By Xiaoting Kou and Jonathan Melvin
Testing physics in a new way is being made possible by smart virtual sensing. Validation and testing are essential phases in the creation of new concepts and product design. Typically, we instrument the important sites with sensors and track the system’s response to the necessary load circumstances. This allows us to confirm whether a system can withstand extreme load circumstances or whether the static and dynamic responses are as anticipated. The need for effective test validation has caused testing technology to advance quickly. New physical sensor types, more precise test channels, integrated post-processing capabilities, XiL testing, and other features have been introduced on a regular basis.
The following issues are common for test engineers to deal with: In situations where it is not possible to deploy physical sensors, how may a measurement be taken? Some instances of these locations are:
- The unusual shape of hot patches makes it impossible to install strain gauges there.
- Instrumenting the accelerator to the critical portion is impossible due to tight packaging.
- Operational loads are challenging to quantify since the dynamics of the structure are altered by the inclusion of a load transducer.
- It took a long time to instrument the structure and a lot of work to place all the sensors needed to cover the entire building.
- It takes time and money to validate individual car components through full vehicle testing.
- Unexpected overload during testing causes damage to the pricey structure.
Countless engineers have wondered if there might be a new technology that could help with these problems.
We described in our last blog post how Simcenter 3D Smart Virtual Sensing assists with load (force, moment) and field estimation (strain, stress, velocity, acceleration, and displacement). It offers a platform for combining physical measurement data with predictions from FE models. With this system, test noise and model inaccuracy are both compensated for, yielding accurate results. It can also export an Executable Digital Twin (xDT) to operate in a real-time platform for real-time testing, in addition to enhancing the test findings following physical testing.
You can: use Simcenter 3D Smart Virtual Sensing
- Utilizing physical sensors positioned in accessible areas, determine the locations of inaccessible hot spots.
- Evaluate the acceleration from a distance to steer clear of crowded areas.
- Rather than installing load transducers, measure the operational loads using a few strain gauges.
- To expedite the test campaign and reduce costs, use virtual sensors to supplement or replace physical sensors.
- After determining the target components’ operational loads from the entire vehicle testing, replicate the corresponding loads on a test bench.
- Throughout the testing procedure, real-time monitoring of the entire field stress enables input loads to be changed when the critical stress is reached.
How can we overcome so many obstacles? From the Simcenter 3D Smart Virtual Sensing program to the testing environments, Simcenter offers an integrated process. This is based on the exported Executable Digital Twin (xDT), which has the adaptability to tackle various test challenges when deployed on Model-based System Testing (MBST) systems.
This approach always begins with Simcenter 3D Smart Virtual Sensing, where we define the input and output of the xDT and build the smart virtual sensing solution. Physical measurements are the inputs, while virtual sensors at the needed locations, loads, and full-field status might be the output. The exported xDT contains embedded versions of the reduced-order FE model and the data fusion solver.
Simcenter Testlab Neo (offline MBST) and Simcenter Testlab RT (real-time MBST) may both use Simcenter 3D Smart Virtual Sensing xDTs. Various user situations are enabled by each choice.
Working offline could be your only option if all you want to do is expand measured data sets. The virtual sensing data can help expand your physical measurements to give you full engineering information, such as operating loads and augmented virtual sensing measurement, since you have already finished the test and data collecting. It makes it simple to incorporate the new technique into already-existing test projects. Conduct durability studies, for instance, using extended virtual sensors in more places.
Deploying Smart Virtual Sensing within Testlab RT provides all the loads and virtual sensor estimation in real time, enabling you to monitor and interact with the test process.
For example, when testing a new part or even a prototype, damaging the part can result in large costs and extended development times. Therefore, methods of protecting the part can be invaluable. With Simcenter Testlab RT together with Smart Virtual Sensing xDT, you gain additional insight on your part during testing. Should loads exceed acceptable values, the test can be stopped, protecting the part.
Smart Virtual Sensing xDT can be deployed within Simcenter Testlab Neo to enhance test results once testing and data collecting are completed. Virtual sensor channels and predicted loads will be the outputs of the xDT, while equivalent test data will be the inputs.
By simply following the steps listed below, we can deploy the Simcenter 3D Smart Virtual Sensing xDT to Simcenter Testlab Neo:
Performance test using Simcenter SCADAS for data collection and instrumented physical sensors
Use Simcenter Testlab Neo Process Designer’s Functional Mock-up Unit (FMU) approach to deploy the Smart Virtual Sensing xDT into the testing environment.
Set up xDT inputs using the outcomes of actual measurements.
Use xDT to increase the number of virtual sensor channels and predicted loads in your physical measurements.
To provide you the complete engineering perspective, conduct additional post-processing on the test data in light of the enriched test findings.
The entire process has been planned to allow for a smooth integration of the exported Smart Virtual Sensing xDT into the testing environment. It creates a plethora of fresh chances to streamline the testing procedure.
The stress of hot spots and operational loads, for instance, can be obtained from a few strain measurements obtained at easily accessible locations, greatly enhancing the usefulness of conventional measurement data. You can perform strength and durability analysis using the estimated loads.
Even though you think the offline method is better, you still need to finish the test before you can argue the test results. For this reason, you need to get the virtual sensing estimate as soon as possible. You can monitor the entire field stress and deformation throughout the test, obtain the expanded virtual test channels, and even use this field estimation to enhance the testing procedure with Smart Virtual Sensing xDT integrated into Real-time MBST. For instance, as was already said, after you reach your safety buffer for the critical stress, you can reduce the input loads. This might aid in safeguarding your pricey or priceless test thing.
Deploying the Simcenter 3D Smart Virtual Sensing xDT to Simcenter Testlab RT will enable real-time MBST to be configured. In order to execute Simcenter 3D Smart Virtual Sensing xDT, feed physical inputs to the FMU input, and obtain the FMU defined outputs in real-time, Simcenter Testlab RT offers the application software and real-time hardware. This will give both the field and load estimates concurrently with the physical measurement. Along with the physical channels, the virtual channel results can be plotted. The visualization tool can additionally receive the whole field estimation data via streaming, providing a complete picture of the field’s status.
Use a real-time data gathering system to link Testlab RT to the instrument sensors.
Use the online interface to deploy Smart Virtual Sensing xDT to Testlab RT.
Set up real-time test channels with the xDT inputs.
To obtain real-time virtual sensing data, do the physical tests and activate the Smart Virtual Sensor xDT.
Provide the full-field status monitoring visualization tool with the findings of the xDT estimation.
Knowing which sensors to use and in what quantity is crucial for both real-time and offline MBST systems. To assist with this, Simcenter 3D offers the Optimal Sensor Placement (new with Simcenter 2406 version).
It is possible to measure even inaccessible areas using Simcenter 3D Smart Virtual Sensing. This creative approach not only solves the problem of putting physical sensors in difficult-to-reach locations, but it also drastically lowers hardware prices and instrumentation time. For off-line test result augmentation, you can create a Smart Virtual Sensing xDT in Simcenter 3D and then export and integrate it in Simcenter Testlab Neo. As an alternative, you can use Simcenter Testlab RT to deploy the xDT for real-time model-based system testing. Your testing skills are improved by these smooth integrations, which offer precise data and insights that were previously unavailable.
This is a revolution that will completely change your testing procedures rather than merely a minor advancement in your testing skills.
- Using instrument sensors positioned in accessible areas, determine the inaccessible hotspot.
- Utilize strength analysis and durability study to obtain operating loads in a useful manner.
- Use virtual sensors to reduce the time and expense of instrumentation when testing massive constructions.
- Test benches should be used for equivalent component testing, with operating stresses being replicated.
- Throughout the entire testing process, gain understanding of the performance and engage with the structure.
