Turbo Charge Innovation by Democratizing Simulation
Suppose that in order to drive a car you were required to be an expert in the dynamics, principles, and physics involved in exactly how a collection of parts interact to propel you down the road? The overwhelming majority of us would be walking. While this may appear to be an exaggerated example, one could argue that the manufacturing world has operated in this way for nearly fifty years.
The Advent of CAE
Today’s product development environment employs intelligent Computer-Aided Design (CAD) models to drive new product development. This is certainly no great revelation; it’s been this way since the 1970s. About that same time the engineering world began to investigate ways to analyze these models in order to validate parts and sub-assemblies. The idea was to significantly reduce (or even eliminate) the number of physical prototypes that needed to be built and tested. Time and cost savings associated with validating design early in the product development cycle are staggering.
The importance of this created a need that was quickly filled by engineers who would develop an expertise in the field. Software tools quickly emerged enabling these experts to put models into motion essentially replicating real-world movement, stress, strains, heat, and failure. The process came to be known as “simulation”. OEMs throughout such industries as automotive, aerospace, construction and off-highway quickly embraced simulation and continued to invest in the tools and resources to support its use and on-going development.
The ability to apply advanced tools, techniques, expertise, and experience is as much an art as it is a science. Consequently there remains a relatively small fraternity of CAE experts – many themselves early pioneers, or direct disciples thereof. These are the custodians of a level of expertise and experience relied upon to perform key analysis.
The dilemma is twofold. Limited expert resources create unnecessarily long analysis processes that impose time constraints. This reduces the number of design alternative that may be evaluated thereby stifling innovation. Second, as this generation exits the workforce there is concern that much of their knowledge will retire with them. The truth is that analysis/simulation is a critical competitive advantage for those who possess it.
What’s New: Simulation Applications
What if there was a way to capture and replicate this expertise? What if a way existed to embed such tangible knowledge and intangible judgement into a template extending capability throughout the product development team? The solution lies in Simulation Applications (SimApps), a new application software approach based not on custom programming but rather robust templates which can be easily built and modified.
Solution-specific SimApps are targeted, easy-to-use applications that drive complex simulation templates while speaking the language of the user/engineer. Project templates are generally set up by your in-house analysis expert as to replicate his/her expertise and your company’s standards. This service may also be provided by third-parties. Embedding expert knowledge and removing the complexity of general purpose CAE tools, SimApps allow product designers and engineers, without expertise in the use of simulation tools, to safely and quickly evaluate their designs using sophisticated simulations.
A SimApps library allows solutions to be built for virtually any industry or application. Manufacturers including Intel, American Axle Manufacturing (AAM), GKN, and Magna Cosma, and others are employing SimApps for Drivelines, Gearboxes, Electronics Reliability, and Electro-Optic Sensors to leverage simulation applications to globally enforce expert best practices while measurably increasing the impact of CAE investments on their business.
Extending analysis expertise is essential to innovation. The faster new designs can be analyzed the more alternatives that can be considered. It tells us quickly and with confidence which designs to reject and why without the need for expensive and time consuming physical tests. Yet innovation is unnecessarily held back given the expertise and experience necessary to perform CAE today. SimApps unleash innovation through the insights of a broader group of designers and engineers.
Local Responsiveness & Global Collaboration
Imagine what is possible with quick access information derived from this expert analysis. Think about how this new level of responsiveness changes the game. Sim Apps deliver the full power of simulation to everyone who needs it, from a salesman who needs to understand the feasibility and cost of a design that meets customer requirements, to a systems engineer who wishes to accurately compare the relative tradeoffs of various architectures, to design engineers who need accurate and rapid assessments of the change in performance of a design variation, to a junior engineer who is still learning the intricacies of CAE codes.
Today, like never before, product development hinges on collaboration. Leveraging the SimApp approach allows companies to work with disperse departments, suppliers and partners confident that they will maintain control, that standards will be enforced, consistency will be maintained, and ensuring that the results of the analysis will be valid.
While this may be a difficult cultural shift for many organizations, it delivers tremendous benefits for cost of product development and innovation. As an example, American Axle Manufacturing reports the following major benefits from SimApps for automated NVH analysis of driveline systems.
- Average 75% time reduction for each analysis iteration.
- Approximately $130,000 in annual cost savings at a single engineering site.
- Improved quality through globally enforced standards and practices which remove human error.
- Ability to run many more analysis iterations, leading to more design decisions, earlier.
- Ability to redeploy resources as less experienced engineers are now able to safely run simulations.
Empower to Innovate
Simulation has been the exclusive domain of too few for too long. It’s time to put to rest the notion that simulation cannot be safely used unless you have deep expertise in the art of extracting reasonable results from today’s simulation software. The confluence of simulation methodologies, software, automation templates, and accessible computing hardware, aided by the advent of mobile devices with ubiquitous high-bandwidth access to the Internet, has the potential to magnify the number of users of simulation by an order of magnitude, over the next decade. The results are more innovative products, less engineering rework, and lower product development costs.
Local 14 Elevates Training for NYC Crane Operators
Imagine the responsibility of operating a 300’ boom crane in North America’s most densely populated setting and you’ll understand why a New York City (NYC) crane license is arguably the most difficult of its kind to obtain in the United States. Even under ideal and open conditions, the operation of construction equipment has its risks. And within the confines of an urban environment such risks increase exponentially. International Union of Operating Engineers (IUOE) Local 14 members sit behind the controls of NYC’s heavy equipment ranging from cranes, excavators and drill rigs, to boom trucks, pavers, and forklifts, etc.
As construction equipment becomes more sophisticated, the importance of training is amplified. Under the direction of IUOE 14 Business Manager, Ed Christian, training and safety have taken on new levels of importance and urgency. With a mission to maintain its rank as the highest skilled trade in the city’s construction industry, Local 14’s training center (Montrose, NY) provides instruction for new and advanced users alike. Among the school’s six training simulators is a 300’ boom crane simulator developed by CM Labs.
Coronavirus and the Supply Chain
The good news is that today’s supply chains are more extended and integrated than at any time in history. The not so good news is that today’s supply chains are more extended and integrated than at any time in history. While this global network allows manufacturers to leverage more resources, advance quality, boost innovation and lower costs – this same connectivity makes companies increasingly vulnerable.
After the global economy took a hit in 2008, many manufacturers adopted lean manufacturing strategies such as Just-in-Time (JIT) and other inventory reduction practices. With support from dependable suppliers, maintaining lower levels of raw materials, parts, and products on-site has become an effective cost-saving practice. But, as we are discovering, it is not without risk.
As a world-leading supplier of raw materials (some estimates are as high as 70%), China is a critical linchpin in the global supply chain. Directly or indirectly, nearly all manufacturers, retailers, and consumers are dependent on materials from China – whether they know it or not.
With the recent coronavirus outbreak, China has slashed production considerably. Consequently, many of its Asian customers have slowed production and even closed factories. And while regional automotive companies have been hit especially hard, this setback is by no means limited to any one industry. When supplies from China are scaled back the ramifications are felt globally.
Intelligent Curtains?
There’s little doubt that the world’s climate is changing. According to the U.S. National Oceanic and Atmospheric Administration (NOAA) twenty of the warmest years ever recorded have occurred in the past twenty-five years. Increasingly hot summers and cold winters will further strain energy consumption and the environment as we become even more dependent on fans, HVAC, and other energy-consuming solutions. How can the average household or business reduce energy use without sacrificing comfort or safety? Is there a solution that is both practical and affordable?
In 2019, University of the Arts Berlin students Anna Koppmann and Esmeé Willemsen were presented with just such a challenge in a course project: Past Present – Conservation for Innovation. As the project’s name suggests, students were asked to identify past artifacts, objects, methods, systems, rituals, etc. that could be adapted to solve today’s challenges. “Esmeé and I were interested in historical methods of controlling climate within the home,” explained Anna. “We wanted to explore the use of common items to address the effects of climate change by regulating indoor temperature in a sustainable, cost-effective, and simple way.”
The classmates found inspiration in a simple and common household item dating back thousands of years: curtains. In addition to restricting airflow, curtains have a long history of insulating and protecting against direct sunlight and drafts. Excavations at Olynthus, Pompeii, Herculaneum, and other ancient sites reveal evidence as to some of their earliest use.
Read the case study here.
No Tipping!
Here’s an interesting post from SecturaSOFT that discusses laser head crashes. For those not in the metal fabrication industry, damage to laser cutting heads is expensive in terms of repair/replacement and downtime. SecturaSOFT has some interesting posts like this on its Blog. Be sure to check it out.
Laser Head Crashes
During the cutting process the laser head is traversing to its next cut often very fast and close to the material surface. If a piece of material is protruding above the surface area (has tipped upward) , a collision is likely to occur. Damage to the laser head is often considerable and costly. Tipping is most common when processing thinner materials.
Fortunately, most crashes are avoidable. With a preview of the nest, an experienced operator can often recognize where there is potential for an issue. The operator can pay extra attention when the machine is cutting in that area and take steps to avoid trouble. This can include slowing the cutting process slightly. A few seconds lost in cutting speed is better than hours of machine down-time replacing a laser head.
In addition to reducing the cutting speed, part tip-ups can often be avoided by implementing micro-tabbing. Most laser programming software today offers an auto-tabbing feature where one or more small tabs (typically about 0.020 in.) are placed in the profile of the part to secure the part to the sheet skeleton.
Once the entire nest is complete and the skeleton is off-loaded, the parts can be easily released from the skeleton. With good quality, flat material and parts that are large enough to lay on two or three of the table grates, the need to tab parts is usually unnecessary. When in doubt, micro-tabbing is a smart approach to avoid laser head crashes, especially when lasers are automated and operating in a lights-out environment.
While you’re there be sure to check out the SecturaSOFT video library.
A New Global Paradigm?
We’ve all read countless articles on how business will never be the same once COVID19 is in the rear-view mirror. I’m not sure I agree with that. In fact, I don’t. Oh sure, the months following “normalization” will see a cautious approach by many. Manufacturers will take a long hard look at their supply chain, consumers will sock a few more dollars away in savings accounts, investors will diversify to include more precious metals, and so on.
Soon enough, however, we’ll be back at it – even more furious than ever. We’ll be spending our money, investing aggressively, and rigorously pursuing the dream.
Although it seems strange to say, I believe that by the summer of 2021 – as we’re all settling in to watch the Summer Olympics, soccer matches, and follow the baseball pennant races – things will be pretty much as they were in the ladder weeks of 2019.
People are resourceful and resilient. And that which doesn’t kill us serves to make us stronger – right?
Look, your guess is as good as mine and who knows, maybe I’m way off base. Maybe the world and business will never be the same. But I doubt it.
Leapin’ Lizzards!
What began as an in-home business 35 years ago has become one of the world’s largest breeding facilities of reptiles, amphibians, and invertebrates. Reptiles by Mack is today a leading supplier to pet stores world-wide.
As with any product, reliable shipping is critical. But when transporting animals, safe delivery is literally a matter of life and death. While shipping live animals has plenty of challenges, one main concern is maintaining safe package temperatures throughout the process. “We ship via next day air using UPS and Federal Express,” explained Chief Executive Officer, John Mack. “For most customers this means delivery by 10:30 a.m., which is fine. However, packages to rural areas are routinely delivered much later in the day. These animals would endure long hours on a truck in temperatures often exceeding safe ranges.”
Because animal safety could not be guaranteed, the company elected not to ship to these remote. In order to expand the reach of safe delivery, a new shipping solution was needed.
Microtek is a leading developer of temperature-controlled shipping solutions. “Adaptek pouches from Microtek minimize unsafe temperature swings that can be fatal to the animals. As temperatures rise and fall throughout a typical day, the pack protects the animals, recharges itself, and reactivates to maintain a healthy environment. This ensures that the animals arrive safe while allowing us to expand our outreach.”
Microtek worked with Reptiles by Mack to design a product to transport a variety of animals with diverse temperature requirements to different climates and in all seasons. “Unlike some other phase change material brands, Microtek has been creative in designing materials for our unique circumstances allowing us to maintain a safe environment longer.”
Go here for the rest of the story.
Lifting Stabilization Tool Advances Offshore Wind Turbine Installation
The wind blows steadier at sea than on land, creating more reliable energy conditions for the generation of renewable energy—a major opportunity to combat climate change without disrupting the lives of those people it will benefit the most. While offshore wind turbines are effective sources of energy, the sheer scale of these massive structures presents significant engineering and installation challenges.
Offshore installation is generally performed by jack-up vessels, which stabilize themselves via extendable legs. However, their use is restricted to shallower water, and the process is time-consuming, slowing installation project schedules.
Read the article here
AmTech Manufacturing: An Interesting Story
After 15 years in software sales, operations, and other leadership positions, Kyle Cleaver was ready for a new challenge. So, naturally, he purchased a metal fabrication shop. That wouldn’t be particularly noteworthy, except that he had no previous experience in the industry whatsoever.
In 2019, Cleaver purchased AmTech Manufacturing in Fort Worth, Texas. With more than 30 years of combined experience in the metal fabrication industry, the company provides a variety of services, from fiber and CO2 laser cutting, bending, milling, welding, and painting to powder coating. It serves customers in such industries as industrial machinery, oil and gas, automotive/trucking, construction, health care, and warehouse/retail.
Read the article in The Fabricator here
Coronavirus
By now we’re all very much aware of the Coronavirus pandemic that seems to be surfacing in new parts of the world almost daily. But what do you know about this microscopic agent that is quickly grabbing global headlines?
Discovered in the 1960s, Coronaviruses are a group of viruses that can infect mammals and birds. In humans, the viruses generally cause mild to moderate respiratory infections such as the common cold. However, in some rare forms the Coronavirus can be lethal.
Throughout history the medical community has been challenged with new virus strains to conquer; and the Coronavirus is no different. It’s just a matter of time before an effective vaccine is developed to eradicate the threat. Until then, however, it is important to remember that we must all take part in the battle. Take the extra precautions to ensure your health and the wellbeing of those around you to help prevent the spread of this latest health risk.
Read more here