Method and a system for the optimized production of a component

Abstract

The invention relates to a computer-implemented method for the optimized production of a component, the method comprising the steps: - Providing (S1) a variety of design requirements; - Selection (S2) of a subset of the design requirements based on at least one component requirement; - Simulating (S3), using a component design model, a plurality of components by varying the subset of the design requirements, depending on at least one design space boundary; - Evaluating (S4) the simulated plurality of components depending on the at least one component requirement and depending on component costs and / or component complexity; - selecting (S5) the simulated component of the plurality of simulated components that has an optimal evaluation result; and - Manufacturing (S6) a real component based on the design parameters associated with the selected component.

Description

[0001] The invention relates to a method and a system for the optimized production of a component. Furthermore, the invention relates to a component manufactured using such a method. State of the art

[0002] The development and manufacture of electrical control units for Advanced Driver Assistance Systems (ADAS) has become a key challenge in the automotive industry. During the acquisition phase of this process, the focus is on creating a proposal within a limited timeframe that not only meets customer requirements but also offers attractive pricing. Thermal requirements, for example, are particularly challenging, as they often significantly influence design and costs.

[0003] Concept decisions are often made based on rough, low-maturity data, as there is no time for detailed simulations of different component concepts to meet customer requirements.

[0004] This generally applies to the manufacture of components that must be designed and manufactured according to customer requirements. Achieving an optimum balance between component design and manufacturing costs and complexity is always a driving force during the design phase.

[0005] The invention is therefore based on the object of proposing an improved method and / or system for producing a component.

[0006] The problem is solved by a computer-implemented method for the optimized production of a component according to the features of patent claim 1. The problem is solved by a system for the optimized production of a component according to the features of patent claim 12. Disclosure of the invention

[0007] According to a first aspect, a computer-implemented method for the optimized production of a component is proposed, the method comprising the steps: - Providing a variety of design requirements; - Selection of a subset of the design requirements, in particular those relevant to the design of the component, based on at least one component requirement; - Simulating, using a component design model, a plurality of components by varying the subset of design requirements, depending on at least one design space boundary; - Evaluating the simulated plurality of components depending on the at least one component requirement and depending on component costs and / or component complexity; - selecting the simulated component of the plurality of simulated components that has an optimal evaluation result; and - Manufacturing a real component based on the design parameters associated with the selected component.

[0008] Particularly preferably, simulating the plurality of components by varying the subset of the design requirements may be preceded by defining a design space within which the plurality of simulated designs are to be located and by specifying design space boundaries of the design space.

[0009] By defining the design space and the design space boundaries, a pre-filter for the simulation is provided and thus prevents abstruse and / or unmanufacturable and / or highly complex designs from being simulated.

[0010] This, in turn, makes the overall design process more efficient. Within the design space, a reasonable sub-area can be defined within the design space boundaries, within which the simulated components should be located. The design space preferably comprises n dimensions, each of which is determined by a component parameter.

[0011] The design space preferably has as many dimensions as the subset of design requirements, wherein each design requirement is preferably describable by a design and / or component parameter.

[0012] It is understood that the steps according to the invention, as well as other optional steps, do not necessarily have to be performed in the order shown, but can also be performed in a different order. Furthermore, additional intermediate steps can be provided. The individual steps can also comprise one or more substeps without thereby departing from the scope of the method according to the invention.

[0013] The process begins by providing a large number of design requirements. A subset of the design requirements is then selected, with at least one component requirement serving as the basis for the selection. A large number of components are simulated using a component design model. This is done by varying the previously selected subset of design requirements, taking at least one design space boundary into account. The simulated components are evaluated based on at least one component requirement and taking into account component cost and / or component complexity. The component with the best evaluation result from the large number of simulated components is selected. Finally, a real component is manufactured based on the design parameters of the selected component.

[0014] The design requirements can, for example, represent customer requirements that a customer places on the component. For example, a design requirement can have an ECU requirement that specifies the requirements a customer places on an ECU. A program for providing such design requirements can be ARCHITECT, for example. Selecting the subset can involve compiling the customer requirements, namely in particular those customer requirements that are relevant, for example, for thermal design of the component. Simulation can preferably be preceded by defining a possible design space for solution search. In this case, it is preferably specified to what extent and / or within which limits a respective design parameter can be varied.Examples of limits for a possible design parameter variation include a minimum and maximum installation space, a heat spreader size and / or heat spreader thickness, and / or a TIM gap thickness and / or a TIM material and / or an HSPR material. The minimum installation space refers specifically to the smallest permissible size or the smallest space that the component may occupy. The maximum installation space, on the other hand, refers to the largest permissible size or the largest space that the component may occupy.

[0015] Heatspreader size refers specifically to the dimensions or area of the heatspreader used in the assembly. The heatspreader is specifically an element used in electronic or thermal applications to dissipate heat efficiently. Heatspreader thickness refers to the thickness of the heatspreader. This thickness can affect thermal conductivity and thermal efficiency. TIM stands for "Thermal Interface Material" and refers to the material placed between two surfaces to improve heat transfer. TIM gap thickness refers specifically to the distance between the surfaces connected by TIM. TIM material refers to the specific material used as the thermal interface material. It can be thermal paste, thermal pad, or another material optimized for heat transfer.HSPR material refers specifically to the material the heat spreader is made of. Different materials have different thermal properties that can affect heat dissipation.

[0016] By using the method according to the invention, a decision regarding the optimal component design, taking into account component requirements and manufacturing costs, can be made quickly and based on sophisticated data. This enables the timely offering and / or production of such an optimal component with the optimum cost / component function. This invention allows for rapid response to new customer requirements with reduced development effort. This allows for overall optimization of component manufacturing.

[0017] This provides a novel process for the rapid evaluation and optimization of design concepts during the acquisition phase with very high accuracy. Optimization is achieved, in particular, by linking to simulation and cost databases and / or querying data with each request using a new process. The invention relates in particular to the digitization / simulation of the mechanical development / design of electronic control units. Such electronic control units are an example of the component to be manufactured.

[0018] This makes it possible to determine component designs with optimal function and price based on highly accurate "pre-calculated" data. This high level of accuracy is achieved in particular by creating reduced parametric function and cost models, which are evaluated in a special data flow based on the respective customer requirements. Depending on the requirements, a real-time calculation of possible component designs can be performed and provided using the current request data, depending on at least one component requirement.

[0019] In a preferred embodiment, the component costs and / or the component complexity depend on a material composition of the respective component variation and / or an assembly complexity of the respective component. The component costs preferably refer to the financial expenditure associated with the production of a component. These costs can include material costs, labor costs, machine costs, and other cost components. The component complexity preferably describes the difficulty or complexity in producing a component. It can be influenced by the number of required work steps, the variety of materials used, the geometric shape, and other factors. The material composition preferably refers to the selection and combination of materials used to manufacture a component.The choice of materials can influence the cost and performance of the component. Assembly complexity primarily describes the difficulty and complexity of the assembly process in manufacturing a component. It can depend on the number of components, assembly accuracy, and other factors.

[0020] In a preferred embodiment, evaluating the simulated plurality of components comprises interpolation with a predetermined component requirement-related component database and / or interpolation using a cost function. Interpolation is preferably a mathematical method for estimating or calculating values between known data points. In this context, it is preferably used to estimate values or results related to component requirements or costs based on existing data or functions. A cost function is preferably a mathematical function that models the costs as a function of various variables. It is preferably used to calculate the costs for different component variants based on the design parameters and other factors.

[0021] In a preferred embodiment, evaluating the simulated plurality of components comprises displaying the simulated component variants in a Pareto front diagram. A Pareto front diagram is preferably a graphical representation tool used to visualize the trade-offs between different objectives or criteria. In this context, the simulated component variants are preferably displayed in a Pareto front diagram to identify the best possible combination of component requirements and costs. It preferably shows which component variants achieve the best results with respect to the specified criteria. All evaluated designs are preferably displayed as a "scatter plot" in a cost / complexity component requirement diagram in the form of a Pareto front. This enables evaluation and design selection by a user or automatically.Filters or other interpretations or rules can be implemented. The evaluation can also be performed through measurements and subsequent evaluation of the measurement results. Alternatively or additionally, the evaluation can also involve expert knowledge. The evaluation can particularly preferably include simulation and / or calculation and / or determination of the component's performance, for example, thermal performance.

[0022] In a preferred embodiment, the simulation of the plurality of components comprises discretizing the respective component-specific design parameters and varying the discrete design parameters within a predetermined limit interval. The simulation or sampling of the plurality of components in the design space preferably comprises defining discrete support values and / or grid points for the respective design parameters, which preferably each cover the design space. In this case, the respective design parameters are preferably discretized in each parameter dimension, e.g. thickness, length, width, material, etc. For example, with a parameter interval of 0 to 300 mm, it is specified that a parameter variation occurs in an increment of 10 mm. For example, the plurality of components is carried out on the basis of such a parameter variation.

[0023] In a preferred embodiment, simulating the plurality of components involves combinatorially combining individual dimension points of the respective varied design parameters to form a design solution. The result is a discrete design candidate cloud in the design space that, in particular, covers the permissible search space.

[0024] In a preferred embodiment, the plurality of component-specific design parameters include a package size and / or a processor performance and / or a power dissipation and / or an ambient temperature applicable for operation. Package size refers in particular to the physical size or space available for the component in a particular application or system. This size can be measured in length, width, height, or other dimensions. Processor performance refers in particular to the computing power or processing capability of an electronic processor or microchip. It is often measured in units such as gigahertz (GHz) or MIPS (million instructions per second). Power dissipation is in particular the energy dissipated in the form of heat during use of an electronic component or part.It is an important factor in the thermal design of components and can influence their efficiency and service life. The ambient temperature refers specifically to the temperature of the environment in which the component operates. It can vary considerably depending on the application and location and has a significant impact on the component's thermal performance.

[0025] In a preferred embodiment, the at least one component requirement comprises a thermal and / or electrical and / or electronic and / or mechanical requirement. The component requirement is in particular a specific prerequisite or criterion that the component must fulfill in order to function successfully in a particular application. These requirements can in particular relate to thermal, electrical, electronic or mechanical aspects. A thermal requirement relates in particular to specific specifications or conditions relating to the thermal performance or temperature stability of a component. This can in particular include the maximum permissible temperature, heat dissipation or other thermal properties. An electrical requirement relates in particular to specifications or conditions relating to the electrical performance or the electrical properties of a component.This may, in particular, include voltage requirements, current requirements, or other electrical parameters. An electronic requirement particularly concerns specific requirements or criteria related to the electronic functionality of a component. This may, in particular, concern switching speed, signal quality, or other electronic properties. A mechanical requirement particularly refers to specifications or conditions regarding the mechanical stability, strength, or other mechanical properties of a component. This may, in particular, include load capacity, tolerances, or other mechanical parameters.

[0026] In a preferred embodiment, a production line comprising the equipment assembly for producing predefined products is further provided. A production line is preferably a sequence of production stations and / or work areas arranged to cooperate to manufacture at least one product. This production line may comprise various devices, machines, and / or systems configured for the production of the predetermined products. In this embodiment, it is emphasized that in the preferred embodiment, a specific equipment assembly is present in the production line. This equipment assembly could, for example, comprise machines, robots, automated assembly lines, tools, and / or other equipment required for the production of the predetermined products.

[0027] In a preferred embodiment, after the production line has been provided, the method further comprises the step of producing at least one predeterminable product using the equipment assemblage. After the production line has been provided, according to this embodiment, a method is carried out which aims to produce at least one predeterminable product. This step takes place using the existing equipment assemblage in the production line. The type of product involved or the exact sequence of the manufacturing process is not specified in more detail here. The focus is on the fact that in the preferred embodiment the method aims to produce at least one predeterminable product using the provided equipment assemblage in the production line.

[0028] According to a second aspect, a system for the optimized production of a component is proposed, the system comprising an evaluation and computing device which is designed to carry out the following steps: - Providing a variety of design requirements; - Selection of a subset of the design requirements based on at least one component requirement; - Simulating, using a component design model, a plurality of components by varying the subset of design requirements, depending on at least one design space boundary; - Evaluating the simulated plurality of components depending on the at least one component requirement and depending on component costs and / or component complexity; - selecting the simulated component of the plurality of simulated components that has an optimal evaluation result; and - Manufacturing a real component based on the design parameters associated with the selected component.

[0029] The statements made for the procedure apply accordingly to the system. It is understood that linguistic modifications of procedurally formulated features can be reformulated for the system according to common linguistic practice, without such formulations having to be explicitly listed here.

[0030] In the present case, a component is also claimed which is manufactured according to the described method.

[0031] The present invention also claims a computer program with program code for executing at least parts of the method according to the invention in one of its embodiments when the computer program is executed on a computer. In other words, the invention relates to a computer program (product) comprising instructions that, when executed by a computer, cause the computer to execute the method / steps of the method according to the invention in one of its embodiments.

[0032] The present invention also proposes a computer-readable data carrier containing program code of a computer program for executing at least parts of the method according to the invention in one of its embodiments when the computer program is executed on a computer. In other words, the invention relates to a computer-readable (storage) medium comprising instructions that, when executed by a computer, cause the computer to execute the method / steps of the method according to the invention in one of its embodiments.

[0033] The described designs and further training courses can be combined as desired.

[0034] Further possible embodiments, developments and implementations of the invention also include combinations of features of the invention described previously or below with regard to the exemplary embodiments that are not explicitly mentioned. Short description of the drawings

[0035] The accompanying drawings are intended to provide a further understanding of embodiments of the invention. They illustrate embodiments and, in conjunction with the description, serve to explain principles and concepts of the invention.

[0036] Other embodiments and many of the aforementioned advantages will become apparent upon review of the drawings. The elements illustrated in the drawings are not necessarily drawn to scale.

[0037] They show: Fig. 1 shows a schematic flow diagram of a present method according to an embodiment; and Fig. Figure 2 shows a representation of various simulated component designs that are evaluated depending on a component requirement and depending on component costs and / or component complexity.

[0038] In the figures of the drawings, the same reference symbols designate the same or functionally identical elements, parts or components, unless otherwise stated.

[0039] Fig. 1 shows a schematic flow diagram of a present method according to an embodiment.

[0040] In any embodiment, the method can be carried out at least partially by a system 100, which for this purpose can comprise several components not shown in detail, for example, one or more provision devices and / or at least one evaluation and computing device. It is understood that the provision device can be designed jointly with the evaluation and computing device or can be different from it. Furthermore, the system can comprise a storage device and / or an output device and / or a display device and / or an input device.

[0041] According to the invention, the computer-implemented method comprises at least the following steps: In a step S1, a large number of design requirements are provided.

[0042] In a step S2, a subset of the design requirements is selected based on at least one component requirement

[0043] In a step S3, a simulation of a plurality of components is carried out using a component design model by varying the subset of the design requirements depending on at least one design space boundary.

[0044] In a step S4, the simulated plurality of components is evaluated depending on the at least one component requirement and depending on component costs and / or component complexity.

[0045] In a step S5, the simulated component of the plurality of simulated components which has an optimal evaluation result is selected.

[0046] In a step S6, a real component is manufactured based on the design parameters belonging to the selected component.

[0047] Fig. Figure 2 shows a representation of various simulated component designs that are evaluated depending on a component requirement and depending on component costs and / or component complexity.

[0048] A component requirement 200 is plotted on the abscissa. Component costs and component complexity 202 are plotted on the ordinate. A plurality of simulated component variants 204, each of which has a plurality of design parameters virtually varied, are plotted as a point cloud 206 in the Pareto front diagram. A Pareto front is shown and provided with the reference symbol 208. Depending on a design requirement 210, which can be provided by the customer, the simulated component 212 from the plurality of simulated components that exhibits an optimal evaluation result can be selected.

[0049] A real component can then be manufactured or produced based on the design parameters belonging to the selected component 212.

Claims

[1] Computer-implemented method for the optimized production of a component, the method comprising the steps: - Providing a variety of design requirements; - Selection of a subset of the design requirements based on at least one component requirement; - Simulating, using a component design model, a plurality of components by varying the subset of design requirements, depending on at least one design space boundary; - Evaluating the simulated plurality of components depending on the at least one component requirement and depending on component costs and / or component complexity; - selecting the simulated component of the plurality of simulated components that has an optimal evaluation result; and - Manufacturing a real component based on the design parameters associated with the selected component. [2] Method according to claim 1, wherein the component costs and / or the component complexity is / are dependent on a material composition of the respective component variation and / or an assembly complexity of the respective component. [3] Method according to claim 1 or 2, wherein the evaluation of the simulated plurality of components comprises an interpolation with a predetermined component requirement-related component database and / or an interpolation by means of a cost function. [4] Method according to one of the preceding claims, wherein evaluating the simulated plurality of components comprises displaying the simulated component variants in a Pareto front diagram. [5] Method according to one of the preceding claims, wherein simulating the plurality of components comprises discretizing the respective component-specific design parameters and varying the discrete design parameters within a predetermined limit interval. [6] Method according to one of the preceding claims, wherein the simulation of the plurality of components comprises a combinatorial combination of individual dimension points of the respectively varied design parameters to form a design solution. [7] Method according to one of the preceding claims, wherein the plurality of component-specific design parameters comprises a space size and / or a processor power and / or a power loss and / or an ambient temperature applicable for operation. [8] Method according to one of the preceding claims, wherein the at least one component requirement comprises a thermal and / or electrical and / or electronic and / or mechanical requirement. [9] Method according to one of the preceding claims, further comprising providing a production line comprising the equipment assembly for producing the component. [10] The method of claim 9, wherein the method further comprises the step of, after providing the manufacturing line, manufacturing the component using the equipment assembly. [11] Component manufactured by the method according to any one of claims 1 to 10. [12] System (100) for the optimized production of a component, the system comprising an evaluation and computing device which is designed to carry out the following steps: - Providing a variety of design requirements; - Selection of a subset of the design requirements based on at least one component requirement; - Simulating, using a component design model, a plurality of components by varying the subset of design requirements, depending on at least one design space boundary; - Evaluating the simulated plurality of components depending on the at least one component requirement and depending on component costs and / or component complexity; - selecting the simulated component of the plurality of simulated components that has an optimal evaluation result; and - Manufacturing a real component based on the design parameters associated with the selected component. [13] Computer program with program code to carry out at least parts of a method according to one of claims 1 to 10 when the computer program is executed on a computer. [14] Computer-readable data carrier with program code of a computer program for carrying out at least parts of a method according to one of claims 1 to 10 when the computer program is executed on a computer.

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