Navigating Digital Transformation

Features - Design & Automation

ANSYS software allows companies to digitally thread simulation across product lifecycle processes for improved workflow, optimized data.

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A user testing ANSYS VRXperience.
Photos courtesy of ANSYS

As simulation impacts product development, users must address interoperability, data and process management, high-performance computing (HPC) integration, and traceability. Sophisticated multiphysics simulation and optimization assets must be widely available throughout engineering teams and across product life cycles. ANSYS 2020 R1 upgrades and improvements to ANSYS Minerva enable users to connect simulation and optimization to larger product lifecycle processes.

ANSYS Minerva transforms simulation intellectual property into a controlled corporate asset, captures best practices, and digitally threads simulation and optimization across the enterprise. Advanced technologies significantly improve workflows and enhance simulation process and data management (SPDM). Dashboards drive improved decision support, dynamic 3D visualization tools explore model data, and a change management system ensures reliable information.

“Navigating digital transformation is about adapting to a constantly evolving environment and using existing tools and data in new ways. With use of simulation expected to expand in the coming years, Minerva is important to Eaton and plays a key part in our larger, enterprise-wide digital prototyping and additive manufacturing (AM) initiatives,” says Todd Earls, Eaton’s vice president of information technology. “Traceability and management are essential for efficiency, and there are many steps necessary to design and manufacture parts using AM or other processes.”

An interoperable knowledge management application with an open, vendor- neutral architecture, Minerva integrates with ecosystems of simulation tools and enterprise systems, streamlining collaboration and traceability across global teams.

Eric Bantegnie, vice president and general manager at ANSYS says, “Customers across virtually every industry seek to radically improve how they leverage simulation, optimize designs, and share data to spur innovation and create products more efficiently. Minerva’s improvements help fuse simulation and optimization processes across the enterprise, establishing simulation-based design optimization workflows as a dynamic standardized process.”

VRXPERIENCE provides cutting-edge innovations for sensor, human-machine interface (HMI) and sound simulations.

Cloud platform

In ANSYS 2020 R1, ANSYS Cloud licensing options enable greater business flexibility. Companies can cost-optimize cloud software use by mixing elastic (usage-based) and traditional (leased or paid-up) licensing while accessing on-demand computer resources.

“We can simultaneously submit multiple ANSYS Mechanical jobs covering different load cases without encountering scheduling or memory capacity concerns,” says Tim Marvel, P.E., vice president, Business Development & Technology at Downing Wellhead Equipment. “For each design, we evaluate 5-to-10 options with multiple load cases. ANSYS Cloud has reduced the time of each job from 20- to-25 hours to only 2-to-4 hours.”

Automotive safety, design, acoustics

Optical simulations and new applications for embedded design deliver digital thread enhancements to boost the safety, reliability, and aesthetics of next-generation autonomous vehicles (AVs).

  • VRXperience – Sensor, human- machine interface (HMI), sound simulations
  • VRXperience Sensor – Reduced order model (ROM) radar simulation for industrial automation applications; enables testing, accuracy improvement of AV radars
  • VRXperience HMI – Streamlined process tests HMI prototypes
  • VRXperience Sound – Improved workflow, user interface; quickly detects and analyzes engine noise
  • VRXperience Light Simulation – (new in 2020 R1) simplifies automotive illumination design; engineering-grade light simulation; combines visual design, advanced engineering review by connecting Autodesk VRED design visualization software, ANSYS’ physics-based lighting simulations; photorealistic visualization of vehicle interior, exterior lighting

Boosting cybersecurity

ANSYS medini analyze addresses increasing market needs for systematic analysis and assessment of security threats to AV cyber-physical systems – beginning early in system design. Automakers can model limitations and weaknesses of AV system components and environmental conditions to provide cybersecurity.

Illuminating simulations

SPEOS incorporates camera simulation to increase accuracy of advanced driver assistance systems (ADAS) and AV simulations. SPEOS lets users model numerous types of lighting variations that AVs will experience and optimize AV lighting performance.

“Mazda is always eager to introduce smarter technology into their vehicles, from ADAS systems to smart headlamps, tackling the challenges to achieve high-quality requirements and scheduled targets,” says Tohru Yoshioka, deputy general manager at Mazda. “Providing physics-based design and testing of optical features, ANSYS SPEOS and VRXperience are extensively used at Mazda to perform early and iterative digital design and optimization of systems, from adaptive driving beams using complex matrices of LED units to camera systems used in AV-ADAS technology. This enables us to significantly reduce the physical prototyping and testing phase of these systems while improving safety and fast-tracking time to market.”

Safety-critical software

SCADE accelerates AV embedded control software design, incorporating capabilities to reduce development time and cost for automatic code generation of safety-critical software by more than 50%.

Extended scalability improves testing and safety of large, artificial intelligence (AI)-based perception software projects by creating direct connections to data lakes on customer cloud clusters.

Slashing development time

Twin Builder now includes Twin Builder Battery Wizard which shortens development time of building, simulating, and testing battery-powered electrical systems.

“A123 uses ANSYS Twin Builder to perform thermal simulation of their 48V battery pack development. With the help of the simulations, A123 can determine thermal dependency on electric performance, design cooling supply, calculate temperature distributions, and predict battery life,” says Shawn Zhang, senior manager, Simulation Engineering at A123 Systems. “A123 also utilizes ANSYS Twin Builder’s read-only memory (ROM) technologies for simplifying complex 3D thermal simulation which significantly reduces the simulation time from days to a few seconds while keeping the required simulation accuracy.”

Twin Builder features improve ROM capabilities, including capturing higher non-linearity components and integrating a tool-agnostic static ROM builder to enable field visualization.

Power, thermal reliability

Redhawk-SC provides insights into complex designs and slashes simulation runtime.

Totem and RedHawk support a comprehensive list of advanced FinFET nodes and 2.5D/3D-IC packaging technologies, allowing users to address multiphysics challenges of power, thermal, and reliability in ultra-large and high-performance systems-on-a chip (SoC) that are at the heart of AI, 5G, and automotive applications.

A123 Systems http://www.a123systems.com

ANSYS Inc. https://www.ansys.com

Eaton Corp. https://www.eaton.com

Downing https://downingusa.com

Mazda https://www.mazda.com

Robot pipe tooling

Single-pipe tooling for robotic applications features quick-release connect/disconnect couplings and bayonets. Suitable for cold and hot stamping, this tooling is easy to configure, has a compact design to minimize collisions, and Industry 4.0 features including electric signals, radio frequency identification (RFID) coding, and sensors for tooling detection and locking control.

Single pipe coupling and bayonet locking mechanisms can be mounted to different beam types, 80mm x 80mm carbon fiber beam, and come in various locking styles including mechanical, air, or electric as well as left or right versions. The tooling features an 8-pin electric plug, up to four air ports, and 10mm diameter air piping.

Combined with a carbon fiber beam, the single-pipe tooling reduces cycle times compared to aluminum and steel systems; weighs less than half of traditional materials; and is stiffer, stronger, and settles more rapidly. This enables quick robot motion paths with less vibration and idle time.

Bilsing Automation North America https://www.bilsing-automation.com

Robots for AM

RobotStudio simulation and offline programming software now includes 3D printing capabilities, enabling users to program ABB robots for additive manufacturing (AM) in 30 minutes.

Part of the PowerPac portfolio of RobotStudio, the 3D Printing feature eliminates manual programming for faster prototype production. The 3D Printing PowerPac supports welding and printing and is suitable for low-volume, high-mix printing.

Any standard slicer software design can be translated into ABB’s simulation environment and robot code.

ABB https://new.abb.com

Hybrid motion control

The Commander core motion controller is a secure 4-axis hybrid integrated circuit (IC), flexible and scalable from prototype to production while remaining cost-effective for high-volume applications.

Its BASIC-like programming language (A-SCRIPT) allows programmers to compile, read, and write standalone programs. The software also provides multi-threading and subroutine support and can be run in PC-based and standalone modes.

Commander core’s advanced functionality includes linear, arc, circular, helix, and tangential interpolation, as well as coordinated motion and continuous buffered motion, due to its 100 buffer registers. It also allows the user to choose between trapezoidal or S-curve acceleration/deceleration, and absolute or incremental positioning. Users can make on-the-fly changes as well, shifting the speed or target position during operation.

Nippon Pulse America Inc. https://www.nipponpulse.com