The SpaceFinder function not only calculates the fill level but also provides the relationship between the volume and the fill level as a graph. Ideally, this should be as linear as possible because shoulders in the graph indicate dead spaces in the transmission that take up unnecessary amounts of oil. In such cases, the user can examine the shoulders in more detail and, if necessary, define sections to identify unused spaces—then make the necessary design changes to eliminate these from the transmission housing geometry.

Ready for use
The results delivered by digital oil level measurement offer a satisfactory level of precision, as tests have shown. While the programmers were using the software to calculate the oil levels for various transmissions, Engel was studying these levels on a physical model to compare the measured values with the results obtained from the simulation. The discrepancy was less than 3.5 ounces and was therefore well within the predefined tolerance. "At first, I was very wary of the software results," Engel says. "But the sample measurements we took at the test bench convinced me that we could trust its predictions."

Getrag Ford Transmissions currently uses SpaceFinder as a standalone solution that is not yet integrated in the existing CAD (NX I-deas) and PLM (product lifecycle management) environment. This is because this C3P data management environment, which consists of a number of decentralized data management systems, is being replaced by a central PLM backbone based on Teamcenter® digital lifecycle management software. Muth says this will provide the ideal platform for integrating SpaceFinder into the development process.

Engel is convinced that the use of this new CAE tool will make many measurements in physical transmission systems unnecessary, saving much time and effort, not to mention the long lead times for the production of a physical prototype. "To perform a basic transmission measurement, we need at least a week in the lab," he explains. "We perform the measurements a number of times to ensure that statistical errors are kept well under control. And if important geometrical dimensions such as the diameter of the gears change during development, we have to check the measurement results again. I can imagine that in the future we will be able to establish all of this faster and more efficiently in the CAD system prior to producing the prototypes."

Dave Taylor is senior director, Automotive Marketing, for Siemens PLM Software.