From Know How to Know Why! - Digital Twin Design Process opening new horizons for Investment Casting
Development based on experience often means that you know what happens, but you don‘t know why! The use of Digital Twins in development helps convert empirical knowledge into physical. This creates a valid basis for optimization and caters the need for rising performance, lightweight or cost requirements.
Watch the webinar recording "From Know How to Know Why!" - Digital Twin Design Process opening new horizons for Investment Casting presented jointly with Feinguss Blank, one of the leading investment casting foundries in Europe and the EICF.
In this webinar recording you will learn how Feinguss Blank applies smart cast processes to address development challenges. The presentation will:
demonstrate the application of simulation-driven design and additive manufacturing to drive next generation lightweight designs through an investment casting process.
show an integrated workflow on simulation-driven-design and manufacturability, to obtain lightweight parts in a single environment.
feature how to apply this digital twin platform for investment casting, sand-casting and within additive manufacturing or hybrid manufacturing processes.
Compute Beam Properties and 3D Stresses of Advanced Composite Structures
VABS offers an unprecedented combination of efficiency and accuracy for composite beam modeling. Saving orders of magnitude in computing time without a loss of accuracy, engineers can consider more design options and arrive at the best solution more quickly in order to accelerate time to market while reducing costs.
VABS is a powerful tool for modeling composite helicopter and wind turbine rotor blades, as well as other slender composite structures, like propellers, landing gear, high-aspect ratio wings, composite tubes, and more. The tool is capable of rigorously reducing an original 3D slender solid with complex cross-sections into simple engineering beam models.
How To Achieve Optimized Trading Analytics
In this webinar, we discuss the benefits of analyzing intraday trading risk and performance, the downsides of waiting for end-of-day reports, and the challenges associated with building and using risk compliance dashboards that traders and compliance managers can use effectively to inform trading decisions. We will also demonstrate methods for code-free development of sophisticated Real-Time analytics systems that can be customized to fit the unique requirements of a firm, desk, or trader.
Simulation-Driven Design for Additive Manufacturing
This webinar will take you through the concept and roadmap phase, all the way to the manufacturing process - all within Altair Inspire and Inspire Print 3D, a revolutionary generative design and 3D printing simulation environment that solves real world production challenges. Learn how to rapidly visualize production defects, rectify problems to avoid downstream production issues, save product weight, reduce material consumption and cost all through the use of intelligent complementary design technologies.
Accelerate Decision Making with GPUs
Harnessing the computational capabilities of the graphics processing unit (GPU) is one of the cornerstones of Altair's mission to empower its customers. First and foremost, utilizing GPUs to accelerate numerical simulation delivers significant increases in speed and therefore, throughput. That means more opportunities to explore and fine-tune designs, faster decision-making based on more accurate results, and consequently the prospect of considerable reductions in time to market. In addition, creativity is enhanced, with more vivid, realistic and accurate rendering and visualization put within easier reach.
Product Overview Videos
Inspire Studio: Designing a Measuring Cup, Part 2
In this episode of the Inspire Studio How-to Series, we keep designing a measuring cup, making a few quick edits and learning how to use tools like sweep, patch, trim, and more. Learn more and get a free trial license at altair.com/inspire-studio.
Training Materials, Use Cases
Inspire Studio: Designing a Measuring Cup, Part 3
In this third episode of designing a measuring cup, we focus on shelling the main body, use lattice to quickly morph the entire shape, and create a handle in very few clicks. Learn more and get a free trial license at altair.com/inspire-studio.
Training Materials, Use Cases
Inspire Studio: Designing a Measuring Cup, Part 4
In the fourth episode of designing a measuring cup, we complete the shape adding rounds, seam lines, and getting ready to render the final product. Learn more and get a free trial license at altair.com/inspire-studio.
Training Materials, Use Cases
Inspire Studio: Designing a Measuring Cup, Part 5
In the fifth and last episode of designing a measuring cup series, we finalize the design and create some photorealist renderings of the product, selecting and customizing materials from the library and editing the environment. Learn more and get a free trial license at altair.com/inspire-studio.
Training Materials, Use Cases
Altair Model-Based Development Customer Stories from 2019 Global ATC
These success stories illustrate how customers are leveraging Altair's Math & Systems technology for Model-Based Development to develop better products, faster. Simulations involve 3D, 1D, and/or 0D modeling approaches based on the integrated use of Altair MotionSolve™, Altair Activate™, and/or Altair Compose™.
Transformative Flight Transportation: Challenges Become Opportunities
Advances in energy storage, motor efficiency, and flight control systems have us on the potential cusp of a revolution in air mobility. This comes at a time when many traditional transportation infrastructures are saturated and new modes of mobility are desperately needed. The presentation will provide an overview of recent developments in urban- and extended-air-mobility and discuss the hurdles that must be overcome, not only technical obstacles but also challenges in regulations, societal acceptance, and business. It will provide context with an overview of our own technical challenges and successes, from the imminent Transition® to the aspirational TF-X.
Multi-Disciplinary Evaluation Of Vehicle Platooning Scenarios
Presenter: Christian Kehrer, Business Development Manager, Altair
This presentation discusses the multi-disciplinary evaluation of truck platooning, with the lead truck sending out acceleration, braking and steering signals for the following trucks to react accordingly. The benefits address safety requirements, fuel savings, traffic capacity and convenience.
The presentation demonstrates why platooning requires a holistic approach in the sense of connecting different modeling and simulation methods for a virtual evaluation of this system of systems.
Altair MBD: Celebrating Accomplishments, What's Next
Presenter: Michael Hoffmann, Sr Vice President of Math & Systems, Altair
In this presentation, Michael Hoffmann, Sr Vice President, shares the company’s vision & strategy for Altair’s Math & Systems tools for Model-Based Development – based on providing an open platform tightly connecting 0D to 1D to 3D modeling & simulation. At different stages of their product development cycles, engineers can model and simulate their increasingly complex products as multi-disciplinary systems by using equations, block diagrams, and/or 3D CAD geometry.
His scope includes Altair Compose™, Altair Activate™, Altair Embed™, and Altair MotionSolve™ as well as the multi-body motion capabilities in Altair Inspire™. He also spotlights several recent success stories about customers who have used these technologies to drive innovation through simulation.
Internal Noise Simulation/Emulation
Presenters: Rafael Morais Cunha, CAE Engineer in NVH, FCA Group & Frederico Luiz de Carvalho Moura, NVH CAE Leader, FCA Group
To make the driving experience more comfortable for passengers inside a vehicle compartment, in an increasingly shorter development cycle, predictive methods for the acoustic response characterization are used by vehicle engineering teams. The main purpose is to estimate the sound field in the car cabin.
The FCA NVH team identified in Altair tools an excellent opportunity to develop a complete solution for acoustics simulation. Supported by the Altair technical team, new methodology was created to convert frequency domain analysis into actual sound waves. This method was used to study the NVH steady-state acoustic performances. And development is in progress to simulate an acoustic environment to reproduce all vehicle noises in operational condition.
Using this methodology, it’s possible to virtually understand the acoustic behavior of vehicles, helping to make decisions in early design stages which could save design cost, time and also improve the driving experience for passengers.
Multi-Fidelity E-Motor Drive Solution
Presenters: Ulrich Marl, Key Account Manager for Electric Vehicle Motor-Feedback Systems, Lenord+Bauer & Andy Dyer, MBD Sr Technical Specialist, Altair
This presentation shows a modeling process to quantify the position/speed sensor (e.g, encoder) effects on an e-motor, and corresponding control system for a concept traction motor similar to the Nissan Leaf. The integrated solution of the e-drive is carried in Altair Activate as a system builder, using other Altair solutions e-motor solutions in FluxMotor and Flux to generate data for the e-motor itself, as well as the optimal current values for the Field-Oriented Contoller. The inverter is driven with efficient space vector pulse width modulation. The integrated solution also supports different levels of modeling fidelity for the system components, for example for the e-motor where either direct co-simulation with Flux for detailed finite element analysis or a reduced order model (ROM) using look-up tables. In this way, sensor design parameters can be evaluated within an accurate system of the e-drive to improve performance and efficiency.
Solving Challenges in Electric Motor Design
Presenter: Berker Bilgin, Assistant Professor of Engineering (ECE) at McMaster University and co-founder of Enedym Inc.
Electric motors in general, are made of certain parts, such as the stator, rotor, coils and magnets, and mechanical parts. These parts might look simple and bulky from the outside, however, the highly interrelated relationship between the geometry of these parts, characteristics of materials, and the way the current is controlled, defines the cost, size, efficiency, performance, and lifetime of the motor. In electric motor design, multidisciplinary aspects are highly interrelated. The effect of various parameters on the electromagnetic, thermal, and structural performance should be investigated together to come up with an optimized design. This is possible by developing the platforms where the multidisciplinary aspects are modeled in a software environment, as we are doing with Altair software.
Heavy Equipment Simulations: Multi-body, Hydraulics & DEM
Presenter: Ronald Kett, Technical Specialist, Altair
For a Stewart-Gough-Platform (Hexapod), various software tools were used to study and design highly dynamic hydraulic drives together with an overall system control. Calculation of Eigenfrequencies, control design and comparison, hydraulic system design, and overall simulation control were done in Altair Activate, the mechanics of the Stewart-Gough-Platform was taken from a CAD model into Altair Inspire Motion. The co-simulation between control + hydraulics and mechanics was performed using Activate and Altair MotionSolve. Altair HyperView and HyperGraph were used to analyze and visualize the results.
With the highly integrated solutions, the results could be achieved within a very short time. The different types of models (linear/simplified/full mechanics/hydraulics) made it possible to start with fast development cycles and finally achieve reliable results.
Real-Time Simulator of a Mobile Crane
Presenter: Arnold Free, Chief Innovation Officer and Co-Founder, CM Labs
Mechatronic systems and off-highway equipment design is rapidly evolving. With advanced control features, operator-assistance systems, and even full autonomy on the horizon, engineers are building complex systems simulation models to better understand their smart machines. Through the use of interactive and immersive VR software, systems models can be derived from high-fidelity engineering simulations and used for operator-in-the-loop, HIL, and SIL testing. Interactive virtual prototypes allow for human-factors test and measuring system performance in hyper-realistic virtual worksites. Simulation is also being used for AI based perception and motion planning in autonomous systems. Sales and marketing departments are now using interactive simulations and visualization to demonstrate products. The value of simulation is expanding rapidly in OEMs.
CM Labs Simulations has recently partnered with Altair to bring together engineering simulation and interactive real-time systems models to perform all of the above. Validated multibody systems dynamics models from Altair MotionSolve can be used to build interactive models in Vortex Studio and combined with advanced real-time 3d graphics to create immersive live simulations with human interaction. With real-time simulation, it is also possible to connect to interactive control models and system level multidisciplinary simulations with Altair Activate.
The presentation uses a mobile crane model as an example. It will demonstrate the process of translating the engineering models to real-time, creating realistic working scenarios and deploying in immersive simulators for operator in-the-loop testing and system demonstration.
Quadcopters: From System Modeling to Real-Time Simulator
Presenter: John Straetmans, Computer Engineering Student, University of Michigan
This project attempts to build an accurate real-time (RT) drone simulator through the full integration of a 1D functional model of a drone created in Altair Activate®, along with its corresponding geometry, into Unreal Engine via the Functional Mock-up Interface (FMI) standard. Then, VR, peripheral controllers, and other functionalities were added to the representation. This task was accomplished by modifying the Altair RT Vehicle Package, making it able to handle not just vehicles, but any system model located in an FMU for co-simulation, in this case a quadcopter model.
Once the FMU containing the Altair Activate® drone model was successfully loaded into Unreal Engine, the tools provided by the application allow additional features to be added, such as VR support. By implementing an FMU, together with its geometry, into Unreal Engine, we can visually analyze the dynamics of the system to further verify the drone model and its performance. In the future, this integration process should be facilitated to automatically load any FMU following just a few steps.
Modelica Library for Real-Time Car Simulator
Presenter: Dario Mangoni, Engineering Professor, University of Parma
In the modern car industry, the advent of hybrid and electric vehicle systems is driving radical changes in the car electronics and software, demanding more and more advanced controlling techniques. Self-stopping, self-starting, ultimately self-driving cars are nowadays possible, because of the multitude of sensors, controller units and actuators making the vehicles “smart”. To simplify and make the interaction between the user and the machine more and more intuitive and user-friendly, a much broader and deeper investigation of different use scenario combined with the human interaction and intervention is critical. In this context, higher-detailed vehicle models are required to provide a valid prototyping tool which can be reliably used to test innovative controlling strategies, such as testing with the Man-In-the-Loop.
The Car Real-Time Modelica library proposed here aims at providing a highly valuable tool for the vehicle control system design and test. The key competitive advantages in this approach are in the Maple model-based compiler for supporting high-level of details modeling; the adoption of the Modelica language which allows a transparent and physical approach to the modeling activities and finally the Activate platform which offers real-time capabilities within an environment meant for the signal-based control design. To graphically validate the library results, a visualization framework for realistic real-time simulations that assures high-fidelity scenario in which to test user experience was also realized.
Multi-body Enhancements & Customer Successes
Presenter: Rajiv Rampalli, Sr VP in HyperWorks Core Development team, Altair
Altair’s products for multi-body system simulation (MBS) – MotionView, MotionSolve, and Inspire Motion – form a key component of multi-disciplinary system simulations. In this presentation, we will look back on several achievements this year, in the form of customer successes as well as recent enhancements to these products which significantly extend the depth and breadth of capabilities.
Some of these application examples also involve connections from MBS to other Altair technology or to 3rd-party technology such as to Altair OptiStruct (for flexible bodies and light-weighting) and Altair Activate (for hydraulics) and EDEM (for discrete element modeling of bulk materials).
System Simulation for HVAC
Presenter: Christian Kehrer, Altair [on behalf of Oliver Höfert, Simulation Engineer at Kampmann]
The increasing virtualization of engineering methods is inevitable. This also holds true for the design of systems that take care for the thermal well-being of humans, e.g. in buildings. If it comes to simulation of so-called HVAC (heating, ventilation, air conditioning) systems, very often high fidelity approaches like CFD are connected to it. In contrary, this contribution illustrates a 1D modeling approach of a heat exchanger in use of Altair Activate.
The presentation explains the implementation of the NTU (Number of Transfer Units) method in a system simulation environment. This includes a short description of the approach itself as well as its current limits. Based on the implementation of a single cell, differing network configurations for the evaluation of use cases of varying complexity will be shown.
ROMs For Battery Cooling Systems
Presenter: Stefano Benanti, R&D materials engineer, Hutchinson
Battery cooling (BC) systems are frequently composed of several parallel branches, each leading to and away from a series of cooling plates. As a correct flow distribution in each branch and overall pressure drop are a key requirement from every customer, numerical computation is extremely important from the first stages of each project: the number of components and their dimensions have a relevant impact on the total cost and it is thus necessary to quickly provide results already in the Request for Quotation (RFQ) phase.The 3D computation of such cases, albeit feasible, takes a relevant amount of time and makes it more costly (both in terms of computational power and of necessary software licenses) to quickly provide results. The goal is then to develop a quicker method to provide results and allow for the necessary optimization cycles.
Altair Activate® was chosen by Hutchinson to develop a library of ROMs representing different circuit components through which is possible to create 1D models able to respond quickly and precisely to such demands.
Integrated Systems Simulation from Requirements
Ed Wettlaufer, Technical Manager Mechatronics Group, Altair [on behalf of NAVAIR]
Government solicitations for proposals, or RFPs, for aircraft and airborne systems require preliminary designs with enough fidelity to accurately predict performance, in order to prove the design's ability to meet the Governments performance requirements. Modern high-performance computing provides the leverage to execute previously expensive analyses in areas such as computational fluid dynamics. The results of these high order analyses can be used to populate parameters in 1D systems models which can be easily coupled to medium order models from other disciplines. These capabilities allow the design engineer to rapidly iterate to levels of model maturity and accuracy not achievable years ago, resulting in high levels of confidence in the designs performance predictions in unprecedented time.
Moving forward, Altair engineers will employ Multiphysics and co-simulation to execute the Engineering and Manufacturing Development phase (EMD) for one subsystem of the preliminary design developed in the afore mentioned pre-acquisition phase.
Inspire Studio v2019 - Getting Started
Overview of Tool Ribbon, Tool-belt, World Browser, Preferences, and Help.
Getting Started, Training Materials, Videos
Altair Inspire Studio Datasheet
Altair Inspire Studio is a new software solution that enables designers, architects, and digital artists to create, evaluate and visualize design ideas faster than ever before.
Features Lists, Technical Papers
Inspire Studio 2019 - Modeling
Overview of Creation Mode, Edit Mode, Guide Bar, and Exit tool.
Getting Started, Training Materials, Videos
Simulation-Driven Design of Sheet-Metal Components
A good Design is not complete unless it meets desired performance and qualifies for efficient manufacturing. Design of sheet-metal components demand the following, From a Design perspective - if sheet-metal can be used for intended design, their sizing & shape, choice of material, weight and cost.
From Manufacturability perspective - manufacturing feasibility of the designed shape, allowable thinning and wrinkling limits, addressing process constrains and importantly forming feasibility.
Leveraging Simulation to drive the design as it unfolds at the concept generation stage, helps design engineers to accrue downstream benefits upfront.
Altair Compose Interface Tour
Introduction to File Menu, Evaluate Toolbar, Command Window, File/Variable/Project Browser, Property Editor, Help and Tutorials.
Training Materials, Videos
To build a very simple, robust, sustainable roof structure for a prosthesis lab associated with the Centre medico-chirurgical de l'Ulcère de Buruli, which is a hospital in Bouaké, on the Ivory Coast of Africa, the project team used Altair SimSolid, to conduct very fast, full assembly tests, saving time and money, while providing increased flexibility, without compromising accuracy.
1D System Simulation Overview
Learn how Activate serves as Altair’s open integration platform for multi-disciplinary system simulation involving mechanical dynamics, controls, hydraulics, thermal effects, electronics, electromagnetics, and more. 1D diagrams can be built using either a signal-based approach or a physical modeling approach based on the Modelica and SPICE standards or both. Hybrid simulations can involve continuous time and discrete events. Models can be linearized for analysis in the frequency domain. Mixed models combining 1D+3D can be constructed and simulated by using the Functional Mockup Interface (FMI) standard. All tools are built-in; no extra-cost add-ons are required.
Transforming Design & Decision Making by Applying Simulation Throughout Product Lifecycles
Seen here presenting at the UK Altair Technology Conference 2019, James R. Scapa brings more than 35 years of engineering experience to his dual role of Chairman and CEO of Altair Engineering, Inc., a title he has held since the company’s inception. In 1985, Mr. Scapa and two partners founded a small consulting activity in the new field of computer-aided-engineering. Today, the company employs over 2,000 employees with more than 82 offices throughout 25 countries.
Through Mr. Scapa’s leadership, the company is now a leading global provider of simulation technology and engineering services that empower client innovation and decision-making. With over 5,000 clients, Altair serves the automotive, aerospace, government and defense, heavy equipment industry sectors as well as the consumer products, shipbuilding, energy, electronics, life sciences, and architecture engineering and construction markets. Prior to establishing Altair, Scapa served as an engineering consultant to the automotive industry, beginning his career with Ford Motor Company in 1978. Scapa holds a Bachelor’s degree in Mechanical Engineering from Columbia University and a Master of Business Administration from the University of Michigan.
By automating the crankshaft modeling process using Altair SimLab, BMW Motorrad, the motorcycle division of BMW was able to significantly reduce their model creation time, and enable accuracy in budgetary forecasting and planning. As a result of making it an inhouse resource, they were able to gain flexibility and consistency in model quality, with a high-degree of efficiency with iterations.
E-motor Design using Multiphysics Optimization
Today, an e-motor cannot be developed just by looking at the motor as an isolated unit; tight requirements concerning the integration into both the complete electric or hybrid drivetrain system and perceived quality must be met. Multi-disciplinary and multiphysics optimization methodologies make it possible to design an e-motor for multiple, completely different design requirements simultaneously, thus avoiding a serial development strategy, where a larger number of design iterations are necessary to fulfill all requirements and unfavorable design compromises need to be accepted.
The project described in this paper is focused on multiphysics design of an e-motor for Porsche AG. Altair’s simulation-driven approach supports the development of e-motors using a series of optimization intensive phases building on each other. This technical paper offers insights on how the advanced drivetrain development team at Porsche AG, together with Altair, has approached the challenge of improving the total design balance in e-motor development.
Customer Stories, Technical Papers
SimLab Tutorials - Setting-up a Model for Molding Process
Import, position and inspect a CAD model; create mesh controls, surface mesh and organize the parts; create solution and define polymer properties to the bodies; define initial and boundary conditions; apply solver settings, export the deck and solve
Analysis, Training Materials
SimLab Tutorials - Topology Optimization with Solutions - Bracket
Create a linear static solution, define loads and boundary conditions then compute; define a topology optimization, design space, constraints, response and objective; export the optimized shape as .stl; import the .stl file and perform a mesh cleanup; transfer properties and LBCs to the optimized geometry and apply TIE contact; re-analyze the model then review the results
Optimization, Training Materials
SimLab Tutorials - Advanced Grid Meshing
Use different methods to create grid meshing; Interactive meshing, Mesh transition, Project to CAD, Three sided faces, Intersection picking
Editing, Meshing, Training Materials
An Altair customer for many years, Schneider Electric at first used only Altair Flux; now the company has extended their usage to several more software products in the Altair HyperWorks suite, including solutions such as Activate, MotionSolve, OptiStruct, and others to apply co-simulation in their development processes. Schneider feels their collaboration with Altair is more like a partnership than the standard supplier-OEM relationship.
Multi-Physics Design and Optimization of a Complex Radar System
Today, most products are complex mechatronic combinations of advanced technologies, mixing electrical parts with controllers and embedded software. To efficiently manage innovative products, organizations are turning to a Model-Based Development approach for concept studies, control design, multi-domain system simulation and optimization. To meet this demand, Altair’s simulation and optimization suite aims to transform design and decision-making throughout product lifecycles with their multi-disciplinary software tools and consultancy services.
Evolve 2016 Introduction
This course contains a set of modules to help familiarize you with basics of using Evolve. We will cover an overview of the Evolve interface and working environment, creation of curves, creation of surfaces, transforming and editing surfaces, creating and editing PolyNURBS, and an overview of rendering models.
Traction-based, patented NuVinci® transmission is a continuously variable planetary (CVP) technology enabling performance and efficiency improvements for machines that use an engine, pump, motor, or geared transmission systems. Fallbrook Technologies has been working on improving oil flow inside the NuVinci products as it affects the transmission’s efficiency, durability, power, capacity, and cost. Altair worked with Amazon Web Services (AWS), a secure cloud services platform, to provide an integrated solution to Fallbrook including advanced GPU hardware, high-performance computing (HPC) and the nanoFluidX software through industry-leading workload management and job scheduler Altair PBS Professional™.
Form Follows Function - thyssenkrupp AG - Reinventing the Elevator Concept
Christian Kehrer presents on behalf of thyssenkrupp Elevator AG.
2017, thyssenkrupp Elevator AG has presented the MULTI concept, the world’s first rope-free elevator. The drive is ensured by a linear electromagnetic motor. To enable an economically feasible operation, it is necessary that the total weight of the lift does not exceed a certain limit. Designing the overall system of the MULTI lift according to this weight specification is one of the major challenge for thyssenkrupp Elevator.
In this presentation, an overview of the partnership between thyssenkrupp Elevator and Altair, the chosen design partner since the early phase of development, will be introduced. Thereby, different aspects of the simulation driven design process will be highlighted, taking into account several tools throughout diverse stages of the development cycle.
Aspects of Heterogeneous System Models in Industrial Applications
Presentation by Robert Höpler, Founder of SysOpt GmbH.
Heterogeneity can be present on various stages in system modelling and simulation. A system model is often called ‘multi-domain’, when different technical domains are present, such as hydraulics, mechanics, and control. When it comes to simulation this is just the surface of this domain level. Various mathematical and modelling formalisms can lie underneath which lead to different mathematical equations of motion, numerical properties, and computational complexity. On a specification level we see the choice between different modelling formalisms and modelling languages, libraries, coding styles, and authoring tools. Often there is a need to mix these. Decisions taken here strongly influence expressiveness of the models and ability for code generation and deeply impact software engineering topics such as development processes and exchange of models. Multi-domain approaches such as Modelica try to reconcile some these sources of heterogeneity. On an executional level we find classical desktop system simulation but more complex settings such as co-simulation, parallelization, real-time systems, and optimization which constrain numerical stability and precision and simulation speed. There might be an intricate feedback to the specification level, e.g., when modelling for specific solvers. Efforts like the Functional Mockup Interface (FMI) address some of these aspects and focus on interfacing and exchange of executional models. Prevalent system simulation tools are usually mature and controllable – as long as one stays within the desired scope of the tool. Following some examples we show how practical considerations influence design decisions and the choice of tooling.
Simulation of a Gas Turbine and Generator System Under Steady State and Transient Conditions using Altair Activate
Presentation by Tomas Suguinoshita Quirino, GT2 Tecnologia.
This work presents the strategy created by GT2 Tecnologia to simulate the dynamics of a system comprised by a gas turbine coupled with an electrical generator, which is a typical schema for thermoelectrical powerplants. The mathematical models of the gas turbine and the generator are based on physical principles, such as mass and energy conservation, as well as on correlations from the literature, including heat transfer coefficients and tables of thermodynamic properties. The models have been developed and tested in native languages (Fortran 90 and C++) and their integration with Altair Activate is achieved through the Custom C Block functionality. The system is first tested in Activate in a base load scenario, being then subjected to load changes. This work discusses the test results and shows the advantages of using sT Activate in the simulation of thermal and electrical phenomena.
Fast and Reliable Software Interfaces to Speed up the Design of Electric Motors
Presentation by Luigi Rizzi, Technical Director at SPIN Applicazioni Magnetiche.
The car industry is undergoing an unprecedented shift, between electrification, car sharing and autonomous drive. Car makers are going to roll out several zero-emission models in the next few years and their engineering departments are going to face new challenges. Engineering methodologies and good-design practices related to the well-known internal combustion engine must be reviewed and adapted to the electric propulsion system, considering multi-physic analyses in order to cover the various aspects of the vehicle performance. In this presentation a fast and reliable solution for the design of electric motors is shown.
A powerful software interface has been prepared in order to help the engineers to setup the model, define targets and boundary conditions, include multi-disciplinary verifications and collect analyses results. Using this tool, designers can easily and quickly perform electromagnetic analysis with the Altair software for electromagnetics, Flux, verify the performance in terms of delivered power, torque, losses and efficiency, check the thermal behaviour by means of equivalent thermal networks built in Activate and at the same time verify the stress levels and the NVH performance with OptiStruct, in order to define the early stage details of the product development. Activate plays a key role to speed-up the analysis because allows to obtain fast and accurate thermal information reducing the time usually required to simulate this domain.
Virtual Tryout - Digitalization for an Efficient Commissioning of Forming Tools
Presentation by Dr. Lars Penter, Head of Machine Technology at University of Dresden.
The life cycle of a forming tool consists of five major phases. It starts with the process and tool design followed by its assembly, the ramp-up and serial as well as spare part production. Due to every increasing system complexities, various simulation tools accompany today’s tool life cycle. A popular term in the current world of production is the “Digital twin”. It is a simulation model, which contains at least two sub-models of different physical disciplines, connects different time scales and regularly synchronizes data with the real system. Such a model must be a highly accurate white box model.The presentation will address the generation of a virtual twin on the example of the virtual try-out of forming tools. The simulation model employs RADIOSS (for forming process simulation), MotionSolve (for multi-body simulation of machine mechanics) or Activate (for more complex multi-domain modelling of mechanics, hydraulics and electrical components). Currently, the digital twin allows for computing the interactions between forming process and die cushion. This enables the calculation of correlations between die-cushion cylinder forces and flange draw-in. The presentation shows how optimizing these cylinder forces in HyperStudy benefits the final part quality and shortens real tool try-out time.
Multi-disciplinary System Simulation for Model-Based Development
Customers share their success stories illustrating how Altair Model-Based Development technology, and especially Altair Activate™, help them design better products faster. These customers give special attention to simulating multi-disciplinary performance aspects of their products as a system-of-systems. Given the complexity of today’s smart products, this often involves a combination of mechanical, electrical & electronic, and/or software aspects – and thus leverages both 1D and 3D models simulated together.
Presentations recorded at the 2018 Global ATC in Paris, France on October 18, 2018.
Redesign and Topological Optimization of Transtibial Prosthesis by Reverse Engineering
Presentation by Eduardo Bajo, FEA Engineer at IDAERO. Presentation of a project consisting of redesign with topology optimization of a transtibial leg prosthesis. It is a project in which the reverse engineering workflow has been followed, starting with 3D digitization of an amputated limb and real old prosthesis. Subsequently, they have been reconstructed in 3D to simplify and applied topology optimization, taking into account the biomechanics of human gait, using Altair Inspire software. Finally, the reconstruction of the optimization through organic design has been carried out with the software Evolve. This project won the 1st prize in the II International Industrial Design Contest UPM-Technical University of Madrid. During the presentation it will be presented the new 2019 Edition of the Industrial Design Contest UPM, open to students and professionals, sponsored by Altair.
Transient Analysis of Switched-Reluctance Motor Drive by FE Model Co-Simulation
Presentation by Lino Di Leonardo, University of L'Aquila.
This presentation showcases an analysis technique of electric motor drive based on transient simulation tools and embedded finite element motor modeling (co-simulation). A couple of software tools, Altair Flux and Activate, are employed suitably interfaced each other. The first one allows the computation of the motor electromagnetic behavior using a finite element model, while the second one allows the dynamic simulation of the control and feeding converter. The interacting use of these tools allows a detailed prediction of the motor transient behavior under a given control strategy and drive scheme. As test case a multi-phase Switched Reluctance motor for aerospace application is considered.
The results demonstrate that the co-simulation procedure allows taking into account not negligible phenomena, such as dynamic torque ripple, usually not considered in similar studies. Hence, co-simulation analysis represents a significant step for the integrate design of the motor and control, as well as a meaningful tool for electrical drives education.
EV Thermal Analysis: 1D and 3D Model Integration for Cockpit and Batteries
Presentation by Massimiliana Carello, from Beond & Politecnico di Torino.
Nowadays automotive climate control systems are evolving at a rapid pace to meet the overall vehicle requirements. System evaluation is one of the major requests currently faced by the automotive manufacturers and their suppliers. Thermal comfort, convenience and range are equally important user expectations, even if they may represent “opposed” performance for a modern EV, especially in an urban driving cycle.
In this framework, to achieve the expected targets and limiting the time-to-market and costs, a complete vehicle thermal model is to be developed to evaluate the cockpit thermal request for occupants' comfort at different ambient temperatures as well as solar radiation. Furthermore, the battery thermal management is to be investigated, to avoid cells damages and deterioration. The aim of this technical presentation is to highlight the integration capabilities of a lumped parameters model (1D) developed with Altair Activate for fast simulations and a CFD model (3D) of the battery liquid cooling system developed in AcuSolve. The Models realized are validated using experimental data.
Altair Inspire Datasheet
Altair Inspire enables design engineers, product designers, and architects to create and investigate structurally efficient concepts quickly and easily. Inspire uses the industry leading Altair OptiStruct™ technology to generate and analyze design concepts. The software is easy to learn and works with existing CAD tools to help design
structural parts right the first time, reducing costs, development time, material consumption, and product weight.
Brochures & Datasheets
Mabe is a Mexico-based international appliance company designing, producing and distributing a wide spectrum of home appliances such as washing machines, dryers, cooking ranges, refrigerators, air-conditioners, microwaves, etc. Altair technology has enabled Mabe to increase the capacity of their washing machines by 35%, and the spin speed by 24% while reducing the cost per cubic foot by 10%.
Leverage the Power of Simulation-Driven Design
In order to stay competitive while pushing the envelope on innovation, simulation must drive the entire design process from the early concept design phase all the way to production. Leveraging robust simulation—including motion analysis, finite element analysis, and manufacturing feasibility analysis—early and often has become a necessary driver to innovation and is helping numerous industry-leading companies to meet quality, cost, and time-to-market targets.
Development of a New Lightweight Aluminum Profile for a Glass Balustrade
The design of architectural components such as a balustrade can be challenging, since the design does not only have to look good, it also has to meet several safety requirements and standards. In addition, all designs have to be developed within the shortest time possible. To meet these challenges the engineers, architects and designers at Faraone are always looking for solutions that can reduce their design and testing cycles.
Customer Stories, Presentations
Thermal Analysis of Electrical Equipment A review and comparison of different methods
Nowadays, it is more and more difficult to design electro-technique devices without having a look at thermal stress. In more and more applications (more electric vehicles, more electric aircrafts, …) designers need to reduce weight, cost, increase efficiency, and keep the same security factor. One possibility is to increase current for the same device, needing to check how to draw away the heat. This is why the classical approximations need to be cross checked with complementary analysis. These new tools have to be rapid and accurate in order to run parametric and even optimization analysis. There is also a need for fast model in order to check robustness versus driving cycles. The goal in this article is to review rapidly the different methods available, depending on the accuracy required and the solving speed.
The method includes equivalent thermal circuits, Finite elements methods and CFD analysis.
Sensorless Field Oriented Control Hardware in the Loop
Employing TI's FAST (Flux, Angle, Speed, and Torque) observer
Getting Started, Training Materials, Videos
Altair Compose Datasheet
Altair Compose enables engineers, scientists & product creators to efficiently perform numerical computations, develop algorithms, analyze & visualize various types of data. Compose is a high level, matrix-based numerical computing language as well as an interactive & unified programming environment for all types of math from solving matrix analysis, differential equations to performing signal analysis and control design.
Brochures & Datasheets
An Interview with Ben Farmer of Robot Bike Co. Discussing the Development of their R160 Bike with Altair
Robot Bike Company (RBC) is a new startup established in the UK by aerospace engineers and mountain biking enthusiasts who identified the potential of combining additive manufacturing technologies with carbon fiber to, in their own words, “create the best bike frames possible”. To deliver a customizable, lightweight, high strength bike, RBC’s frame was intended to be created from carbon fiber, a material very common in the industry. The carbon fiber tubes, as well as the bike’s other components and systems were to be joined by additively manufactured titanium ‘nodes’, manufactured based on the specification of individual riders. Altair ProductDesign’s engineering team was tasked with optimizing these joints, which included the head tube, seat post and chain stay lugs, to ensure they were as lightweight as possible and still able to withstand the forces of downhill mountain bike riding, all while being fit for the AM process.
Forming Simulation of Woven Composite Fibers and Its Influence on Crash Performance
The automotive industry, in its constant quest for weight reduction, is increasingly considering composite materials as a substitute for sheet metal components to meet future fuel consumption standards. However, composite forming processes are expensive and difficult to control because of the complexity of the material behavior with fiber and matrix layers or plies and its dependency on many parameters, such as non-linearity of tensile stiffness, effect of shear rate, temperature and friction. Hence, numerical simulation could be a viable approach to predict material behavior during composite forming. The objective of this study is to highlight capabilities of RADIOSS™ to simulate forming simulation of composite plies made from woven fibers, each ply modeled as a layer of woven fibers along two directions of anisotropy, warp and weft. For validation the well-known double dome model published in NUMISHEET’05 proceedings is used. The compared result is the shear angle after stamping that is, the final angle between warp and weft fibers, at several prescribed points on the ply. The variation of this angle has a strong impact on material characteristics which severely deteriorates when a critical value is reached. Hence, a study on crash simulations is performed, after mapping fibers angles from stamping simulation.
HyperWorks’ Simulation Technology Enables Godrej to Streamline Sheet Metal Tooling Processes
Using Altair HyperForm, HyperWorks’ stamping simulation technology, Godrej was able to design and
fine-tune a successful tool for a rear fender, while minimizing die testing time by reducing physical
trials. Leveraging numerical analysis, Godrej was also able to predict the size, shape and location of
the blank accurately. HyperForm’s ability to visualize failure in incremental simulation enabled them to
finalize the draw bead location and characteristics.