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Computer Aided Engineering at BMW, Powered by High Performance Computing


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Computer-aided-engineering (CAE), e.g. virtual modeling and simulation, has become a very important part in the automotive engineering process to achieve the necessary high quality. At the BMW Group a strong contributor is the progressive use of HPC to support the engineering process in many aspects of vehicle development, e.g. passive safety, aerodynamic drag and engine performance. The approach to provide HPC services is built around “cells” – modular, portable units of defined capability. After the talk of Mr. Burke, Fujitsu presents its concept of standardized HPC units; provides lessons for an SME community battling against hurdles to HPC adoption; how to consolidate HPC skills, ensure productivity and widen the HPC workforce.

Ian Godfrey
Wolfgang Burke

Published in: Technology
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Computer Aided Engineering at BMW, Powered by High Performance Computing

  1. 1. 0 Copyright 2015 FUJITSU Human Centric Innovation in Action Fujitsu Forum 2015 18th – 19th November
  2. 2. 1 Copyright 2015 FUJITSU Computer Aided Engineering at BMW, Powered by High Performance Computing Apps and Appliances, HPC insights for SMEs
  3. 3. 2 Copyright 2015 FUJITSU Speaker 1 Wolfgang Burke, HPC Operation and Solution Build, BMW Group Ian Godfrey, Solution Business Development, Fujitsu Systems Europe Speaker 2
  4. 4. 3 Copyright 2015 FUJITSU Product Development Ecosystem AutomakerSub-assembly suppliers Consultants Component manufacturers Touchstone for an HPC community  Domains of modelling and simulation  Model quality and precision  Project duration and constraints IDC 2015 BMW [among the] leaders for effectively exploiting HPC technology  Creative Testing Research Service providers
  5. 5. 4 Copyright 2015 FUJITSU A BMW HPC “Cell” Powered by Intel® Xeon® Processor. 132 servers Big node PRIMERGY RX2540 M1 Rack-Server 2xCPU Intel Xeon E5-2660v3 10C/20T 2.6 GHz 256 GB RAM, 3.15 TB HDD or 3.2 GB SSD Compute node PRIMERGY RX2530 M1 Rack-Server 2xCPU Intel Xeon E5-2660v3 10C/20T 2.6 GHz 128 GB RAM, 600 GB HDD File server node PRIMERGY RX2540 M1 Rack-Server 2xCPU Intel Xeon E5-2660v3 10C/20T 2.6 GHz 128 GB RAM, 36 TB HDD Gateway node PRIMERGY RX2530 M1 Rack-Server 2xCPU Intel Xeon E5-2660v3 10C/20T 2.6 GHz 16 GB RAM, 600 GB HDD Fast Interconnect Intel True Scale Fabric Switch 12300 2 core switches 36 port 40Gb/s 6 leaf switches 36 port 40Gb/s
  6. 6. 5 Copyright 2015 FUJITSU Defining an optimal architecture
  7. 7. 6 Copyright 2015 FUJITSU Automotive HPC trends – Modelling & Simulation Applications in the future  Full vehicle simulation (crash)  Remove all prototypes  Virtual Factory (idea-design-test-factory)  Integration of higher manufacturing precision into the simulation  Variance on parts and impact on durability, safety, etc.  Aesthetics -- precise, ultra fine grid representation of design’s look, color, sheen, image  Better ability to see a new design under multiple light conditions, in different locations (showroom, on the street, by a mountain)  Virtual test track (long term durability) Applications Today  Primarily Crash (60%-70% capability utilization)  Then CFD, then NVH Product behaviour Process integration Source: IDC 2015 More businesses looking at more potential for HPC
  8. 8. 7 Copyright 2015 FUJITSU HPC potential for SMEs  HPC is distinguished by being applicable to problems at arbitrarily levels of scale  Used effectively, therefore, any enterprise of individual can derive value from HPC  European manufacturing production was €6.8B in 2012 – around 40% from firms with under 250 employees (SMEs) Source: Economic Models For Financial ROI And Innovation From HPC Investments, IDC August 2015 Intersect360 Research  40–50% of small manufacturers view R&D leadership as their competitive advantage. 
  9. 9. 8 Copyright 2015 FUJITSU SME challenges to adopt HPC 1. Lack of knowledge, or skilled HPC support staff 2. Lack of support by management 3. Financial barriers – budgets, system costs, other costs 4. Difficulties related to scaling 5. Ease-of-use issues
  10. 10. 9 Copyright 2015 FUJITSU Insights into modelling & simulation  Too many smaller businesses not even doing FEA/CAE  Necessary first step towards HPC – but then come others  One thing to run a few jobs – another to embed HPC into regular engineering processes  Workforce profile threshold  Comfortable with physical testing  Unsure about virtual analysis  Different roles, different purposes  Enable design engineers – feedback, trade studies  Enable simulation analysts – verification Economic pressure Change drivers Experimental constraints Experienced recruit
  11. 11. 10 Copyright 2015 FUJITSU  Organisations need technical simulation, but seldom sophisticated HPC  Emerging concept of apps are an emerging part of the answer  Cross between workflow and traditional simulation suite  Usable by simulation analyst and design engineer  Apps need to speak language of intended user  Democratisation of CAE, and HPC  Process: Workflow capture – App creation – Controlled publication  Attempts to solve these problems to date tend to remain used by experts, or are brittle 80M Engineers + Non-engineers A way forward 8M Engineers 750K CAE Users Source: Cambashi, Beyond CAE, Front End Analytics (2014)
  12. 12. 11 Copyright 2015 FUJITSU Increasing Usability  Embed expertise to avoids experts being the bottlenecks  Create access to capability for non-engineers, casual users and HPC newcomers Simplicity Expertise
  13. 13. 12 Copyright 2015 FUJITSU Spectrum of HPC users Workgroup Under $100K Departmental $100K-$250K Divisional $250K-$500K Supercomputer Above $500K
  14. 14. 13 Copyright 2015 FUJITSU Increasing Accessibility Workgroup Under $100K Departmental $100K-$250K Divisional $250K-$500K Supercomputer Above $500K PRIMEFLEX for HPC Appliance Line Converged Infrastructure methodology Dedicated processes Application- and segment- defined architectures Streamlined customer support with SPOC Factory build, test and certification of appliance Proactive performance analysis and design
  15. 15. 14 Copyright 2015 FUJITSU PRIMEFLEX Line of Appliances Management software User workplace PRIMEFLEX for HPC HPC Gateway Application Catalogue System design Head node Compute nodes Interconnect Graphics Storage Rack & Power Batch Operation Administration Application Appliance Platform Appliance Powered by Intel® Xeon® Processor.
  16. 16. 15 Copyright 2015 FUJITSU HPC Democratisation HPC expert HPC consumers HPC calculators  Standardised processes  Optimal workflows  Traceability, machine learning  Higher productivity and throughput  New applications and physics  New processes  First applications  New domains  Consumer processes Userreach
  17. 17. 16 Copyright 2015 FUJITSU