Altair® Flux® Can Take the Heat - Optimizing The Energy Exchange of an Induction Hob System at Groupe SEB

Crashworthiness optimization at BMW with AI-enhanced surrogate modeling. BMW uses Altair’s integrated Machine Learning solutions within HyperWorks to generate optimization constraints that mimic engineering expertise. Clustering, an unsupervised machine learning algorithm, helps engineers to understand how crash kinematics affect key performance indicators (KPIs). Favorable crash kinematics are then enforced during the optimization process through the use of a classifier that, in effect, emulates engineering decision making throughout the process.

ZF develops a wide variety of e-motors and e-drives for a broad spectrum of automotive customers. To optimally incorporate development and production costs from the outset, their designers must find solutions to maximize shared parts within the given requirements for the motors. ZF, in collaboration with Altair, employed a simulation and data-driven solution that empowered them to consider shared parts, costs, and further constraints to automatically find best configurations for a modular motor platform.

High accuracy sensors and encoders are integral components of an e-motor drive, greatly impacting the quality and efficiency on the system. A purpose-driven simulation approach is needed to account for all the physical interdependencies within these complex multi-domain systems. Lenord + Bauer worked with Altair to develop a system simulation process for their high-accuracy encoders to understand their impact on the quality and efficiency of the system.

The competitive consumer device industry has quick time-to-market deadlines. Smartphone cameras use voice coil motor (VCM) actuators to translate a lens in three degrees of freedom in order to bring an object to focus on the image plane and to optically stabilize the camera. To ensure optimal design, the Motorola Mobility team selected Altair Flux™ to simulate the entire VCM and camera system. Flux allowed the team to quickly validate designs and ensure that the part compatibility and camera performance met the design targets. Other devices within the phone, such as speakers, antenna shields, accessory magnets etc. can affect the VCM performance due to magnetic interference. With Flux, the team simulated the entire VCM and phone layout, accounting for all possible magnetic interference from other devices.

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.

French startup Gulplug, located in Grenoble, France, has set out to revolutionize plug and charging technology used in today's electric and hybrid vehicles. To create new products and to drive innovation in the market, Gulplug is using Altair Flux™ and the Altair startup program. Flux helped Gulplug to model and create an innovative, clean, automatically self-plugging, magnetic based charging solution for electric vehicles.

Analysis and optimization to improve crash performance while reducing reliance on physical tests.

Gestamp selected Altair to develop a set of custom tools within HyperWorks, eliminating the need for an initial 'trial and error' design loop while reducing mass and increasing durability of a rear twist beam suspension system. The company achieved a reduction in lead time while producing competitive low cost, low mass RTB designs.

One of the world’s leading suppliers of oilfield services, products, technology and systems, Baker Hughes operates globally with nearly 59,000 employees. The company, headquartered in Houston, Texas, recently recorded $21.4 billion in annual revenue from sales of both services and highly innovative products for the world’s oil and natural gas industry.

This success story illustrates how a reputed engineering institute of national acclaim has set-up a CAE - Optimization Lab, equipped with Altair HyperWorks CAE tools, to expose their students to the latest technologies in product design, analysis, and optimization. Within the range of the CAE - Optimization Lab, CoEP has launched various courses to impart knowledge on Altair HyperWorks. This CoEP initiative bridges the gap between industry expectations and needs and the knowledge that graduating students possess. Being trained on advanced and contemporary technologies such as the HyperWorks suite has opened new opportunities for students to embark their career, has improved the national ranking of the college due to investing in a modern and robust infrastructure, and also has benefitted the industry by creating a talent pool of well-trained manpower, available to work on breakthrough engineering initiatives.

CAE is a core element in developing high-end, long-lasting professional power tools at DeWalt, a Stanley Black & Decker brand.

CAE Simulation driven Product Development of Expandable Liner Hanger presentation given by Ganesh Nanaware of Baker Hughes at ATCx Energy 2014.

As design exploration and optimization methods have become commonly accepted across a range of industries, such as aerospace, automotive or oil and gas, they are frequently utilized as standard practice to efficiently produce designs and aid critical engineering decisions. The widespread acceptance of these methods coupled with the power of modern computing has led to applications across a range of design problems and ever-increasing complexity. The size and scope of this expansion continually pushes the boundaries of existing exploration and optimization methods. Furthermore, a complete exploration of the optimal design space includes computationally intensive features such as multi-objective optimization, to understand the trade-off between competing objectives, and global optimization, to avoid local extrema.

Automating CAE connectors creation in HyperMesh and utilizing HyperStudy for pedestrian impact simulation helped optimize Tesla’s design cycle and get better crash and safety performance.

Gestamp Tallent Ltd is a world class designer, developer and manufacturer of cutting edge, chassis structural and suspension products, body in white structures, modules and systems for the automotive industry. Gestamp used the BMW MINI front subframe tower to demonstrate the weld distortion optimisation approach. The tower is particularly susceptible to distortion due to its tall and thin dimensions. The objective of this optimisation was to minimise the distortion of the tower measured by the displacement of the top of the tower as the weld sections cool. In order to further investigate weld removal optimisation they chose HyperStudy.

Using HyperWorks for Teaching Computational Optimization Methods in Engineering Design at Northwestern University

Carmakers the world over are investing heavily in the development of lighter vehicles and more economical engines that can go further on less fuel. Renault’s powertrain division wanted to further decrease the weight and increase the performance of existing and in-devolopment engines by redesigning key components to use a minimum amount of material. As an existing user of Altair’s simulation solutions, Renault approached Altair ProductDesign to assist in the development of the required optimization design methods and processes for use at component and sub-system levels.

HBPO GmbH optimizes their design process by utilizing multiple products, such Total Materia and MADYMO, alongside HyperWorks products for the development of their front end modules.

Assystem is an international engineering and innovation consultancy group with a presence in 14 countries and 8500 employees. HyperMesh, RADIOSS and HyperStudy were used to design the safest possible nuclear encapsulation vessel for securely containing nuclear material. The designs not only achieved pressure vessel code PD5500 standards, but also helped Assystem gain external accreditation for the pressure vessel’s compliance to code. Download the Assystem Case Study

Much more goes into a golf club than simply wood, iron and graphite. To shape the performance, the distinctive appearance, the personalized feel and even the sound of the club striking the ball, manufacturers must precisely engineer every aspect of the design. Today, simulation-driven design has dramatically reduced development time for new golf clubs while allowing them to meet strict regulations more efficiently.

Sophisticated simulation tools enable aerospace engineers to study the feasibility of airbag landing systems.

Optimization technology delivers innovative suspension design for Alfa Romeo's sleek concept car.

Wagon Automotive, a system and module supplier of components to major car builders, sought ways to accelerate product development and reduce prototyping costs while maintaining high quality. Adopting the HyperWorks suite of advanced CAE tools enabled the company to achieve both those goals. Wagon Automotive now uses HyperWorks during the entire development cycle, from concept design to optimization.

Bental Motion Systems, a member of the Gevasol Group, produces a variety of end applications including motors, alternators, and electrical brakes for the aerospace & defense, and semiconductor industries. To accelerate the design of electric machines while reacting fast to customer specific requirements, Bental uses Altair FluxMotor to enable quick concept exploration including valuable predictions on machine performance, parameters, and productivity feasibility checks.

In 2019, engineers at Schneider Electric’s R&D center in Mexico took on a project to study the dynamic performance of a microgenerator designed to power a wireless communication card for lighting switches by self-harvesting energy. However, to achieve a successful design, particular consideration needed to be given to operating temperature specifications. Differing operating conditions had to be explored to determine the energy performance of the generator. A fully integrated, multi-physics toolkit was achieved by complementing Altair Flux with Altair Activate™, Altair Compose™, and Altair HyperStudy™. The flexibility and capability of these tools had a dramatic effect not only on the performance outcome, but also the speed with which results were obtained. Moreover, robust risk management was assured, with effective simulation and optimization preventing engineers from heading in the wrong direction, or building prototypes that did not meet the desired objectives.

The shift toward e-mobility is increasing pressure on the automotive industry as the world awaits more sustainable and affordable solutions. New players are entering the market with fresh ideas and groundbreaking technologies. EVR Motors Ltd. is one of these. The company designs and develops cost-effective radial flux Permanent Magnet (PM) electric machines for a range of power conversion applications. EVR, established in 2012, began developing patents for wind turbine generators. They then adjusted their roadmap to include e-mobility, and developed an innovative e-motor called TS – RFPM based on new, patented technology that provides superior power and torque density – all at lower production costs. When looking for a powerful and accurate electromagnetic and mechanical simulation tool, they chose the Altair simulation tools to simulate their motors before prototyping. Through simulation, EVR developed and tested its new patented motor, which is half the size than some of the industry’s best e-motors.