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Technical Papers


Ship Foundation Design using DDAM-coupled Optimization MethodsShip Foundation Design using DDAM-coupled Optimization Method

Ship Foundation Design using DDAM-coupled Optimization Methods

This paper presents a case study of a ship foundation optimized for DDAM early in the design phase to validate and optimize the
structural integrity of a ship foundation subject to underwater shock conditions.

 

What’s the State of Nonlinear Simulation?What’s the State of Nonlinear Simulation

What’s the State of Nonlinear Simulation?

Engineering.com audience survey of
nonlinear simulation practices

 

Cost Optimization in Composite StructuresCost Optimization in Composite Structures

Cost Optimization in Composite Structures

Cost optimization is a driving force in all fields of industry, with every manufacturer competing to provide a cost-effective solution to the end customer. The paper addresses how to perform an early-stage design of components with emphasis on cost optimization and without consuming too much of a construction designer's precious time. The main objective of this paper is to generate a proposal for a car seat design, based on free size optimization and cost optimization using Altair OptiStruct commercial engineering software.
 

Providing the Ecosystem for Next Generation Vehicle Powertrains - Altair - Romax White PaperProviding the Ecosystem for Next Generation Vehicle Powertrains - Altair - Romax White Paper

Providing the Ecosystem for Next Generation Vehicle Powertrains - Altair - Romax White Paper

While designers are juggling with multiphysics constraints to deliver their next vehicles generation in time,
together Altair and Romax Technology offer a complete model-based, multiphysics solution for design, simulation and optimization of complex electro-mechanical powertrains. With extensive expertise, we are available to respond to questions from different design teams to help dive down into the technologies, including motors, controllers, gearbox, noise and vibration, oiling and cooling.

 

Altair Inspire Studio DatasheetAltair Inspire Studio Datasheet

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.
 

Magneto Vibro Acoustic Design of PWM Fed Induction Machines Magneto Vibro Acoustic Design of PWM Fed Induction Machines

Magneto Vibro Acoustic Design of PWM Fed Induction Machines

Induction Motors (IM) are widely used in various industries. To ensure their speed control, IM will be supplied with pulse width modulation (PWM). This kind of supply, can impact efficiency of the motor and degrade its vibro-acoustic behavior, generating noise nuisance. To tackle these technical challenges and ensure best-in class acoustic comfort for users, it is necessary to design a quiet e-motors at the early stage of design.
The first aim of this paper is to show a new method to reduce noise and vibration due to PWM supply of induction machine. The proposed approach allows the passive reduction of air-gap flux density harmonics in an induction machine. The second interest, is to show a new method to analyze the vibro-acoustic behavior of a PWM-fed IM. The method is fully finite element (FE) computation. Finally, the third interest of this article, is to compare noise and vibration results between the proposed FE method, magneto-vibro-acoustic coupling and measurements. Good agreement between measurements and computation will be shown.


 

Simulation-Driven Design of a Portable Basketball Hoop System - Initial StepsSimulation-Driven Design of a Portable Basketball Hoop System - Initial Steps

Simulation-Driven Design of a Portable Basketball Hoop System - Initial Steps

A simulation-driven design process is proven to generate improved, more robust and cost-effective designs within a shorter design cycle. Incorporating simulation and optimization early in the design cycle helps shape the concept designs so less iterations and rework is necessary as the design matures. This paper is intended to discuss the initial steps that can be taken when using a simulation-driven design approach to design and engineer products. Several of Altair’s design and engineering tools will be coupled to achieve various design goals.
 

Feko Lua Script: High-resolution range profile calculationFeko Lua Script: High-resolution range profile calculation

Feko Lua Script: High-resolution range profile calculation

This plugin computes a high-resolution range profile (HRRP) of an object. An HRRP is a one dimensional signature of the target object, and one of the main applications is in automatic target recognition systems.
 

Model-Based Development of Multi-Disciplinary SystemsModel-Based Development of Multi-Disciplinary Systems

Model-Based Development of Multi-Disciplinary Systems

Readily simulate complex products as systems-of-systems throughout your development cycle – from early concept design, to detailed design, then hardware testing (HIL). Combine mechanical models with electrical models (in 0D, 1D, and/or 3D) to enable multi-disciplinary simulation and leverage automatic code-generation for embedded systems
 

E-motor Design using Multiphysics OptimizationE-motor Design using Multiphysics Optimization

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.


 

Multi-Physics Design and Optimization of a Complex Radar System Multi-Physics Design and Optimization of a Complex Radar System

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.

 

Flat Panel Post-Buckling Analysis with Implicit Method using OptiStructFlat Panel Post-Buckling Analysis with Implicit Method using OptiStruct

Flat Panel Post-Buckling Analysis with Implicit Method using OptiStruct

Many commercial aircraft are designed so that fuselage skins can elastically buckle below limit load and continue to operate safely and efficiently. This design regime makes for a very lightweight semi-monocoque structure compared to a non-buckling design. Therefore, predicting the local buckling, post-buckling behavior, and failures are critical to design and optimization of this kind of structure. The local panels buckle in a combination of compression and shear. Excess compression is redistributed to surrounding axial members (frames and stringers) and shear is continued to be carried by the buckled panels via tension parallel to the buckle waves. The compression redistribution and diagonal tension put special strength considerations on all involved structural components. This post-buckling behavior and the analysis method are both called intermediate diagonal tension (IDT).
 

Altair SimSolid Technology OverviewAltair SimSolid Technology Overview

Altair SimSolid Technology Overview

An overview of the theoretical foundation of SimSolid, including mathematical background, computer implementation, and positioning among numerical methods.
 

Magnet Weight Minimization of PMM over Multiple Operating PointsMagnet Weight Minimization of PMM over Multiple Operating Points

Magnet Weight Minimization of PMM over Multiple Operating Points

Magnet Weight Minimization of Electric Traction Interior Permanent Magnet Motor Over Multiple Operating Points

This paper describes the process of using Altair tools such as Flux for synchronous permanent magnet motor EM FEA analysis and HyperStudy to minimize the weight of the NdFeB magnets of a typical IPM motor for electric traction application such as the IPM motor of the Toyota Prius 2010.

 

Simulation-Driven Design: Solving the Geometry ProblemSimulation-Driven Design: Solving the Geometry Problem

Simulation-Driven Design: Solving the Geometry Problem

One of the challenges of simulation is that geometry of CAD and traditional FEA are different, necessitating time consuming simplification work to define the mesh and resulting in losses in accuracy.

Altair SimSolid takes a different approach, analyzing fully featured CAD assemblies directly with no absolutely no mesh.

 

Ultra-Fast High-Fidelity Computational Fluid Dynamics on GPUs for Automotive AerodynamicsUltra-Fast High-Fidelity Computational Fluid Dynamics on GPUs for Automotive Aerodynamics

Ultra-Fast High-Fidelity Computational Fluid Dynamics on GPUs for Automotive Aerodynamics

In this white paper, we present the innovative commercial GPU-based Computational Fluid Dynamics (CFD) solver Altair ultraFluidX. This work features simulations of the DrivAer model, a generic, publicly available vehicle geometry that was developed by the Chair of Aerodynamics and Fluid Mechanics at the Technical University of Munich and which is widely used for testing and validation purposes.

The DrivAer model features rear end, underbody designs, and underhood flow. This model was then used to perform both wind tunnel tests and numerical simulations of the 40% scale open cooling geometry using perforated aluminum sheets with different opening ratios to mimic different radiator properties. Within, we will compare some of the results from these wind tunnel tests with numerical results obtained with Altair ultraFluidX.

 

Non-Linear Optimization of Suspension Link for Optimal Performance using Altair’s OptiStruct and HyperWorksNon-Linear Optimization of Suspension Link for Optimal Performance using Altair’s OptiStruct and HyperWorks

Non-Linear Optimization of Suspension Link for Optimal Performance using Altair’s OptiStruct and HyperWorks

In recent times there is a high demand for lightweight automotive components which will reduce oil consumption and emissions. The components that are under non-linear load conditions would need optimization techniques that would yield a design which satisfies all performance targets and at the same time maintains the process efficiency with respect to time and cost. The use of CAE tools such as Altair’s OptiStruct and HyperWorks allows engineers to explore various design solutions starting from concept level to matured design that meets multiple requirements simultaneously with due consideration of manufacturing methods that allows engineers to arrive at an optimal design and process.
 

Testing Aerial Ladders in FEA: Wind Load Standard Equation vs CFD Wind Tunnel AnalysisTesting Aerial Ladders in FEA: Wind Load Standard Equation vs CFD Wind Tunnel Analysis

Testing Aerial Ladders in FEA: Wind Load Standard Equation vs CFD Wind Tunnel Analysis

To design and build an aerial ladder for a firetruck, the engineer needs to accurately determine the working loads the ladder will encounter. Some of these can be easy to interpret such as the weight of the firefighter in the basket at the end of the ladder, or the weight of the water being supplied to the nozzle. Other loads can be a little harder to quantify, such as how wind affects the ladder. There are several different ways to determine this effect, and two of those will be explored in this paper: the standard equation (ASCE 7-10), and CFD.
 

Fully Polarimetric Analysis of Wireless Connectivity for Smart Home and IoT ApplicationsFully Polarimetric Analysis of Wireless Connectivity for Smart Home and IoT Applications

Fully Polarimetric Analysis of Wireless Connectivity for Smart Home and IoT Applications

This white paper presents a study of wireless connectivity of electronic devices in the Wi-Fi band. For accuracy, the analysis will use the full polarimetric information for each device’s antenna pattern. The study focuses on wireless connectivity between lamps and light switches in an indoor environment, with the goal to set guidelines for spacing between transmitters and receivers: wall-mounted switch boxes and ceiling-mounted lamps, as well as pairs of lamps. In general, the work flow would be similar for any type of wireless connectivity in environments such as a smart home, an industrial site, as well as streets and intersections (vehicle-to-vehicle or vehicle-to-infrastructure communication).
 

Multiphysics Design Optimization Using an Adjoint Sensitivity AnalysisMultiphysics Design Optimization Using an Adjoint Sensitivity Analysis

Multiphysics Design Optimization Using an Adjoint Sensitivity Analysis

Optimal design methods involving the coupling of fluid and structural solutions are a topic
of active research; particularly for aerospace applications. The paper presents a coupled fluid and structure approach to topology optimization using two commercial finite element solutions; AcuSolve and OptiStruct. A gradient based method is used to minimize the compliance of a structure subject to thermal loading. The optimal material distribution to minimize compliance is computed using the Solid-Isotropic Material with Penalty (SIMP) method available in OptiStruct. A volume fraction constraint is imposed in order to iteratively reduce the parts mass. Draw constraints are used to ensure manufacturability. The thermal loading is computed iteratively using a computational fluid dynamics (CFD) solution from AcuSolve. The optimization produces an innovative design which increases the heat rejection rate of the part while reducing the mass.

 

Seat Design for Crash in the Cloud Seat Design for Crash in the Cloud

Seat Design for Crash in the Cloud

The benefit of design exploration and optimization is understood and accepted by engineers but the required intensive computational resources have been a challenge for their adoption into the design process. The HyperWorks Unlimited (HWUL) appliance provides an effective solution to these challenges as it seamlessly connects all the necessary tools together in the cloud. The aim of this study is to showcase the benefits of HWUL on an optimization driven design of a
complex system. For this purpose an automotive seat design for crash loadcases is selected.

 

Magnet Weight Minimization of Electric Traction Interior Permanent Magnet Motor Over Multiple Operating PointsMagnet Weight Minimization of Electric Traction Interior Permanent Magnet Motor Over Multiple Operating Points

Magnet Weight Minimization of Electric Traction Interior Permanent Magnet Motor Over Multiple Operating Points

This paper describes the process of using Altair tools such as Flux for synchronous permanent magnet motor EM FEA analysis and HyperStudy to minimize the weight of the NdFeB magnets of a typical IPM motor for electric traction application such as the IPM motor of the Toyota Prius 2010.
 

Fast contact method for speeding up solving finite element problems involving non-linear contact behaviorFast contact method for speeding up solving finite element problems involving non-linear contact behavior

Fast contact method for speeding up solving finite element problems involving non-linear contact behavior

For large aerospace assemblies in finite element (FE) analysis problems, contact interaction between the surrounding bodies has to be established to simulate the load transferred between the components, like aircraft engine carrying bracket assemblies, spigots assemblies etc., and understand the effects of interaction between respective parts. In some cases, depending upon geometry of the assembly, the region of study may not be contact area but the stresses acting within the parts themselves. If there is no geometric or material non-linearity in such problems, a new contact formulation method known as Fast Contact can be used in these contact regions.
 

Antenna Placement Optimization for Vehicle-To-Vehicle CommunicationsAntenna Placement Optimization for Vehicle-To-Vehicle Communications

Antenna Placement Optimization for Vehicle-To-Vehicle Communications

Vehicle-to-vehicle (V2V) technology has the potential to significantly enhance driver safety. The type, placement, and orientation of V2V antennas all affect the performance of the communication system. Simulation software for high frequency electromagnetics can be used to analyze the farfield effects of various vehicle antenna configurations without the need to perform physical testing. We present a simulation-based method for optimizing the placement and orientation of a monopole antenna on a vehicle using a Global Response Surface Method (GRSM).
 

MIMO System Simulation in WinPropMIMO System Simulation in WinProp

MIMO System Simulation in WinProp

This white paper presents and discusses practical examples of communication simulations involving Multiple Input Multiple Output (MIMO) technology. Two workflows exist for MIMO simulations in WinProp; this note discusses the workflows, and presents an example with relevant results for each.
 

Topology Optimization and Casting Feasibility of a Robot Arm Topology Optimization and Casting Feasibility of a Robot Arm

Topology Optimization and Casting Feasibility of a Robot Arm

Oftentimes, in the design of a casting, suboptimal structural concepts are developed which at the same time are not castable, requiring multiple and time-consuming design iterations. This paper describes a process to generate both structurally efficient and also castable parts, while reducing the overall design cycle time. The optimal structure is determined by topology optimization, reducing component mass while maintaining performance requirements. This step is followed by a design smoothing operation and then by a casting simulation to check for casting defects. To demonstrate this software driven product design and process validation, solidThinking Inspire® is used to develop the concept design and Click2Cast® for casting process validation.
 

Design Optimization for Additive Manufacturing in OptiStruct with consideration of Overhang Angle in Topology OptimizationDesign Optimization for Additive Manufacturing in OptiStruct with consideration of Overhang Angle in Topology Optimization

Design Optimization for Additive Manufacturing in OptiStruct with consideration of Overhang Angle in Topology Optimization

This paper gives a technical review and guidelines for positioning the current capabilities. Note that the following uses OptiStruct version v2018. There have been some changes to the discussed algorithms compared to previous versions. Generally, version 2017.2.3 can be used to reproduce all the presented results.
 

Snap-Fit Optimization for Achieving Desired Insertion and Retention ForcesSnap-Fit Optimization for Achieving Desired Insertion and Retention Forces

Snap-Fit Optimization for Achieving Desired Insertion and Retention Forces

Snap-fits are ubiquitous engineering features used to quickly and inexpensively assemble plastic parts. The geometric, material, and contact nonlinearities associated with snap-fit problems can present modeling challenges. Quasi-static solutions with explicit solvers are commonly used to analyze snapfits; however, OptiStruct’s nonlinear solver now possess the ability to solve these highly nonlinear problems implicitly. The first part of this study discusses an effective approach to using OptiStruct for the implicit finite element analysis of snap-fits. Once an accurate simulation model has been created, engineers typically make design changes in order to achieve desired insertion and retention forces. The second part of this study details how HyperMesh morphing and HyperStudy can be used to optimize the snap-fit design, resulting in desired insertion and retention forces while minimizing mass and ensuring structural integrity. The approach documented in this report can reduce the design time, material use, and failure rate of snap-fits used in industry.
 

FEKO Lua Script: ISAR Image ProcessingFEKO Lua Script: ISAR Image Processing

FEKO Lua Script: ISAR Image Processing

The script computes and displays an inverse synthetic aperture radar (ISAR) image from backscattered radar cross section (RCS) data over frequency and angle. Windowing functions, resampling and extracting the local maxima positions to file are supported. The script requires a far field RCS request or far field RCS data imported from a file containing far field data (a .ffe file). Data imported from a .ffe file must be added manually to a 3D view.
 

Multi-physics Electric Motor Optimization for Noise ReductionMulti-physics Electric Motor Optimization for Noise Reduction

Multi-physics Electric Motor Optimization for Noise Reduction

In an electric machine, the torque is generated by electromagnetic forces which also create some parasitic vibrations of the stator. These vibrations excite the mechanical structure on which the motor is fixed and generate sound. When designing the electric machine, this aspect has to be taken into account from the start since it depends on the harmonic content of the currents that feed the machine, on the shapes of the rotor and stator, and on the interaction of the electric frequencies with the natural mechanical modes of the structure.
To simulate this phenomenon, a coupling between electromagnetic calculations and vibration analysis has to be set-up. Some optimization procedure can also be added in order to reduce the noise.
In what follows, it is shown how Altair HyperWorks suite; specifically FluxTM, OptiStruct®, HyperMesh® and HyperStudy® products have been successfully used to perform a multi-physics optimization for noise reduction in a fuel pump permanent magnet motor.

 

OptiStruct for Structural Analysis: Not Just for Optimizations AnymoreOptiStruct for Structural Analysis: Not Just for Optimizations Anymore

OptiStruct for Structural Analysis: Not Just for Optimizations Anymore

Reprint of Engineering.com article on OptiStruct as a structural analysis tool with built-in optimization capabilities
 

Analysis of Grounding Performances of a Car Body Using FEM Shell ElementsAnalysis of Grounding Performances of a Car Body Using FEM Shell Elements

Analysis of Grounding Performances of a Car Body Using FEM Shell Elements

In the automotive domain, the EMC phenomenon of the current return occurs over a wide frequency band due to the fact that the paths followed by the current are very different between the lowest frequencies (a few Hz) and medium frequencies(hundreds of kHz).
 

Checking Remanence Issues with New Hysteresis ModelChecking Remanence Issues with New Hysteresis Model

Checking Remanence Issues with New Hysteresis Model

Remanence is what is left when all current is removed, and there is still some flux density left in the iron core. This is often the case with a close path for flux density, especially in U or E shape devices. To get rid of this effect, it is sometimes useful to add a so-called remanent airgap. This paper explains what we have incorporated into Flux to model this effect due to hysteresis.
 

Cogging Torque Computation and Mesh for Non-radial Electrical Motors in Flux®Cogging Torque Computation and Mesh for Non-radial Electrical Motors in Flux®

Cogging Torque Computation and Mesh for Non-radial Electrical Motors in Flux®

All electrical motor designers know that the computation of cogging torque is a tricky task, particularly in 3D. Indeed, the amplitude of this variable is almost the same as numerical noise. In most cases, conventional mesh methodology is not sufficient and specific methodology must be used. At CEDRAT, thanks to its experience, the application team has developed methodologies to successfully compute
cogging torque in most cases. This article presents a specific mesh methodology to compute cogging torque for 3D non-radial electrical motors.


 

Cogging Torque Computation and Meshing for Radial Electrical Motors in Flux®Cogging Torque Computation and Meshing for Radial Electrical Motors in Flux®

Cogging Torque Computation and Meshing for Radial Electrical Motors in Flux®

All electrical motor designers know that the computation of cogging torque is a tricky task in 3D. Indeed, the amplitude of this quantity is almost the same as the numerical noise. In most cases, a classical meshing methodology is not sufficient and specific methodology must be used. At CEDRAT, the application team, thanks to its experience has developed methodologies to successfully compute cogging torque in most of cases. This article presents a specific meshing methodology to compute cogging torque for 2D and 3D radial electrical machine. It begins with some general recommendation concerning the definition of the geometry in order to facilitate the meshing operation. Then, it presents the specific meshing methodology applied to a 2D SPM motor and to a 3D IPM motor.
 

Comparative Study of Concentrated and Distributed Winding Using Flux®Comparative Study of Concentrated and Distributed Winding Using Flux®

Comparative Study of Concentrated and Distributed Winding Using Flux®

The paper presents a comparative study of 3-phase permanent-magnet (PM) synchronous machines (PMSM) with concentrated and distributed windings. The purpose of this study is to identify the machine that gives the better electromagnetic performance (torque, efficiency, back electromotive force…). Two PMSM with concentrated and distributed windings having identical output power, stator and rotor outer diameter, airgap, axial length, are designed. Machine performance of the two machines is compared using finite element analysis (Flux 2D).
 

Eccentricities Faults in a Rotating Machine Analyzed with Flux®Eccentricities Faults in a Rotating Machine Analyzed with Flux®

Eccentricities Faults in a Rotating Machine Analyzed with Flux®

In the present energy efficiency context of electrical machines, diagnosis of rotating machines is increasingly studied. Designers seek to include the on-line, non-invasive diagnosis and typical signatures of the rotating machines faults in the stator winding currents, torque, leakage magnetic field…etc. Among the rotating machine’s faults, 7 to 10% are located in the rotor and some of these faults are eccentricities. These faults generate electromagnetic torque oscillations: electromagnetic forces acting on the stator, particularly the stator winding, which can accelerate wear of its insulation. Friction between the stator and the rotor is not excluded; this can also have an adverse effect on the bearing.
In the literature we often find three types of eccentricities: static, dynamic and mixed. Our Flux 2D/3D/Skew finite element solution can be of considerable help to predict the typical signatures of eccentricities faults and the influence of these defects on the electromagnetic and vibro-acoustic
performances of these machines, a very differentiating feature of the software. The purpose of this article is to show the feasibility of the different eccentricities with Flux 2D/3D/Skew thanks to the
possibilities offered by mechanical sets.


 

Eccentricities Faults Magnetic Signature of an Induction Machine Determined with Flux®Eccentricities Faults Magnetic Signature of an Induction Machine Determined with Flux®

Eccentricities Faults Magnetic Signature of an Induction Machine Determined with Flux®

In the literature we can find two approaches to make diagnosis: Model approach - a specific method for automation engineers. Depending on the mechanism adopted, we can distinguish three branches in this method: monitoring by observers, by analytical redundancy and by parametric estimation. Signal approach - this approach is based on measurable signals data, such as current, torque, stray flux, noise and vibration, temperature. The principle of this method is to look for frequencies unique to the healthy or fault operation. Faults in electrical
rotating machines can induce other phenomena such as noise and vibrations and possibly other faults like friction between the stator and the rotor or accelerated wear of insulations.


 

 

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