Smart Virtual Sensing is changing the way physical testing is conducted. Testing and validation are crucial steps in product design and the evolution of new concepts. Typically, sensors are instrumented at key locations and the system’s response to required load conditions is measured. This allows verification of whether static and dynamic responses are as expected or whether a system can survive under critical load conditions. Testing technology has evolved rapidly due to the demand for efficient test validation, with new types of physical sensors, higher-precision test pipelines, new integrated post-processing capabilities, XiL testing and more being regularly released…
Challenges for testing and validation
Test engineers often face the following challenges: How can you make a measurement in locations where physical sensors cannot be placed? Examples of such places include:
Strain gauges cannot be installed in hot spots due to complex geometry
Tight packing makes accelerator instrumentation in the critical section impossible
Operational loads are difficult to measure because adding an additional load transducer changes the dynamics of the structure
Long instrumentation time and great effort to place a large number of sensors to cover the entire structure
Conducting full vehicle testing to validate specific vehicle components is time-consuming and expensive
Damage occurs to expensive structure during testing due to unexpected overload
Many engineers have asked themselves: isn't there a new technology that can help address these challenges?
Revolutionary Solutions – Simcenter 3D Smart Virtual Sensing
Simcenter 3D Smart Virtual Sensing helps you make field estimations (deformation, stress, velocity, acceleration, and displacement) and load estimations (force, moment). It provides a framework for merging FE model prediction and physical measurement data. This framework delivers accurate results with compensation for both model inaccuracy and test noise. Additionally, in addition to augmenting test results after physical testing, it can export an Executable Digital Twin (xDT) to run on a real-time platform for real-time testing.
With Simcenter 3D Smart Virtual Sensing, you can:
Measure inaccessible access point locations from physical sensors placed in accessible locations
Measure acceleration from remote locations to avoid crowded places.
Measure operating loads using a few strain gauges instead of adding load transducers.
Use virtual sensors to replace or enrich physical sensors, to speed up the testing campaign and optimize cost
Determine the operational loads of the target components of the whole vehicle test and then reproduce the equivalent loads on a test bench.
Monitoring all field stress in real time during the testing process allows input loads to be adjusted when critical stress is reached.
Implementation
How can such a challenge be addressed? Simcenter provides an integrated workflow from the Simcenter 3D Smart Virtual Sensing application to the test environments. This is based on the exported Executable Digital Twin (xDT) that can be deployed to Model-based System Testing (MBST) platforms , giving it the adaptive capability to solve various test problems.
The starting point of this workflow is always with Simcenter 3D Smart Virtual Sensing, where the smart virtual sensing solution is created and the input and output of the xDT are defined. Inputs are the required physical measurements, output can be virtual sensors at required locations, loads and full field status. The data fusion solver and reduced-order FE model are embedded in the exported xDT.
Off-line vs real-time Model-based System Testing
Simcenter 3D Smart Virtual Sensing xDTs can be deployed in Simcenter Testlab RT (real-time MBST) and Simcenter Testlab Neo (offline MBST). Each option enables different user scenarios.
You may choose to work offline because you simply want to expand your measured data sets. Since you have already completed testing and data acquisition, virtual sensing data can help you extend your physical measurements to provide you with a complete engineering view, such as operational loads and augmented virtual sensing measurements. It allows you to easily integrate the new method into existing test projects. For example, perform durability analysis on more locations with extended virtual sensors.
Implementing Smart Virtual Sensing in Testlab RT provides all virtual sensor loads and estimates in real time, allowing you to monitor and interact with the testing process.
For example, when testing a new part or even a prototype, damaging the part can result in high costs and extended development times. Therefore, part protection methods can be invaluable. With Simcenter Testlab RT together with Smart Virtual Sensing xDT, you gain additional insights into your part during testing. If loads exceed acceptable values, the test can be stopped, protecting the part.
The off-line Model-based System Testing
You can first perform testing and data acquisition, and then scale up the test results by deploying Smart Virtual Sensing xDT within Simcenter Testlab Neo. The inputs of the xDT will be corresponding test data, the outputs are virtual sensor channels and estimated loads.
Deployment of off-line Model-based System Testing
You can implement Simcenter 3D Smart Virtual Sensing xDT in Simcenter Testlab Neo by simply following the steps below:
Step 1:
Performance testing with instrumented physical sensors and Simcenter SCADAS for data acquisition
Step 2:
Deploy Smart Virtual Sensing xDT to the test environment using the dedicated Functional Mock-up Unit (FMU) method in Simcenter Testlab Neo Process Designer
Step 3:
Configure xDT inputs with physical measurement results
Step 4:
Run xDT to extend your physical measurements with more virtual sensor channels and estimated loads
Step 5:
Perform further test data post-processing based on the enriched test results to provide you with a complete engineering view.
The complete workflow is designed so that the exported Smart Virtual Sensing xDT can be seamlessly integrated into the test environment. It opens up many new opportunities to facilitate the testing process.
For example, some strain measurements made in accessible locations can produce hot spot stresses and operational loads, which can overwhelm the usability of traditional measurement results. With the estimated loads, you can perform strength and durability analyses.
Real-time Model-based System Testing
You may think that the offline approach is fine, but you need to complete the test first and then perform the test data argumentation. Therefore, you want to obtain the virtual sensing estimate in real time. With Smart Virtual Sensing xDT embedded in the real-time MBST, you can obtain the extended virtual test channels, visualize the full field stress and strain during the test, and even use this field estimate to optimize the test process. For example, as mentioned earlier, you can decrease the input loads once you reach your safety margin for the critical stress. This can help protect your expensive or irreplaceable test object.
Real-time MBST can be configured by deploying Simcenter 3D Smart Virtual Sensing xDT in Simcenter Testlab RT. Simcenter Testlab RT provides the application software and real-time hardware to run Simcenter 3D Smart Virtual Sensing xDT, feed the physical inputs to the FMU input, and get the FMU defined outputs in real-time. This will provide the load estimation and field estimation at the same time as the physical measurement. The results of the virtual channels can be displayed as a graph along with the physical channels, the full field estimation results can also be passed to the visualization tool to get the full field status.
Deployment of Real-time Model-based System Testing
Step 1:
Instrument sensors and connect them to Testlab RT via a real-time data acquisition system
Step 2:
Deploy Smart Virtual Sensing xDT on Testlab RT via the web interface
Step 3:
Configure xDT inputs with live test channels
Step 4:
Perform physical tests and run Smart Virtual Sensor xDT to get real-time virtual sensing data
Step 5:
Stream xDT estimation results to the visualization tool for full field status monitoring
Conclusion
For offline and real-time MBST solutions, it is important to know where to place sensors and how many sensors are needed. Simcenter 3D provides Optimal Sensor Placement to help with this.
With Simcenter 3D Smart Virtual Sensing, even inaccessible points become measurable. This innovative solution not only overcomes the challenge of placing physical sensors in hard-to-reach areas, but also significantly reduces instrumentation time and hardware costs. By creating a Smart Virtual Sensing xDT within Simcenter 3D, you can export and embed the xDT in Simcenter Testlab Neo for offline test result augmentation. Alternatively, you can deploy the xDT in Simcenter Testlab RT for real-time, model-based system testing. These seamless integrations enhance your testing capabilities by providing accurate data and insights that were previously unattainable.
This is not just a small incremental step in your testing capabilities, but a revolution to transform your testing processes.
Measure the inaccessible access point from instrument sensors placed at accessible locations
Obtain operational loads in a practical way to leverage resistance analysis and durability studies
Save time and instrumentation costs when testing large structures using virtual sensors
Perform tests of equivalent components on a test bench reproducing operational loads
Gain insights into performance and interact with the framework throughout the testing process
Schedule a meeting with CAEXPERTS and discover how Simcenter 3D Smart Virtual Sensing can transform your testing processes. Innovative virtual sensing technology optimizes testing in hard-to-reach locations, reduces costs, and improves the accuracy of results. Let’s explore together the solutions that can boost your efficiency, reduce instrumentation time, and provide a complete and accurate view of your product’s performance. Don’t miss this opportunity to take your testing to the next level. Contact us now!
WhatsApp: +55 (48) 988144798
E-mail: contato@caexperts.com.br
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