Knowledge-Based Engineering (KBE), The Future of Experience.

What is Knowledge-Based Engineering (KBE) and How is it Used in Automotive Design?

In the past, experienced masters who shaped industry and technology carried their professions into the future by transferring the knowledge and experience they gained over the years to their apprentices.

This process was shaped by observation, practice and insights gained over time, creating a mastery chain passed down from generation to generation.

Today, the knowledge-based engineering (KBE) approach brings this traditional transfer of mastery into the digital age.

KBE, which systematically codifies experience and engineering knowledge and integrates them into design processes, offers the mastery of the past to the new generation of engineers with modern tools.

In today's engineering world, digitalization and automation are becoming increasingly important.

Knowledge-Based Engineering (KBE) is a powerful method to speed up design processes, reduce error rates and create space for engineers to produce more innovative solutions.

Especially in the automotive industry, KBE systems optimize design processes, reducing costs and improving product quality.

What is Knowledge-Based Engineering (KBE)?

KBE is an approach to automate design processes by integrating engineering knowledge and rules into computer-aided design (CAD) and computer-aided engineering (CAE) softwares.

Its main objectives are to reduce repetitive engineering tasks and to produce more efficient solutions by systematically utilizing expert knowledge. This approach is covered quite comprehensively in the book Intelligent Automation and its application areas in different sectors are detailed.

https://intelligentautomationbook.com/

KBE systems usually consist of the following components:

• Knowledge Base: This is where the design processes, engineering rules, and knowledge from past projects are stored (which is the most time-consuming and valuable part of a KBE project).

  
  

• Rules and Algorithms: Automated design decisions are made according to predetermined engineering rules. This process is the part where the company integrates all engineering competence into the system.

  
  

• CAD/CAE Integration: Knowledge-based design models can be dynamically updated by working integrated with CAD and CAE systems. This process is the part of the project that will never end. As long as the company exists, new knowledge and new experiences will continue to feed this system.

  
  

Advantages of KBE in Automotive Design

The automotive industry is one of the areas where KBE systems are most widely used due to its complex design processes and high precision requirements. KBE offers automotive engineers the following advantages:

1. Automation of Design Processes:

KBE systems speed up design processes by automating frequently repeated engineering operations. For example, the geometric optimization of an automotive exterior trim component can be automatically updated and quickly adapted to design changes thanks to KBE.

2. Reducing the Error Rate:

Human errors are inevitable in manual design processes. However, KBE systems minimize errors because they work according to predefined rules. In this way, potential design errors are detected in advance before going into production.

3. Cost and Time Savings:

KBE enables engineers to produce more accurate and efficient designs in less time. This both speeds up the development process and provides a competitive advantage by reducing costs. Studies shows that a design engineer spends 70% of his/her time on routine engineering activities and 30% on research and creative activities. This is where the role of KBE begins. Many routine engineering activities can be minimized by this method so that capacity can be allocated to innovative processes.

4. Standardized and Optimized Designs:

Knowledge-based engineering improves quality by ensuring consistency in design processes. It makes it possible to create designs that comply with the standards set for automotive manufacturers.

5. Internalization of Knowledge and Experience:

Engineering knowledge and experience are stored digitally through KBE systems, ensuring the preservation of corporate memory in the long term. Thus, the training of new designers becomes faster and more efficient.

Some KBE Application Examples in the Automotive Industry:

KBE technology is applied in many different areas in the automotive industry, you can find some examples below, I have included a few here, you can find hundreds of them with a short internet search:

1. Optimization of Automotive Exterior Trim Parts

The KBE-supported CAD system, which is used to design exterior trim parts (spoilers, grilles, etc.), enables engineers to produce designs in accordance with set standards. This system minimizes errors by automatically applying design rules such as material thicknesses, connection points and aerodynamic requirements.

2. Rule-Based Optimization in Body Design

In wheel design, KBE is used to automatically create designs that are optimized according to weight, strength and manufacturability criteria. In chassis design, material choices and cross bracing locations are optimized according to the loading scenarios, thus increasing durability and reducing unnecessary weight.

3. Intelligent Modeling in Crash Test Simulations

The KBE approach enables the models used in crash test simulations to be created automatically and adapted to changing regulations (Euro NCAP, IIHS, etc.). Thus, test criteria can be quickly adapted for each new vehicle model without the need to model from scratch over and over again.

4. Automatic Optimization in Air Duct and Cooling Systems Design

KBE-based parametric design systems are used to improve the flow efficiency of air ducts inside the engine compartment. This system reduces the need for manual intervention by engineers by producing designs that meet set heat management targets and aerodynamic requirements.

5. Intelligent Robot Programming in Assembly and Production Processes

In robotic welding or bonding processes used in assembly lines , KBE-supported software automatically determines the most suitable welding points and sequences according to part geometry, assembly sequence and tolerances. Thus, the production process becomes more efficient and the margin of error is minimized.

6. RAMSIS Integration in Ergonomics and Interior Design

KBE systems, integrated with human ergonomics simulation software such as RAMSIS for automotive interior design, automatically optimize the ideal seat positions, viewing angle and accessibility of controls for different user groups.

7. Parametric Wind Tunnel Simulations for Vehicle Aerodynamics

Parametric aerodynamic analysis systems developed using KBE can automatically make changes to the vehicle's body form to provide the best design alternatives that reduce wind resistance. This allows engineers to move forward with the best solutions suggested by the system instead of conducting hundreds of manual analyses.

A brief patent search reveals that there have been more than 200 patents in this field in the last 20 years. It should be noted that the most striking of these are the methods developed to collect engineering data.

And most importantly; this field should be considered as the first step to integrate the engineering design discipline with artificial intelligence. The preparation of the necessary data sets to train Artificial Intelligence for specific engineering fields will only be possible with a knowledge infrastructure such as good KBE.

In conclusion: Knowledge-Based Engineering will continue to stand out as a technology that revolutionizes design processes. This approach, which enables faster, more efficient and more cost-effective product development, will be one of the cornerstones of engineering work in the future.

Companies that cannot feed their experience as well as their data into their digital system will withdraw from this race one by one!!!

Sources

• Stjepandić, J., Verhagen, W. J. C., Liese, H., & Bermell-Garcia, P. (2015). Concurrent Engineering in the 21st Century. Springer International Publishing.

• Infosys Limited. (2018). Knowledge-Based Engineering: Key Product Development Technology to Enhance Competitiveness.