Pratt & Miller 2013 Engineering Services Brochure

Design Develop Build Race Win

Engineering Services

Design Engineering l Modeling & Simulation I Electronics I Manufacturing Testing & Development l Robotics l Software Solutions l Program Management

Design Develop Build Race Win

Pratt & Miller Engineering

Prepared to win in ALL we do “ We believe in our commitment to our customers… we have to win.”

- Jim Miller, President For over 20 years Pratt & Miller has used the world’s legendary race tracks as technology proving grounds to develop many race programs, including Corvette Racing, the most successful team in the history of the American Le Mans Series. “ The success and the passion that we have for motorsports permeates throughout the entire building.”

- Gary Pratt, Vice President As a dominant force in professional motorsports, the team has used a proven formula of integrating people, processes, and technologies, advancing Pratt & Miller’s worldrenowned motorsports operations, into the innovative, full-service engineering and low volume manufacturing company it is today. With over 200 employees, Pratt & Miller is proudly serving a global customer base including those in the Defense, Automotive, and Powersports industries.

Winning the prestigious “24 Hours of Le Mans” seven times is a testament to the company’s dedication to being the best in all we do. The most stringent quality requirements are met, within the most time-compressed deadlines. No project leaves the facility that is anything less than beyond customers’ expectations – ensuring that Pratt & Miller will be the creator of tomorrow’s standards.

CAPABILITY NAME

ISO 9001:2008 CERTIFIED

A Michigan Small Business

VALUE

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ADVANCED TECHNOLOGY

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“There is a reason we always turn to Pratt & Miller for highly technical projects and rush projects. We can always rely on Pratt & Miller to complete the project as fast as possible a nd it is always done right the first time.”

- A satisfied Pratt & Miller customer

Table of Contents 1

Design Engineering

3

Modeling & Simulation

5

Electronics

7

Manufacturing

9

Testing & Development

11

Robotics

13

Software Solutions

15

Program Management

INNOVATION

ST

BU

RO

Our commitment to attracting and retaining talented and driven people, developing robust processes, and investing in advanced technology, results in superior value and satisfaction for our customers.

YEE SATISFACTION PLO EM

Engineering Services

Design Develop Build Race Win

Design Engineering At Pratt & Miller, we have excellent, proven design resources that can take an idea from concept to a well-engineered solution. Using the latest Computer Aided Engineering (CAE) technologies, our designers work alongside our machinists, fabricators and engineers throughout the development process, ensuring delivery of the highest quality product.

Industrial Design Capabilities: • Concept Creation Brand development Sketching Brainstorming Styling • Prototyping and Physical Model Creation Rapid prototyping Class A surfacing Clay modeling • Human Factors Market research Ergonomics Human Machine Interface (HMI) Safety • Visualization Animations Realistic CAD rendering Technology: • • • •

Design Engineering 1

ALIAS Rhino Photoshop Showcase

Computer Aided Design (CAD) Capabilities: • • • • • •

Conceptual design Parametric solid and surface modeling Class A surfacing Packaging/architecture design Reverse engineering Weight reduction

Technology: • • • •

NX SolidWorks CATIA Pro/ENGINEER

Structural Analysis & Simulation Capabilities: • • • • • • •

Static linear analysis Non-linear analysis Kinematic and dynamic analysis Composite structure analysis Optimization Impact and crash analysis Durability/fatigue analysis

Technology: HyperWorks ANSYS Laminate tools Optistruct Genesis Radioss

Design Engineering

• • • • • •

2

Design Develop Build Race Win

Modeling & Simulation Pratt & Miller’s world renowned modeling and simulation capabilities allow us to develop solutions virtually and optimize performance prior to building hardware. By front loading the product development process with modeling and simulation, Pratt & Miller is able to compress the overall project timeline and improve the performance of the first prototypes. Once physical hardware is undergoing testing, modeling and simulation is used to refine the system performance, quickly analyze alternatives, run sensitivity studies, and correlate test data. Utilizing the latest advancements in computer hardware and software run by expert analysts, Pratt & Miller can predict and develop vehicle and system performance for attributes such as ride, handling, mobility, acceleration performance, durability, structural performance, blast analysis, crash analysis, safety system performance, aerodynamics, HVAC, and cooling management.

Vehicle Dynamics Capabilities: • Track lap time optimization • System analysis and optimization • H igh-level code routines, database applications, MATLAB applications and GUI development • Data analysis applications • Test data analysis and correlation • Ride, handling and mobility analysis • I ntegration of supplier generated subsystems (control systems, tires, etc.)

• Component load generation • D etailed system modeling of brakes, clutches, and power steering Technology: • • • •

Modeling & Simulation 3

A DAMS, ADAMS/Car and ADAMS/Chassis CarSim Dymola Optimization using HEEDS/MDO

Survivability Capabilities & Technology: • S ystems engineering approach applying extensive knowledge of all vehicle systems • E xpertise in theoretical shock physics analysis • A bility to conduct and correlate appropriate experiments • P roprietary explicit software code with continuous development to improve prediction of blast events • A ccess to one of the largest, privately owned super-computing systems in the U.S. used to conduct large-scale full-3D calculations Applications: • • • • • • • • • • • •

System solutions for occupant protection Underbelly blast Ballistics Vehicle structure development Add-on protection kit development Material evaluation Manufacturing process evaluation Energy absorbing device development Floor development Seat development Restraint development Injury prediction

Computational Fluid Dynamics Capabilities & Technology:

Applications: • Drag reduction for fuel economy • Downforce management for performance • Airflow through radiator, coolers, brake ducts • Engine bay temperature management • Underbody air flow • Interior heating and cooling performance

Modeling & Simulation

• E stablished processes to generate high-quality grids rapidly on complex configurations • Proprietary tools to improve overall grid quality and increase local grid refinement • Proprietary flow solver software and post-processing tools to simplify the analysis of large 3D data sets • Super-computing system to conduct large-scale full-3D calculations • Test execution including component prototyping, scale and full-size wind tunnel testing, and on-road testing

4

Design Develop Build Race Win

Electronics The foundation of Pratt & Miller’s electronics department has evolved from the competitive world of motorsports to include many industries with the same commitment to exactness, functionality, and reliability. Through the latest technologies and manufacturing strategies, our experienced team is on the cutting edge of development in Motorsports, Defense, Automotive, Powersports and Product Innovation. Our electronics group provides comprehensive control systems, advanced electrical engineering, electronic hardware design, and inhouse manufacturing.

Electrical Engineering Capabilities: • Vehicle power distribution systems • Vehicle data & information networks • Circuit design & PCB layout Technology: • MATLAB Simulink Stateflow • PSpice • Eagle PCB design

Control Systems & Embedded Software Capabilities: • • • • •

Algorithm design Human Machine Interfaces (HMI) Rapid control system prototyping Autonomous vehicle control systems C omplex multi-domain system modeling and model-based control systems • Vehicle dynamics control systems

Electronics 5

Technology: • MATLAB Simulink Stateflow • Mototron/Motohawk • Custom solutions

EV/HEV Engineering Capabilities: • Architecture modeling & simulation • V ehicle and component architecture trade studies • C omplete system prototyping and vehicle integration • V ehicle and energy system supervisory controllers Technology: • MATLAB Simulink Stateflow • Mototron/Motohawk • Eagle PCB Design

Electrical Manufacturing Capabilities: • A nalog and digital electronics design and testing of circuit boards, electronic devices and mechatronics • D esign and engineering of custom MIL-SPEC/motorsport wire harnesses and cable assemblies • E mbedded micro-controller PCB layout and assembly • H igh-voltage/hybrid electric wiring assemblies Technology:

Electronics

• MIL-SPEC hardware • Autosport • Production intent

6

Design Develop Build Race Win

Manufacturing Pratt & Miller specializes in low-volume, prototype manufacturing with capabilities that include rapid prototyping, CNC machining, metal fabrication, composite tooling, and precision assembly. Under one roof, we offer seamless integration of manufacturing with design, engineering, testing and development, and quality assurance. This integrated process ensures the highest quality products are delivered within an accelerated time frame.

Machining Machining Processes: • • • • •

3D CNC milling CNC turning ID/OD grinding Jig grinding E lectrical Discharge Machining (EDM) • Splining • Shot peening • Honing Machined Materials: • • • • • • • • •

Tooling board Aluminum Steel Stainless steel Titanium Magnesium Brass Plastics Tungsten

Fabrication Capabilities:

Manufacturing 7

• • • • • • • • • • • •

Complete chassis fabrication Full vehicle prototype builds TIG - MIG - ARC welding Sheet metal forming Tube notching Tube bending Sheet metal laser cutting Sheet metal water jetting Fixturing Engine header fabrication Sandblasting Powder coating

Composites Capabilities: • Prepreg or wet layup • Honeycomb core (aluminum & Nomex) • F oam core (short run molded cores available) • Proprietary lost core RP process for ducting or tubular structures (Patent pending) • Post-cure oven for controlled heat cycling • Resin Transfer Molding (RTM) • V acuum Assisted Resin Transfer Molding (VARTM) • Prototype and short production runs • Mold manufacturing and prep onsite • H ard tooling, composite tooling, metal molds, and bladder molding • Clay modeling

Assembly Capabilities: • • • • •

Full prototype vehicle assembly Electrical system assembly Hydraulic and line assembly Vehicle modernization Data acquisition installation

Quality Assurance Pratt & Miller’s quality management system is certified to the ISO 9001:2008 standard.

Equipment and processes:

Manufacturing

• Z eiss CONTURA G2 10/12/6 CNC CMM with a VAST XT active scanning sensor running CALYPSO • F aro Edge 12’ portable CMM arm with a Laser Line Probe for 3D scanning of complex surfaces • F aro Quantum 6’ portable CMM arm running CAM2 Q, and a FARO Gage portable CMM arm running CAM2 Gage • Rockwell digital hardness tester • N on-destructive testing and inspection methods including magnetic particle inspection and fluorescent dye penetrant inspection

8

Design Develop Build Race Win

Testing & Development Pratt & Miller’s testing & development department is composed of qualified engineers with diverse real-world testing experience. Utilizing state of the art software tools, specialized test equipment, and efficient product development planning our team can accommodate a wide variety of projects. From custom test benches to full vehicle build and validation, our team is prepared to support your testing needs.

Component, System, & Full Vehicle Testing Core Capabilities: • S uspension system development and tuning • V ehicle dynamics, durability, and validation • I nstrumentation and data acquisition • S hock dynamometers • P roduct showcasing and benchmarking • F leet/event management and support • A dvanced data analysis and correlation • K inematics & compliance testing • A erodynamics and cooling system testing • F atigue testing and correlation • H ydraulic systems test bench • D ynamometer testing • F ailure mode analysis Full Vehicle Dynamics and Development Services:

Testing & Development 9

• R ide quality and handling analysis • I terative design, simulation, and testing process • E xperienced vehicle dynamic evaluations • M ass inertia testing • S even post shaker rig analysis • C ertified test drivers/engineers • E fficient test plans minimize cost and time • A ccess to all major testing sites • T ransporters and mobile testing headquarters

Specialized Testing Support: • • • • • • • • •

T est bench design and manufacturing S pecialized software controls L ightweight, modular DAQ systems P rofessional quality wiring harnesses A ccelerated survivability/reliability testing P roduction launch support I ndependent 3rd party evaluations M ilitary vehicle testing E xtreme mobility and off-road development & testing

Tire Testing & Modeling Capabilities and Resources: • C omplete program for tire test planning, execution and model generation • E xperience with test machinery worldwide • C ustom software development for testing, data visualization, data analysis and model fitting • T ire model fitting capability including Magic Formula, Pacejka or 3rd party black box models • C ustom tire model creation for specific vehicle dynamics applications • L ibrary of existing tire data • T ire model integration to 3rd party simulation packages such as ADAMS, Carsim, Dymola

Testing & Development 10

Design Develop Build Race Win

Robotics Pratt & Miller understands the value of robust, reliable systems, and robotics applications are no exception. The Pratt & Miller robotics team consists of highly technical and trained engineers from an array of engineering disciplines and technical specialties. This vertical integration of departments, combined with a multidisciplinary approach, provides us the unique ability to offer solutions that consider all aspects of complex electromechanical systems. Our team of engineers is dedicated to providing high-end performance mobility solutions capable of exceptional vehicle stability in the harshest terrain.

Applications: • System integration Pratt & Miller’s electronics and robotics teams are uniquely suited to integrate existing sensors and cameras into any intelligent transportation system • Autonomous controls Experts in developing high performance vehicle mobility controllers • U nmanned platforms Design and development of ground robotic mobility platforms that are low cost, lightweight, tough, and modular

Robotics 11

Technology: • Custom mechanical design & manufacturing using: NX SolidWorks CATIA Pro/ENGINEER CNC machining Composite materials

• Custom electronics using: PSpice Eagle PCB CAD Atmel, PIC, and TI microcontrollers • C ustom software/firmware development using: C/C++ Python Java Verilog Linux OpenCV Image Processing

Robotics 12

Design Develop Build Race Win

Software Solutions Pratt & Miller’s software development team provides professional-grade software development services to support internal engineering and data management initiatives. By utilizing robust design, documentation, development, and quality assurance processes, we can rapidly develop enterprise-level software solutions that are highly effective and configurable for a wide range of clients. Pratt & Miller’s software solutions group strives to take the cutting-edge engineering technology developed by our race programs and package it into easily deployable applications in a variety of industries.

PM-VES

(Pratt & Miller - Vehicle Engineering System)

Parts Database: • A comprehensive parts database to store and manage the various components used by the vehicle fleet during the development process • Ability to create part types, with each part type having an unlimited number of user-defined attributes • Time-varying part attributes allow users to track changes in part attributes as they degrade or are modified • Allows tracking of part wear, as well as inspection and rebuild activities Vehicle Development and Testing: • D evelopment and testing activities organized as a series of events, sessions and outings • D iscrete vehicle tests organized by time to assemble full development and configuration history of vehicle • Ability to recall complete vehicle configuration at any point in the development cycle

PM-LTS

(Pratt & Miller - Lap Time Simulation)

Features:

Software Solutions

• • • • • • • • • • • • •

13

13 DOF (Degrees of Freedom) vehicle model that can be used to predict lap times Fully dynamic solver capturing true dynamics of sprung and unsprung masses Support for both open loop and closed loop events Support for Pacejka tire models - 94, 94, 2002 Asymmetric chassis, non-linear kinematics, compliance, non-linear spring dampers, and bump rubbers Configurable driver model Smart shifting powertrain model 3D engine map - torque versus RPM and throttle position Automatic track creation from lateral acceleration and velocity, GPS, or Pi Survey Detailed track specification including elevation, banking, friction, high frequency corner specific road input, and atmospheric conditions Multiple aerodynamics definition from simple coefficients to 3D map as function of bounce/pitch/roll/yaw Support for Design of Experiments (DOE) functionality Support for post-processing and post-process interface to Pi Toolbox

PM-DOE

(Pratt & Miller - Design of Experiments)

Analysis: • A bility to import DOE response surface results and organize them into unlimited experiment sets • U nlimited configuration sets allow users to study different factor settings • U nlimited chart option to plot responses • A bility to cascade responses of one experiment as factors to another • E xport option to export analyzed data to other applications Charting: • 9 different chart types including: Paretos Polynomial Surface Trends • V iew data in both two and three dimensional formats • W ork on single or multiple chart views Optimization: • • • •

Q uick determination of the optimum design criteria R esponse optimization while varying a few or all the factors S imple constraints allow user to specify ranges the factors must fall within C omplex constraints allow user to constrain factors together so that they are linked together • M ultiple DOE support such that they can be optimized at the same time with the results of one simulation being input to a different simulation

PM-CST

(Pratt & Miller - Combined Simulation Toolset)

Features:

• • •

• •

S ingle, integrated toolset that combines essential basic vehicle engineering activities F ull-vehicle suspension geometry assembly from component geometry K inematic analysis S teady-state load transfer analysis Provides

both a simple, grid-based view of geometry and setup parameters for easy comparison, as well as user-customizable setup pages A ll output content, both plotting and data grids, is also customizable, allowing users to define the most appropriate views for their application I nteractive 3D view of assembled suspension allows users to visually inspect setups and simulation results All setup data, as well as chassis components and their associated geometries are stored in an efficient parts database to eliminate the need for managing individual data files Analysis

results can be exported to generic XML and Excel formats, but can also be exported to ADAMS and Mitchell data file formats T ight integration with the PM-VES databases is also available for clients who are already using PM-VES to manage component and setup data

CAPABILITY Software NAME Solutions

• • • • •

14

Design Develop Build Race Win

Program Management Pratt & Miller program management engineers provide project planning, estimation, implementation, execution, and ongoing support. Translating user, customer, and stakeholder needs into programmatic requirements, the Pratt & Miller program managers usher projects through design, development, testing and production on-time and within budget.

As the primary liaison between the various internal departments, the Pratt & Miller program manager draws upon our strengths to maximize efficiency and effectiveness between disciplines. Our program managers also direct external functions to achieve program and customer objectives, from inception to completion.

By establishing processes and procedures based on industry best practices, the Pratt & Miller program manager will: • E stablish and manage internal and external resources to execute projects successfully • C oordinate an organized and efficient project plan based on deliverables • Evaluate and manage program risks • C oordinate with internal team on program priorities and issue resolution • M aintain program timeline for communicating key tasks, dependencies, and deliverables • I mplement project control systems for managing schedules and budget • P rovide clear and consistent communication with client on project status

Program Management 15

Pratt & Miller Contact Pratt & Miller Engineering 29600 W. K. Smith Drive New Hudson, MI 48165 Phone: (248) 446-9800 Fax: (248) 446-9020 www.prattmiller.com

Pratt & Miller Engineering is located just off Grand River on William K Smith Dr. between Milford Rd. and Wixom Rd.

Pratt & Miller Engineering (Trident location) 29201 Trident Indsutrial Drive New Hudson, MI 48165 Scan with mobile device