Overcoming the Thermal Challenges of Electronic Devices

Dactem (a DAM group company), developer of specialist test, measurement and assembly solutions for the aerospace industries, presents an overview of the optimization of a thrust balance used for accurate measurements in electrical thruster qualification endurance testing. The presentation will provide details on how a Multiphysics simulation approach was used to find the optimum design taking mechanical, thermal and electromagnetic performance into account. Speakers: Emmanuel Pouleau, CEO, Dactem (a DAM Group company) Pierre Moutet, Engineer, Dactem (a DAM Group company) Duration: 15 minutes

Electrification is everywhere! It brings energy efficiency into systems and also helps add new smart functionalities to products. The electric motor is a key element of such systems, converting electricity into mechanical power. It is multiphysics by nature. Electric machine engineers need to take into account various constraints from the early stage of the design, looking at electromechanical performance, as well as respecting thermal and NVH constraints. Simulations need to integrate these multiple physics and also coupling effects. Dedicated tools and streamlined multiphysics workflows are developed in order to reduce complexity and speed up the design. Speakers: Limin Huang, Electromechanical Engineer, Altair Samia Saaidi, Senior Technical Specialist - Electromechanical Solutions, Altair Duration: 20 minutes

This workshop demonstrates how a simulation-driven design approach to product development can have a drastic impact on the performance, design time, and profitability of a new product. Using a belt sander tool as a demonstration model, our presenters show how Altair’s design and simulation technologies can conduct a concept design analysis and optimization of the sander external housing to improve stiffness and reduce weight. They go on to show how we can simulate the manufacturing process itself by looking at filling, packing, cooling and warpage of the plastic housing; before concluding with a series of stress analysis and validation studies such as a virtual drop test, 3-point bending simulation and even a study of the effect of the heat transfer of the electric motor. This is a valuable session to see how simulation technologies can be used throughout the design process, adding value and reducing development time at each stage. Speakers: Ujwal Patnaik, Global Business Development Manager, Altair Chris Sambell, Application Engineer, Altair Duration: 60 minutes

The usability of a headset is largely determined by a comfortable fit and its resistance to everyday use. Learn from Alice Lin, Manager of Mechanics at GN Audio R&D how she introduced FEM simulation capabilities at Jabra. The presentation shows how product design benefits from structural analysis, design for comfort, and drop test simulation. A future extension of simulation capabilities intends to address more areas and improve the simulation-driven design process efficiency. Speaker: Alice Lin, Manager of Mechanics, GN Audio Duration: 22 minutes Click the AD icon to select alternative audio translations - French, German, Portuguese and Spanish.

AAM has been providing mechanical drivelines to automotive customers for more than 25 years. As the automobile transitions to electrification, so too must the driveline. AAM has developed a suite of innovative, lightweight, compact and cost-optimized electric drive units and electric beam axles to meet the growing global technology demand as electric vehicles continue to expand over the next decade. Engineering simulation, optimization and validation tools were significant enablers to increase the validation confidence and reduce the time to market for these new products.

An intuitive and robust CFD workflow is available in Altair® SimLab® - a process-oriented, feature-based finite element analysis software that allows you to quickly and accurately simulate the engineering behavior of complex assemblies. For fluid and thermal analyses, SimLab can make the model setup process even faster, repeatable, thereby minimizing tedious manual steps that can be automated. A live demo will be performed using real-world models to show the simple and smooth analysis process in Altair SimLab that goes from CAD to results in minutes.

For the past three decades, Altair’s optimization solutions have driven the innovative, lightweight, and structurally efficient designs of many products you see and use every day. The intense focus on additive manufacturing in recent years have given a boost to topology optimization and generative design, providing more freedom to explore alternatives. Today, we keep on innovating the technology, looking at including multiple physics, like thermal, electromagnetics, and fluid flow to drive design. Altair AcuSolve – coupled with Altair Optistruct – enables engineers to find the optimum shape by simply defining inlets, outlets, and the allowable space in which the solver can work. AcuSolve’s gradient-based topology optimization method will quickly and efficiently find the path of least resistance to deliver fluid flows with minimal effort.

The increasing complexity of machines requires active management and evaluation of potential product failures and simulation of physically accurate conditions during development. Achieved through multiphysics simulation, Altair SimLab can simulate a wide range of interacting physical models including fluid-structure interaction (FSI) and thermomechanical simulation. By helping with complex design problems, simplified modeling workflows give a deeper understanding of phenomena and root causes of unwanted behavior.

Brett Chouinard, President and COO of Altair discusses Development challenges in Industrial machinery and illustrates how Altair's scalable simulation solutions provide the environment for simulation-driven innovation and how machine learning expands the capabilities furter.

Felix Koerfer, Technical Consultant at Altair, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how accurate structural assessment with real loading conditions allows assessment of global stress and deformations, evaluation of bolt forces, and how accuracy & deformation of linear bearings cna be achieved.

Altair CTO James Dagg presents an overview of the journey Altair took to develop the leading modeling and visualization technologies we have today, and provides a look at what’s coming next to help you reduce your product delivery time. James Dagg has been at Altair for more than 30 years and is a visionary behind Altair’s software strategy and development activities. He has also led the development of Altair’s concept design technologies and oversaw the development of Altair’s CAE software suite for more than a decade.

Stephen White, Technical Support Manager, introduces Altair SimLab, a process-oriented, feature-based finite element modeling software that allows you to quickly and accurately simulate behaviour of complex assemblies. SimLab covers multiple physics including structural, thermal and fluid dynamics which can be easily setup and automated, helping to drastically reduce the time you spend creating finite element models and interpreting results.

BMW Motorrad is the motorcycle division of BMW, a German multinational company manufacturing luxury automobiles and motorcycles. With the first motorcycle manufactured in 1923, their current product line includes a variety of shaft, chain, and belt-driven models designed for off-road, dual-purpose, and sports powered by a variety of engines ranging from a single cylinder, various two cylinder (parallel twin, flat twin, boxer etc.), four cylinders inline and six-cylinder inline ones. BMW Motorrad faced a challenge with their model build processes, needing to move previously outsourced crankshaft modeling work in-house while also reducing lead time. Through a semi-automated modeling process based on Altair SimLab, BMW Motorrad developed scripts which reduced FE model generation time down 80%, from 2 weeks of manual work to just half a day. Ruediger Ott, HyperWorks Business Development at Altair, presents a use case from BMW Motorcycles who found that they could significantly reduce the model build time of their powertrain assemblies with SimLab, making use of the automation capabilities to minimize manually effort and refinement.

More and more engineers need to solve problems that can span multiple physics including structural, thermal, electromagnetics, and fluid dynamics.

Simulation-driven design powered by topology optimization was created by OptiStruct over two decades ago. Its success has changed the CAE/CAD industry as today all vendors have embraced this trend.

This presentation introduces an application of a unique, highly automatic, multi-physics design strategy for E-motors, based on a current program at Mercedes-AMG GmbH. The strategy considers essential development requirements including electromagnetics and thermal requirements, NVH, stress and durability. It accommodates for DOE, multi-objective optimization and design exploration methods to be used to explore and find feasible motor designs. The presentation will show how the strategy adds efficiency to the E-motor development process and how it impacts the total costs of development.

Altair SimLab: The New Platform for Multiphysics Gunaseelan Krishnasamy, Vice President, SimLab Development, Altair

Presentation by Kamalraj Rajagopal, Senior Application Engineer at Altair.

Using a realistic example involving Python as the scripting and process automation tool used by Altair SimLab™, learn how to use Compose to create and debug Python scripts.

Presentation by Juan Pedro Berro Ramirez, Radioss Expert at Altair.

Using a realistic example involving nonlinear FEA codes such as Radioss, learn how to use Compose to help characterize and calibrate material models to improve the match between simulation results and experimental results.

Presentation by Livio Mariano, Technical Specialist, Math & Systems at Altair.

Using a realistic example of calculating home heating efficiency, learn how to leverage the interoperability between Compose and Excel to get the best of both worlds: Excel for the front-end (i.e., GUI generation) and back-end (i.e., results analysis) with Compose for the middle (i.e., modeling and simulating complex systems).

Presentation by Michele Macchioni, Director, ModVis Program and Development Management at Altair.

Using a realistic example of performing standard handbook-type calculations for aircraft structural components (in this case, calculating reserve factors for aircraft fasteners), learn how functions can be easily created in Compose, registered there, and then re-used with other Altair tools such as the Matrix Browser in HyperWorks – optionally visualizing calculation results directly on your FEM.

Learn how to use Compose for 0D modeling & simulation, as complementary to 1D and 3D CAE simulations – to perform useful numerical computations; to do parametric modeling; to create scripts; to automate commonly repeated product development processes; to complement or replace legacy in-house codes; to visualize and manipulate CAE data; and more.

Compose uses OpenMatrix Language (OML) syntax that is directly compatible with MATLAB/Octave and interoperable with Python – so you can preserve and reuse existing scripts constructed with these other languages.

Presentations recorded at the Global ATC in Paris, France on October 16, 2018.

Presentation by Franck Delcroix, VP, Program Management Math at Altair.

This interactive session will highlight the following capabilities of Altair Compose: using its OpenMatrix Language (OML) for calculations, scripts, debugging, data visualization and post-processing; Working with Python; Using multiple languages together; Creating your own GUIs; Optimization; Integrating with Altair HyperWorks.

Presentation by Michael Dambach, Vice President, HyperWorks Program Management at Altair.

Presentation by Joe Kovacs, Director - Model Assembly at Altair.

Presentation by Jose Maria Cueva De Leon, Senior Program Manager at Altair.

Presentation by Michele Macchioni, Director, ModVis Program and Development Management at Altair.

Presentation by David Ravi, Director SWAT Team at Altair.

Presentation by Mariana Mendes Leal, Structural Engineer at OHB Systems AG.

Even as engineers, a considerable amount of our time is spent producing reports. These can be FE-Model Descriptions, Sine Response Analysis or papers detailing investigations carried out internally.

For the FE-Model Descriptions, automation of some items can represent a major time saver, as well as reducing the chances of typos or mistakes being introduced, and Altair’s Automated Reporting Director does offer a solution to this. At OHB System AG, we had a chance of working with the Product Design team be introduced to this feature and custom OHB modules were developed. These modules proved to be major time-savers, for documents which can easily be over 100 pages with copious amounts of tables and associated images. The capability of generating document templates to be used across the company has also meant that a standardized approach can be taken.

Presentation by Karthikeyan Sankarraj, Team Leader – Loads/BC Tools at Altair.

Presentation by Roland Zettler, Development Engineer at BMW Motorrrad, Simulation and Predevelopment Power Train.

Motorcycle crankshaft simulation uses a detailed FE-mesh for structural and fatigue analysis. Due to long time durations for FE meshing, the idea was to establish a process for automated crankshaft meshing in SimLab.

The outcome of the project was a process that is subdivided into four stages that conduct meshing and modelling in a semi-automated manner.

Seminar held during 2018 Global ATC in Paris, France on October 16, 2018.

This Workshop Presentation on Powertrain was conducted by Arnaud Sohier, Dave Mason, Nirmalkumar Subbaiah and Manohara Mariyyapa at the Americas ATC on May 5, 2015. Attendees to this workshop leanred how HyperWorks offers a complete and efficient solution to model, simulate and optimize powertrain systems. Practical examples evaluating NVH, coolant and air flow (CFD), lubrication and thermal-mechanical durability load cases were reviewed. Novel new optimization techniques for radiated noise, engine mount and overall crankcase light-weighting were presented.

This Workshop Presentation on Powertrain was conducted by Arnaud Sohier, Dave Mason, Nirmalkumar Subbaiah and Manohara Mariyyapa at the Americas ATC on May 5, 2015. Attendees to this workshop leanred how HyperWorks offers a complete and efficient solution to model, simulate and optimize powertrain systems. Practical examples evaluating NVH, coolant and air flow (CFD), lubrication and thermal-mechanical durability load cases were reviewed. Novel new optimization techniques for radiated noise, engine mount and overall crankcase light-weighting were presented.