Feature Manufacturing Software
Reliability and speed = performance I
nfiniti Red Bull Racing has won both the Drivers’ and Constructors’ Formula One Championship titles in 2010, 2011, 2012, and then doing it all again in 2013. To achieve this, polished performances on the track and in the pits need to be sup- ported by behind the scenes team- work. From concept, through design and simulation, to manufacturing and assembly - development never stops. Integration of all engineering processes is crucial, and Siemens PLM Software solutions - NX software for computer aided design/manufactur- ing/engineering (CAD/CAM/CAE) and Teamcenter software for complete PLM - underpin the team’s engineering endeavors. Together, they form the digi- tal backbone of Infiniti Red Bull Racing.
Pushing the boundaries The emphasis on performance enhance- ment generates a high volume of updates, and their implementation requires a dis- ciplined development process that is effi- cient and predictable. All this has to be achieved during the days between races and coordinated on a global scale. The key is to iterate new ideas, select the solutions that promise the most improve- ment and develop them virtually as far as possible before committing to manufac- turing the physical parts. Working within the Formula One
resource restrictions is simply another challenge to be addressed. The regula- tions limit physical testing at the track, headcount versus external spend, and also the total amount of aerodynamics activity, allowing the teams to decide the split between computational fluid dynamics (CFD) and wind tunnel test- ing. This all further drives the need for very efficient virtual processes once there is correlation and confidence that the virtual processes match the physical testing done on rigs, in a wind tunnel and on the track. Interestingly, even if extensive phys- ical tests were allowed, such methods would be too slow to cope with the rate of innovation required to remain competitive. In addition, the introduc- tion of garage curfews reduced the time available to assemble, upgrade and repair cars. In the majority of cases, the first time that the upgrades come together is at the racetrack. It is therefore essential that the pit crew is able to assemble the car easily and effi- ciently the first time.
Automation JANUARY 2014
To enable fast paced design and development at Infiniti Red Bull Racing, the Formula One racing team has integrated Siemens PLM Software solutions Refining the concept
Aerodynamic optimisation directly correlates to performance improve- ment. New parts are created with NX, which is then used to develop the geometry, and then tested virtually in the engineering team’s CFD solution or tested in the wind tunnel using parts made through the technique of Additive Manufacturing. Once the aerodynamics department has agreed on the external form, then the part can be released for detailed design and val- idation to verify that it can be manu- factured and will meet the team’s reliability and performance criteria. This is all done using the
Teamcenter managed environment, which enables various downstream disciplines to utilise and develop the part definition and the associated details for manufacturing, test, inspec- tion and installation. To maximise the potential perfor- mance gain from a design concept, engineers run as many iterations of the design as possible within the time available. Having confidence that the virtual environment in which they are developing a component, assembly or system accurately reflects the physical world during testing on a Friday and Saturday of a race weekend, enables engineers to rely increasingly on vir- tual design iterations and validation.
Realising the design
Since the launch of the team in 2005, the number of design changes each year has significantly increased, relative to the number of designers. Good manage- ment of the engineering process is essential to ensure that up to date infor- mation flows from design through simu- lation, manufacturing, inspection test, and finally onto the car. During this process, the full car for an event is avail- able for visualisation to everyone on the team - from the factory to the track. Given the increasing number of modifications and new parts, it is also important that everyone involved in the engineering and manufacturing processes has early, comprehensive visibility into changes, so that they can prepare and respond accordingly. Using Siemens PLM Software’s solu- tions, everyone is automatically designing within the context of the next upgrade and doing so within a secure, confidential environment. Frequently, one can find parts
already being machined while NX is being used to update the machining program with the next refinement of the design. The ability to work collab- oratively within the PLM environment also means that CAM programmers can commence their tasks at the same time that designers are developing the models, thus minimising the lead time from design to manufacture. Designers are also taking full advan- tage of the NX Advanced Simulation tools to perform stress analysis on parts during the iterative design and develop- ment process. The dedicated finite ele- ment analysis (FEA) team works in parallel with the design team, sharing the same 3D master geometry. This helps ensure that components meet demand- ing requirements and are designed in the shortest possible timeframe.
Manufacturing, for example, auto- matically provides the whole package of information to the shop floor, including the machining tool paths, tool setting sheets, feedback sheets, tool library information, and valida- tion data for integrated simulation and verification with NX.
A calm and calculating approach The efficiency of the entire develop- ment process is increasing year after year, enabling more updates to be made to the car in a predictable manner. New designs can be reviewed while they are maturing by managers, inspectors and mechanics for planning purposes, by the race team for geometry information debriefs between track and factory, and by suppliers in preparation for fast and accurate turnaround.
A spokesperson for Red Bull con- cluded, “To develop the complex product that is a Formula One racing car in approximately a five month period requires intense activity and an extremely robust and efficient PLM infrastructure, coupled with world class talent and highly developed business processes.
“For us, the innovation process is relentless, unyielding and publicly demonstrated on the track each race weekend. As an innovation partner, Siemens PLM Software assists us in building on our existing knowledge and technological expertise and goes one step further in our search for per- formance and reliability. In this indus- try, success can depend on a fraction of a second.”
Siemens
www.plm.automation.siemens.com T: 01276 413 200
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