturing processes         correlating experimental measurements
light versions are able to transport         and joint configurations. All this may      with predicted results and correcting
payloads of 14 and 2 tons respectively.      lead to serious errors in dynamic load      the finite-element model for one of

| 26 | LMSNEWS - March 2010
Modal test results (left) show how a 29-blade, 21 kg rocket engine turbine rotor (right)
deforms at 1168.3 Hz, one of 20 eigenfrequencies identified by LMS Test.Lab.

their engines. To increase this engine’s               The rotor specimen was hit sequentially      density of the shroud ring surrounding
durability, NPO Energomash engineers                   at 187 points with an instrumented           the rotor was the best way to correct the
also work with LMS technology.                         hammer while measurements were taken         finite-element model,” noted Vladimir
                                                       simultaneously at 6 locations. Ideal         Tkach, lead engineer and designer at
Technical assistance and system training               locations for impact and accelerometers      NPO Energomash. “The LMS software
on the project was provided by Octava,                 placement were determined using              indicated parameters that should be
a partner of LMS International in the                  LMS Virtual.Lab simulation tools.            changed that were not obvious.”
Russian Federation. “We are honored that
LMS technology was selected by NPO                     LMS Test.Lab PolyMAX readily identified      These corrections were made to the
Energomash for such an important role in               more than 20 eigenfrequencies,               mathematical model and a subsequent
their long-range work developing rocket                automatically highlighting resonances        finite-element analysis for all major
engines for international launches,” said              on straightforward plots, so that the        eigenfrequencies showed a close
Sergey Panov, Octava chief application                 engineers could visually identify natural    correlation within an average of 2% –
consultant and head of the engineering                 frequencies in minutes instead of            an appreciable improvement that will
support team for the NPO Energomash                    spending hours looking through raw data.     enable NPO Energomash engineers
project. “Their selection demonstrates                 LMS Virtual.Lab Correlation software         to better design future turbine rotors
confidence in the technology behind                    then compared test measurements              more closely matched to engine
LMS test and simulation tools as well                  and predicted results using a Modal          service-life requirements.
as the expertise of our application                    Assurance Criteria (MAC) matrix diagram
engineers for a project of this scope.”                that showed where the two types of
                                                       data align and where they diverge. In
Turbine rotor testing                                  this case, the MAC diagram indicated
                                                       that the eigenfrequencies identified         “LMS technology is a key
To validate the approach, tests were                   through testing were on average more         element in our strategy to
performed by NPO Energomash engineers                  than 8% higher than those predicated
on a 29-blade nickel alloy turbine rotor               by finite-element calculations.              increase the fatigue life of
measuring 340mm in diameter and
weighing 21kg. Tests were conducted                    “A sensitivity analysis of the results
                                                                                                    rocket engines while
using a 40-channel LMS SCADAS III                      using LMS Virtual.Lab Optimization           reducing costs.”
data acquisition system and LMS Test.                  software indicated that adjusting material
Lab for signal processing and analysis.                properties such as Young’s modulus and       Sergey Skibin, NPO Energomash

                                                                                                                  LMSNEWS - March 2010 |   27 |
Behind the scenes at DAF
Revolutionary virtual test bench cuts costs and improves
overall engine performance for next-generation MX engine

       “We are dealing with extremely complex engine
       designs and our deadlines are tight. LMS Virtual.Lab
       is an ideal tool for the tough times.”
       Eric Van Velthooven, team supervisor at DAF

| 28 | LMSNEWS - March 2010
It began with what seemed to be a simple      The easy part of the job was discovering     virtually allows us to develop different
leaf spring issue on the MX engine’s          the root cause leading to the undesired      engineering scenarios to present clear-
turbo support. Flagged by DAF’s test          behavior. It turned out that high            cut design options to our managers –
department, DAF’s in-house CAE-Engines        acceleration rates on the MX’s turbo         without the time and expense of putting it
team in Eindhoven, the Netherlands was        unit and high thermal expansion              on an actual test bench. It is a leap ahead
asked to investigate. It was their job        caused overloading of the leaf spring.       in the development process,” stated Eric
to simulate the issue and figure out a        Something that the test data alluded         van Velthooven, the team’s supervisor.
viable design for the existing operating      to, but the work in LMS Virtual.Lab
conditions. Using LMS Virtual.Lab Motion      took the process a step further: it          During the simulation studies on the
and LMS Virtual.Lab Noise and Vibration,      explained how to fix it optimally.           virtual test bench, Jarno Lathouwers
they not only discovered what was wrong       “We’re not like an automotive OEM where      noticed that the concept of the leaf
and how to fix it, they also found out that   you have teams of people working on          support wasn’t optimal, and redesigned
the actual structure wasn’t optimal. The      specific issues. The six of us are pretty    it in LMS Virtual.Lab Motion. Developing
final result? A time and money saving         much an engineering services center for      the leaf spring support in different
revelation that will improve the next-        the engine development department.           ways really affected the overall engine
  generation MX engine.                       Jarno Lathouwers, our LMS Virtual.Lab        vibration performance. With validated
                                              specialist, developed a model to virtually   LMS Virtual.Lab simulations, he could
                                              replicate the engine test bench for the      see exactly which solution was the right
                                              next-generation MX engine. Working           one and why it worked. The added value

                                                                                                         LMSNEWS - March 2010 |   29 |
                                                                                    DAF Trucks is a fond user of LMS Virtual.Lab (as well as LMS
                                                                                    Test.Lab) and uses LMS solutions in some rather revolutionary
                                                                                    ways to develop better performing and globally compliant
                                                                                    truck engines – most recently the next-generation MX engine.

is not only in reproducing tested behavior         directly from the time simulation results            solving a certain problem in a certain
but in understanding the mechanisms                carried out in LMS Virtual.Lab Motion.               way. With LMS Virtual.Lab, you can
behind potentially undesired behavior.                                                                  see the full calculation and relevant
                                                   It led the team right to the possible                data and know that your total result
Beyond the leaf spring design                      source. On top of that, LMS Virtual.                 works,” stated Eric van Velthooven.
                                                   Lab Noise and Vibration lets the team
DAF already converted to LMS Virtual.Lab           easily incorporate and post-process                  This doesn’t mean that testing is a
Motion some years ago. And like many               results from DAF’s test department.                  thing of the past. After a particular
other companies, they were eager to                With dynamic models created in LMS                   optimized configuration is selected
discover exactly how they could use the            Virtual.Lab, the engineering team                    using LMS Virtual.Lab simulation, it
LMS Virtual.Lab platform to improve                could create possible ‘what-if’ design               is validated using test data acquired
their process. The CAE Engines team                scenarios on a virtual test bench and                using the LMS Test.Lab platform and
uses LMS Virtual.Lab Motion to analyze             use these development scenarios to                   LMS SCADAS hardware. Then the DAF
engine dynamic behavior in the time                guide internal design decisions.                     project team manufactures the prototype
domain using engine models with both                                                                    piece and mounts it on the engine and
rigid (CAD) and flexible (FE) components                                                                run the tests on the actual prototype
                                                     “For most issues, every
for more dynamic model content. In                                                                      to validate the solution as a whole.
addition, they also acquired LMS Virtual.
                                                     involved engineer will propose
                                                     a solution and most of the
Lab Noise and Vibration for in-depth                                                                    Driven by emission
                                                     time, they are all different.”
engine forced response analysis in                                                                      standards… and cost
the frequency domain. One of the key
benefits of this combination - LMS                  “When you have a tool like LMS Virtual.             Regarding engine development, most
Virtual.Lab Motion and LMS Virtual.Lab             Lab, you can quickly validate or rather              recently the next-generation MX engine,
Noise & Vibration - is that the frequency          invalidate various design options and                DAF faced the typical challenges that
domain load input can be derived                   easily support your arguments for                    every engine developer faces today: new

      The team at DAF used LMS Virtual.Lab Motion to create an in-depth test bench to examine the best-possible design solution for its next-
      generation MX engine. Thanks to LMS Virtual.Lab, the research team could give management a variety of different options.

| 30 | LMSNEWS - March 2010
stricter emission regulations, customer
demands for better fuel efficiency and
reliability and, of course, keeping the
engine cost as low as possible. All these
changes affect not only the engine itself,
but also how the engine interacts with
the various truck models as a whole.

 “The amount of time saved
 can be impressive. You can
 eliminate 4 to 5 ideas without
 having to go to the test
 bench saving a substantial
 amount of prototyping costs,
 right from the start.”

 Eric Van Velthooven, DAF

 If one considers the fact that the DAF
CAE-Engines team completes an average
of 150 CAE-jobs per year, this represents
a superb cost-saver that
LMS Virtual.Lab contributes to.

“We are dealing with extremely complex
engine designs and our deadlines are
tight. You can easily imagine that the
pressure is on and the stakes are high.
Add in the global economic crisis and
it is clear that we have to be faster and
smarter with the tools and people that       The PACCAR MX engine range is the result of 50 years DAF experience in developing heavy-
we have. From this point of view, LMS        duty diesel engines, combined with the latest technologies and design techniques.
                                             A compact design and advanced materials ensure a low weight and maximum durability.
Virtual.Lab is an ideal tool for the tough   High performance and massive torque combine to deliver an exceptional driving experience.
times,” concluded Eric Van Velthooven.

                                                                                                         LMSNEWS - March 2010 |     31 |
Ground-breaking vehicle co-simulation at Volvo
Construction Equipment cuts virtual prototyping in half

| 32 | LMSNEWS - March 2010
To maintain its leading brand position, the Volvo Construction Equipment
(Volvo CE) engineers were challenged to develop top-performing wheel
loaders and articulated haulers even faster than before. To start, this
meant reducing prototype test cycles by two-thirds. The final goal?
Chopping the virtual prototyping time in early design phases in half.

                                                                        LMSNEWS - March 2010 |   33 |
                                                                     Hydraulics, powertrain and cooling systems must work together
                                                                     properly to provide the right balance of power, performance and fuel
                                                                     efficiency in these tough, complex machines.

Creating a unified co-simulation solution                       Why LMS Imagine.Lab AMESim?

In this ground-breaking project, the Volvo Construction         Not surprising, the primary reason Volvo CE opted for
Equipment design team in Eskilstuna, Sweden, replaced           the LMS Imagine.Lab solution is that it is one of the
its piece-meal department-by-department process with a          few products on the market today that can accurately
single solution based on LMS Imagine.Lab AMESim. With one       predict vehicle fuel consumption and operability – both
unified model, they could simulate the behavior of four major   make-or-break brand criteria for Volvo CE. On the nuts-
vehicle subsystems in wheel loaders and articulated haulers:    and-bolts side, the project, code-named SamSim, aimed
hydraulics, powertrain, thermal management and the actual       to streamline and accelerate the overall development
driver. Subsystem models exchanged data seamlessly.             process by building a collaborative simulation platform
                                                                using a reduced number of consolidated software tools.
The team could refer to the master LMS Imagine.Lab AMESim
co-simulation model, including MATLAB for electronic control
subsystems, to review subsystem interaction and full vehicle     Previously, Volvo CE had 5 separate - mostly
performance under real-world operating conditions. Rather
                                                                 incompatible - software packages so hearing
than using many separate tools, engineers collaborated using
                                                                 that there was a single, unique solution on
LMS Imagine.Lab AMESim for all physics-based models,
                                                                 the market made the choice pretty easy.
which serves as a common language to compare various
design alternatives, predict fuel consumption and equipment
operability and optimize design concepts early on.
                                                                “After a six-month evaluation period and six months of further
In a sense, the development process was turned upside           model synthesis and validation, the impressive results led
down. The easy-to-use, click-and-go graphical user interface    us to massively invest and widely deploy the LMS Imagine.
let the team work together quickly to refine the design         Lab AMESim solution. It is a critical component of our global
from the start. All the engineers had to do was drag,           simulation platform,” explained Jonas Larsson, Simulation
drop and interconnect simple icons – pre-defined and            Coordinator for hauler and loader development at Volvo CE.
validated one-dimensional units selected from libraries
– to create a unified physics-based model. The resulting        Not only could LMS Imagine.Lab AMESim exchange
block diagram looks simple enough, but underlying it is a       data efficiently among the various modules, it was also
sophisticated representation of exactly how all the different   compatible with other in-house SamSim software –
vehicle parts will operate together in the real world.          specifically, third-party packages for multi-body, engine

| 34 | LMSNEWS - March 2010
design and electronic control simulation as well as special     One model for all major subsystems
in-house Volvo CE codes. In a sense, LMS Imagine.               (and hybrids, too)
Lab AMESim became the one common language that
all the engineers on the design team could “speak”.             To model the loaders and haulers to accurately predict fuel
                                                                consumption and operability, LMS engineers had to take many
Value of LMS Engineering Services                               complicating factors, transients and boundary conditions into
                                                                consideration – not only for each subsystem, but how each
As part of the primary evaluation, LMS Engineering Services     subsystem interacted within the entire vehicle as well. There
performed a process audit that thoroughly examined              was also the electrical vs. engine power of hybrid models to
Volvo CE’s simulation structure. The goal was to optimally      consider as well.
implement the LMS software and yield a maximum benefit
quickly within a defined budget and time frame. This audit      With the powertrain, for example, LMS Imagine.Lab AMESim
showed that by replacing legacy code with LMS Imagine.          proved to be an extremely flexible tool. The Volvo CE engineers
Lab AMESim, Volvo CE could cut the number of simulation         could select the number of gears as well as multi-disc brakes,
tools they were using to two: an impressive return on           various types of differentials and engine models merely by
investment considering that all maintenance and renewal         pointing and clicking on the appropriate icons. Likewise, fuel
contracts for the old software could be eliminated as well as   consumption was readily calculated for hybrid wheel loaders
training and time spent working out incompatibility issues.     in which the internal combustion engine complemented with
                                                                an electric motor was used to power the vehicle around the
“This audit gave us valuable information regarding the ten      worksite while performing scooping, lifting and dumping
models we wanted to create to start. The idea was to jump-      operations.
start the implementation of LMS Imagine.Lab AMESim
with a set of basic models created by LMS – models that         “LMS Imagine.Lab AMESim played a key role in the hybridization
our engineers could then use as templates in representing       of the Volvo CE wheel loader and proved to be an effective
different new vehicle designs,” said Mr. Larsson.               flexible tool in evaluating the many options and optimizing the
                                                                final design,” Mr. Larsson noted.

                                                                                                    LMSNEWS - March 2010 |   35 |
Simulating the driver from the start                               The basic idea was to find the right balance. The oil temperature
                                                                   couldn’t be too high because that causes rapid oil deterioration
A success factor for the machine model was a representation        and damage to mechanical parts. Other factors that the LMS
of expected driver actions during typical vehicle operation.       Imagine.Lab AMESim model could simulate included warm-up
Vehicle measurements were taken on the Eskilstuna test tracks      times and the effect of weather conditions and operating
and used to create operating profiles in the LMS Imagine.Lab       cycles – all vital aspects to determine a thermal management
AMESim simulation. Profiles included speed and acceleration        control strategy for the hydraulically driven radiator fan (which
to fit various weather and terrain conditions and road grades in   consumes a considerable part of vehicle power) and other parts
the hauler case. Operating profiles for loaders included bucket    of the cooling circuits heat exchangers.
scooping, lifting and dumping for various gravel types and
operator driving styles.                                           Impressive ROI: virtual prototype in half

The hydraulic system modeling was done in close conjunction        “Manually tracking and balancing these multiple requirements
with the driveline since components from these two subsystems      is not practical given our time and resource constraints,” said
had to be sized together with respect to operational transients.   Mr. Larsson. “To maintain the high fidelity of the co-simulation,
These models included hydraulic pumps connected directly           the common platform provided by LMS Imagine.Lab AMESim
to the engine as well as the loader bucket and hauler dump         was absolutely essential. Moreover, with all members of the
bed. Another major consideration was the power for the             design team using the same tool in their work, they now
hydraulically-driven cooling fan pumps. LMS Imagine.Lab            ‘speak the same language’ and can collaborate more closely in
AMESim balanced these and other critical requirements to           development. The team can study more alternative concepts
maintain hydraulic oil pressure for the major components with      early in development and better optimize designs throughout
optimal efficiency and minimal drag on engine power.               the entire process.”

Optimizing fuel consumption with
thermal management
One area of critical importance in predicting and optimizing
fuel consumption and machine operability was thermal
management – that is, the sizing and control of the cooling
system regulating the engine temperature,
transmission and hydraulic oil for brakes and
axles. Simply stated: oil temperature determines
its viscosity and therefore friction. And the more
friction, the more fuel consumption.

| 36 | LMSNEWS - March 2010
The return on investment for Volvo CE is huge. According to
Larsson, engineers can now optimize the design of a single
new vehicle using simulation, verify the design with a physical
mock-up, and then develop multiple derivatives of the same
design using simulation alone. This allows the company to
develop a whole range of vehicles with down to a third of the
physical testing ordinarily required.

Engineers can readily adapt vehicles to specific customer
requirements using different electronic control strategies
in optimizing fuel consumption and vehicle performance for
particular load/unload cycles. Customized design is a huge
selling point in the competitive global construction equipment

“This project is a quantum leap in engineering productivity in
the construction equipment market. With process improvements
in collaboration and co-simulation – plus improvements
in developing simulation models, control strategies and
derivative models – Volvo CE has cut overall vehicle virtual
prototyping time in early design phases in half. This yields
a valuable reduction in overall product development time.
It shows what LMS engineering innovation can do for a
company willing to make a commitment to fully leveraging
cutting-edge LMS technology in their design processes,”
concluded Mr. Larsson.

                                                                  For powertrain design and thermal management, LMS Imagine.
                                                                  Lab AMESim modeled the engine, gearbox, transmission,
                                                                  power steering, hydraulic actuation, cooling circuits, fans and
                                                                  mechanical devices – all in a single unified intelligent solution.

                  “This project is a quantum leap in engineering productivity in
                  the construction equipment market. Volvo CE has cut overall
                  vehicle virtual prototyping time in early design phases in half.”

                                                                                                   LMSNEWS - March 2010 |       37 |
Putting Temsa buses
on the international map
Turkish bus manufacturer Temsa credits the full suite of LMS tools and engineering
services with helping the company bounce back from its country’s economic
crisis to become a leading player in the global coach and bus market

A crisis provides an opportunity for         and financial collapse. Temsa bus sales     engine as specified by the distributor,
change and growth. So goes the old           all but dried up and the firm was on        giving birth to Temsa’s original Safari
adage, which reflects the can-do spirit      the verge of bankruptcy with 50% of its     long-distance coach. The Temsa Safari
and never-say-die determination of           workforce gone.                             soon became popular in Europe and
Temsa. Founded in 1968 as part of the                                                    saved the company from certain collapse.
Sabanci conglomerate, Temsa made a           In the midst of all this, opportunity
comfortable living for decades fabricating   knocked at Temsa’s door. A French           Global sales climb
buses for sale exclusively in Turkey         distributor quickly needed a fleet of 200
according to designs from Mitsubishi         rugged and dependable buses – just the      Since those dark days nine years
Motors. Then in 2000 and 2001, a             kind of vehicles Temsa made to withstand    ago, Temsa has gone global, with an
financial crisis left Turkey’s economy in    the rigors of punishing Turkish roads.      international office in Mechelen, Belgium,
shambles with a de-valued local currency,    Temsa engineers scrambled to modify         and brisk sales across most of Europe –
widespread unemployment, bank failures       their bus design around the German MAN      particularly France, Germany and Italy.

| 38 | LMSNEWS - March 2010
LMSNEWS - March 2010 |   39 |
                                                                                           smaller. Indeed, in the fast-moving bus
 Their secret to success is the right combination of                                       business, vehicles are often sold before
 exuberant professional enthusiasm and the power of                                        they are designed – with hefty penalties
                                                                                           levied if delivery deadlines are not met.
 advanced engineering technology.                                                          This is the nature of the bus business, and
                                                                                           all in a day’s work for Temsa engineers.
Business has also been climbing in the       Focusing on customized
Middle East, Africa and Russia, with         design and small orders                       Big jobs for a small
inroads into the Indian, Chinese and US                                                    engineering staff
markets. Exports to 40 countries now         Temsa has made these huge gains by
account for 75% of Temsa sales, which        focusing primarily on a niche market          At its Marmara Research Center in the
have leaped almost 20-fold from 7.3          design largely shunned by its bigger          Technology Park in the city of Gebze near
million Euro in 2000 to 134 million Euro     competitors. With a good-value-for-money      Istanbul, a relatively small team of just 90
in 2008. From a low of just a handful        reputation, Temsa has become known            design engineers routinely completes this
of vehicles a year and only two models,      for its customized bus designs that meet      development work for all Temsa buses.
production has been ramped up to meet        very particular customer requests. And        How they do this is a lesson for other
increased demand for Temsa’s current         more often than not, these buses are          companies – not only in the bus industry
range of 12 models – which include           fast-turnaround, small-scale orders.          but other manufacturers as well: their
luxury long-distance coaches, a variety of                                                 secret to success is the right combination
smaller, lightweight “midi” buses and a      While most bus manufacturers have             of exuberant professional enthusiasm
newly launched city bus, the Avenue.         off-the-shelf take-it-or-leave-it models or   and the power of advanced engineering
                                             highly customized luxury vehicles, Temsa      technology.
Annual production capacity is 3,000          offers an extensive range of 186 variants
buses at Temsa’s main production plant       – all of which can be customized with         “Temsa really gives its engineers
in the southern Turkish city of Adana,       different engines, transmissions, frames,     freedom,” explained Bertan Bayram,
and another 1,000 coaches can be             suspensions, interiors, etc. All are          Temsa CAE and Test Team Leader at the
manufactured annually at a new facility      durable, fuel-efficient designs that meet     research center. “Our engineers design
in Egypt, 50 km outside of Cairo. In         stringent safety regulations and comfort      something and the next day see the
2008 at Belgium’s Busworld Kortrijk, the     requirements. And all must be developed       change on the bus.”
largest international trade show in the      quickly – typically in 6 to 12 months.
bus and coach industry, Temsa won the        This makes the 24-month cycle times for
prestigious “Manufacturer of the Year”       car models in the automotive industry
award – quite an accomplishment for a        seem like a snail’s pace – especially when
relatively small upstart Turkish company     you consider that a bus is a bigger, more
dwarfed by decades-older established         complex structure and, in most cases,
bus-makers more than 30 times its size.      the development budgets are a great deal

| 40 | LMSNEWS - March 2010
A forced response analysis based on loads in mounts and bus modes.             Structural frequency response at specific points on the steering column to
                                                                               identify problem frequencies.

One of Temsa’s first steps into the world
                                                      “Temsa is a place for                              Enter LMS’ hybrid road
of specialized engineering technology                                                                    approach
for its vehicle development process                   engineers who like to do
came five years ago while working on                  engineering, and Temsa                             To overcome these drawbacks, Temsa
the Safari HD. Its partnership with LMS               provides best-in-class                             began a cooperative relationship with
International started as a simple initiative          technology for them to get                         LMS International to implement the
to attain the necessary technological                 their job done right.”                             LMS hybrid road approach to accurately
skills, software and hardware to test bus                                                                predicting fatigue life of a new vehicle
durability virtually.                                                                                    early in development. The approach was
                                                    Engineers also performed finite-                     selected based on its success in the
Previous durability testing methods                 element stress calculations and some                 automotive industry, the experience of
involved long-haul road testing on a                rather “loose” fatigue analysis based                LMS from its years of working closely with
commercial test track usually taking                on rough load assumptions, and often                 car companies, and the extensive support
about 3 to 6 months. If a part failed or            guesswork. However, results were only                that LMS would provide in transferring
cracked, it would be repaired and the test          considered rough approximations for                  technology and know-how so Temsa
would continue. But this method was not             sizing components and did not account                engineers would be able to complete such
foolproof and left room for doubt. The              for dynamic, time-varying effects of                 a project on their own in the future.
engineers needed a better representation            real-life loads or the flexible nature of the
of the actual loads vehicles would                  overall bus chassis. Moreover, as with               Today, the hybrid road approach uses
encounter on real roads. Also, durability           test iterations, material added to improve           LMS Virtual.Lab multibody simulation
testing was not performed until a bus               component durability increased overall               and fatigue life prediction software in
prototype was nearing the end of its                vehicle weight and decreased the fuel                combination with durability load data
development cycle, when major changes               efficiency – techniques which are best               analysis and an LMS test system for
were difficult and costly to make.                  avoided considering today’s eco agenda.              measurement, data acquisition and signal

Modal participations to identify the most important structural modes causing   Checking acoustic modes and frequencies for potential coupling
the response at problem frequencies.                                           at the problem frequencies.

                                                                                                                           LMSNEWS - March 2010 |     41 |
 The whole MBS model, including front suspension, rear suspension (shown right) and flexible bus body.

analysis. Mr. Bayram explained that first,            The LMS data analysis system                       the individual components in the bus
a fully loaded, instrumented processor                automatically determines the damage                suspension and frame. To do this the team
or “mule” vehicle is driven over typical              content of these signals, identifies which         counts on LMS Virtual.Lab to simulate
routes in the region where the bus would              portion of the CUP test drive produced             aspects of the bus design and LMS Virtual.
normally operate. Accelerometers and                  these loads, and categorizes signals               Lab Durability to predict the fatigue life.
strain gauges on the wheel center and                 based on amplitude, repetitiveness and
suspension measurements on this vehicle               duration. Removing the non-damaging                The benefits of process change
create a customer usage profile of the                and extraneous portions of signals, the
wheel forces and body acceleration for                tool generates a condensed wheel load              “The LMS hybrid road approach lets us
the target market.                                    data file of cumulative damage over time.          develop new bus designs much faster,”
                                                                                                         noted Mr. Bayram. “Evaluating durability
Next, analysis tools are used to                      From this compressed wheel load data               on a test track can take between 3 and
determine the fatigue content for each                file, an inverse transfer function back-           6 months – if no major cracks occur. For
signal measurement part. In other words,              calculates an effective road profile of            major cracks or breakdown, you have
the cumulative impact of small but highly             vertical wheel displacements that are              to wait with the test until a new bus
repetitive loads, such as a standard road             more dependent on the road surface                 arrives...and that can add weeks to the
surface vibration are put together with               characteristics than on the individual             schedule.
very large but infrequent loads, such as              vehicle. The road profiles are then used
the wheel hitting a pothole.                          as input to determine fatigue life of

The durability results of the most critical hot spot, and the crack caught on the proving ground.

| 42 | LMSNEWS - March 2010
                                                                             Out of the initial LMS hybrid road project
                                                                             came the Safari HD bus, which was
                                                                             developed in just one year rather than the
                                                                             more than two years previously required.
                                                                             Costs were similarly reduced because
                                                                             fewer prototype testing cycles needed.

Now with LMS tools and our virtual           bus designs, like the Avenue city bus,        Temsa design, but was rather a torsional
models, we can do a durability               based on advanced lightweight materials.      vibration in the powertrain. More
assessment in 5 to 7 days.                   The entire roof and floor of the Temsa        specifically, a transmission problem,
                                             Avenue is composite-based with high           which the transmission manufacturer
                                             strength-to-weight ratios, making these       then corrected. Temsa didn’t have the
 With such a fast response,                  buses lighter and safer at the same time.     right specialized equipment for this
 we can iteratively refine the                                                             rotating shaft measurement and LMS
 computer model and perform                  Expanding the use                             Engineering Services measurements
 a series of simulations until               of LMS solutions                              confirmed Temsa suspicions.
 the design is optimized to                  Following the success of LMS’ hybrid          Total value of the
 remove excess material, for                 road approach, Temsa most recently            LMS total solution
 example.                                    increased the range of LMS test systems
                                             at its Gebze research center and has          “LMS has provided tremendous support
                                             added a LMS Virtual.Lab Noise and             to our vehicle development activities, and
In this way, we can maximize fatigue         Vibration solution to its repertoire of       the LMS tools all work well together as
life while at the same time developing       LMS tools. This gives Temsa engineers         a unified suite of packages,” explained
the best-possible lightweight design for     the capability to investigate the best        Mr. Bayraktar, General Manager of Temsa
improved fuel economy.”                      placement and materials for engine            R&D and Technology. “We started from a
                                             mounts, for example, and determine            blank slate and changed the way we work
Out of the initial LMS hybrid road project   noise and vibration flows into the cabin      as a company. Today, we can leverage
came the Safari HD bus, which was            interior through transfer path analysis,      the power of all the LMS integrated
developed in just one year rather than the   frequency response function calculations      simulation and test solutions. And we
more than two years previously required.     and acoustic coupling. Such capabilities      are proud to point out that we’ve done
Costs were similarly reduced because         further reduce bus development times by       this change in a few years whereas other
fewer prototype testing cycles needed to     as much as 10% but also helps avoid NVH       much larger companies in automotive,
be performed and production problems         issues with customers, many of whom           aerospace and other industries have
were greatly reduced.                        have sophisticated NVH testing systems        taken 50 years to do.”
                                             for evaluating vehicles before accepting an
Vehicle weight was minimized by shaping      order.                                         “In our turnaround, the use of LMS
the profile of the entire frame to develop                                                 integrated engineering solutions has
Temsa’s Space Frame, which is 30%            Temsa also continues to call on LMS           enabled us to save time, lower costs,
lighter than other comparable frames.        Engineering Services for support when         and overall to develop some of the
Because of this durable, fuel-efficient      needed, as on a recent torsional vibration    most reliable, fuel-efficient and safest
design, the Safari HD soon became            problem. After considerable NVH testing,      buses in the world – quite impressive
Temsa’s flagship product. Simulation         Temsa engineers determined that the           accomplishments for a relatively small
has also facilitated alternative Temsa       vibration was not originating in the          Turkish company that was virtually
                                                                                           unheard of nine years ago.”

                                                                                                         LMSNEWS - March 2010 |   43 |
More problem-solving simulation goodies
for better and faster engineering

 Without question, LMS Virtual.Lab Rev 9 is getting great reviews. It is the most comprehensive,
 capable and versatile performance simulation package on the market. Vice President Simulation
 Division Stefaan Goossens explains how LMS continues to set the reference standard for
 acoustic simulation and multi-domain system simulation with LMS Imagine.Lab Rev 9.

LMS News: The LMS Virtual.Lab Rev 9
is a milestone release. Why?

Stef Goossens, Vice President Simulation Division: We
have focused on developing and enhancing our overall 3D
simulation solution so it can tackle more problems for more
attributes and provides improved applicability and solving
capability. Acoustics received our special attention. We have
really concentrated on ramping up our solver technology. LMS
Virtual.Lab Revision 9 Acoustics is filled with breakthrough
performance features in both solving speed and accuracy to
increase engineering productivity, most notably with our new
FEM Acoustic solvers. These breakthrough developments
show why we’re the acoustic simulation market leader.

                                                                  Stef Goossens, Vice President Simulation Division
LMS News: What are the breakthroughs in acoustic simulation?

SG: Without a doubt, the extension of the FEM acoustic solvers.
This area is of great importance to our customers since their
modeling and solving needs keep increasing. With the ever-          More info at
increasing model size requirements, we had to expand the
FEM frequency range. We have achieved this by implementing
the technologically advanced PML (Perfectly Matched Layer)          www.lmsintl.com/imagine-lab-rev9
method. This technique solves these noise radiation mega-
problems more efficiently while not compromising accuracy.

| 44 | LMSNEWS - March 2010
We have also introduced iterative solving methods that exhibit   Deere and our LMS Imagine.Lab development teams
superior efficiency, robustness and convergence properties.      have really succeeded in improving the software.

Another crucial improvement is a time-domain BEM solver,         LMS News: What types of improvements were
which helps acoustic engineers perform realistic simulations     made? And for what type of applications?
and gain more insight into short duration events, such as
injector ticking noise. LMS continues to lead the innovation     SG: LMS Imagine.Lab AMESim Revision 9 comes with turn-
race in the area of Fast Multiple BEM (FMBEM) with the           key simulators for various applications in a wide range of
addition of patented ATV (Acoustic Transfer Vector) technology   industries: powertrain, hybrid vehicles, comfort and driving
to the FMBEM solver. Using this solution for powertrain          dynamics for the automotive sector, fluid actuators for aviation
acoustic radiation, one can address higher frequencies.          and full-wheel loader simulators for the off-highway industry.
                                                                 With these simulators, users no longer have to build their
And the brand-new ray tracing acoustics technology               model from scratch and only need to adapt the model to the
helps acoustic engineers deal with the full audible              architecture. Users can then quickly assess drivability and
frequency range, including sound system optimization             comfort issues as well as performance and fuel consumption.
in aircraft, train or vehicle interiors.

LMS News: What about the other modules of LMS Virtual.Lab?

SG: LMS Virtual.Lab Motion now offers multi-body
simulation solutions for key industrial applications, such
as driving dynamics, aerospace, off-highway and tracked
vehicles. This presents enhanced productivity and specific
modeling and solving capabilities. Advanced co-simulation
methodologies have been implemented to leverage the
unique combination of LMS Imagine.Lab Amesim (1D) and
LMS Virtual.Lab (3D). This lets users combined the two
necessary modeling techniques for active suspension systems,
ESP, electric steering in the vehicle dynamics arena, and
combined mechanical, hydraulic and electric actuation.

We might add that the new thermal fatigue solution in
LMS Virtual.Lab Durability addresses fatigue problems
caused by cyclic thermal loading, hot parts under cyclic
mechanical loading or a combination of both.

LS-DYNA™ coupling provides complete pre-processing
for safety simulation with LMS Virtual.Lab Structures,
for example in side or roll-over crash simulation.

LMS News: LMS Imagine.Lab, our 1D system                         The expanded FEM solver handles large noise radiation problems.
simulation solution, is truly unique on the market.
Why should engineers consider Rev 9?

SG: The new release delivers a straightforward, interactive
framework with advanced capabilities for performing 1D
system simulation. With improved ergonomics, enhanced
data management and ready-to-use simulators, it is an
easy path to model-based design of complex structures like
hybrid vehicle architectures or model-based vehicles.

LMS News: You already have customers like
John Deere Werke Mannheim on board.

SG: At John Deere Werke Mannheim, they use LMS Imagine.
Lab AMESim software to build virtual tractor models for
model-based design, system integration and validation.
The LMS Imagine.Lab AMESim Revision 9 interactive
environment helped them create a more efficient process          The new LMS Imagine.Lab release features improved ergonomics and data
from system definition to result analysis. Good responsiveness   management to optimize productivity.
to software enhancement proposals is important to John

                                                                                                         LMSNEWS - March 2010 |    45 |
Power up productivity
with LMS Test.Lab Rev 10A

The news is certainly acoustics with new-patented technology for SSL (Sound Source
Localization) that easily cuts the interior acoustic sound source localization process
by more than 50% while at the same time providing unprecedented insights. Bruno Massa,
Vice President Test Division, highlights this and other high-tech goodies in LMS Test.Lab Rev 10.

LMS News: What are the highlights of the                         LMS News: Which enhancements have been
new LMS Test.Lab Rev 10A release?                                introduced for Ground Vibration Testing?

Bruno Massa, Vice President Test Division: For the new           Bruno Massa: We have added a new coherence plotting
release, we have focused on providing advanced productivity      functionality in our ground vibration testing (GVT) solution.
as well as increased efficiency and user-friendliness.           This new feature delivers a direct efficiency benefit for time-
We’ve introduced brand-new applications such as MIMO             consuming and mission critical GVT campaigns. Users can
FRF testing and time domain transfer path analysis. We           visualize averaged coherence values of selected frequency bands
have also completed our portfolio for acoustic testing and       and easily identify weak coherence areas. This reduces the
integrated new solutions for sound source localization.          risk involved in GVT campaigns and shortens the total testing
                                                                 time. The coherence plots are available on all structural testing
LMS News: How will the LMS Test.Lab Rev 10                       acquisition modules for immediate measurement validation.
make multi-excitation testing more efficient?

Bruno Massa: The MIMO FRF testing solution is an important
extension to the existing modal testing techniques. Users can
define excitation spectra with shaped amplitude for random
and multi-sine excitation. Periodic random excitation can
be used to obtain the best linear fit for a non-linear system.
Users can simply record time data and import it into the new
application for replay. The other new application, time domain
TPA, complements frequency domain TPA and is the perfect
solution for transient phenomena analysis and auralization
of partial and summed contributions. In combination with
the component editing add-in, users can visualize and listen
to the impact of proposed structural modifications.

                                                                 Bruno Massa, Vice President Test Division

| 46 | LMSNEWS - March 2010
The new and motorized LMS Test.Lab 3D Acoustic Camera has a laser that automatically scans the geometry without operator
intervention. During the scanning, pictures are taken to obtain a full 3D photorealistic image of the vehicle.

LMS News: The integration of advanced acoustic                              LMS News: What are the benefits of the LMS E-series
testing capabilities has been another important                             modules for the LMS SCADAS acquisition hardware?
achievement in this latest version?
                                                                            Bruno Massa: The new E-series modules offer a true 150dB
Bruno Massa: Yes, we are very proud to offer the most                       dynamic range no matter what input range is used. This
complete acoustic testing and analysis solution currently                   gives the LMS SCADAS Mobile an extra measurement power
on the market. In terms of sound quality, the portfolio                     boost. The new modules ensure faster test set-ups and
has been enhanced with psycho-acoustic metrics used in                      accurate measurements without data loss – even for the most
the automotive, aerospace and white goods sectors. For                      demanding applications with the highest channel count.
sound intensity measurements, the application module
now includes a 3D acoustic mesh generator. This helps
users easily analyze, browse and interpret data for sound
power, source ranking and sound source localization.

LMS News: Which innovative solutions does LMS offer
for sound source localization measurements?

Bruno Massa: For real-time near-field and far-field sound
source localization, we have the new high definition acoustic
camera, which can be used for stationary and transient
applications. The camera’s array with wide angle lens provides
sharp pictures even when taken close to the structure. For
interior noise sound source localization, we have another
solution – the new and motorized LMS Test.Lab 3D Acoustic
Camera. The camera has a laser that automatically scans the
interior geometry without operator intervention. Users can
quickly detect interior noise sources with high precision.

LMS News: What are the highlights of the new release
of the LMS Test.Xpress noise and vibration analyzer?

Bruno Massa: LMS Test.Xpress Rev 4A now comes
with a newly integrated sound level meter, a new ISO
3747 sound power standard for in-situ measurements                          The intensity analysis sheet provides a clear view of the available test data,
and a triggered intensity functionality that assesses                       quality indicators, intensity, sound power, partial sound power from different
synchronous sound intensity even in noisy environments.

     More info at www.lmsintl.com/testlab-rev9

                                                                                                                         LMSNEWS - March 2010 |      47 |
                                                                            LMS is an engineering innovation partner for

                                                                                                                                 LMS Gateway and LMS OPTIMUS are registered trademarks of LMS International. All other trademarks acknowledged.
                                                                                                                                 LMS SYSNOISE, LMS DADS, LMS Tec.Manager, LMS CADA-X, LMS Test.Lab Mobile, LMS PolyMAX, LMS SCADAS III,
                                                                            companies in the automotive, aerospace and

                                                                                                                                 LMS International, LMS Test.Lab, LMS Virtual.Lab, LMS Test.Xpress, LMS Imagine.Lab AMESim, LMS FALANCS,
                                                                            other advanced manufacturing industries. With
                                                                            approximately 30 years of experience, LMS helps

                                                                                                                                 LMS SCADAS Mobile, LMS SCADAS Recorder, LMS SCADAS Durability Recorder, LMS TecWare, LMS TWR,
                                                                            customers get better products to market faster
                                                                            and turn superior process efficiency into key
                                                                            competitive advantages.

                                                                            With a unique combination of 1D and 3D
                                                                            simulation software, testing systems and
                                                                            engineering services, LMS tunes into mission
                                                                            critical engineering attributes, ranging from
                                                                            system dynamics, structural integrity and
                                                                            sound quality to durability, safety and power
                                                                            consumption. With multi-domain solutions for
                                                                            thermal, fluid dynamics, electrical and mechanical
                                                                            system behavior, LMS can address the complex
                                                                            engineering challenges associated with intelligent
                                                                            system design.

                                                                            Thanks to our technology and dedicated people,
                                                                            LMS has become the partner of choice of more
                                                                            than 5,000 leading manufacturing companies
LMS INTERNATIONAL                                                           worldwide. LMS is certified to ISO9001:2000
Researchpark Z1, Interleuvenlaan 68                                         quality standards and operates through a network
B-3001 Leuven [Belgium]                                                     of subsidiaries and representatives in key
T +32 16 384 200 | F +32 16 384 350                                         locations around the world. For more information
info@lmsintl.com | www.lmsintl.com                                          on LMS, visit www.lmsintl.com.

Worldwide            For the address of your local representative, please
                     visit www.lmsintl.com/lmsworldwide

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