RESOURCE LIBRARY

Using modeFRONTIER to optimize exhaust aftertreatment systems BASF’s Catalysts division is the world’s leading supplier of environmental and process catalysts. Responding to a request from a customer - a truck manufacturer - BASF researched to provide an alternative technology capable of reducing catalysts costs and improving the performance of the current Euro VI production exhaust aftertreatment system. BASF proprietary exhaust simulation models were integrated in modeFRONTIER software, with the aim of optimizing the operational parameters for accurate emissions prediction. ## Challenge The global automotive industry faces enormous challenges from increasingly tightening emissions legislations. Regulatory differences between European, Asian and American markets enhance complexity while vehicle manufacturers are constantly seeking to reduce development cycle times. There is a continuous demand for efficient strategies to develop cost effective solutions that meet regional emissions regulations. As a result, simulation techniques for exhaust aftertreatment system has gained popularity. Engineers at BASF focused on developing a model-based simulation for an exhaust system comprising a diesel oxidation catalyst in order to investigate the trade-off between cost and catalytic performance. Besides the minimization of the tailpipe NOx emissions by simulating a transient homologation cycle (WHTC), several functionalities of the oxidation catalyst like NO and hydrocarbon oxidation needed to be optimized in parallel. ## Solution An effective model based development toolchain was developed building upon BASF proprietary exhaust catalyst models to simulate accurate emissions prediction. Four catalyst design parameters, considered as major cost drivers, were investigated in modeFRONTIER multiobjective optimization platform. As a first step, performing Design of Experiments (DOE) analysis allowed to identify the most important parameters and explore sensitivity of the system performance. Consequently, the optimization task was driven by the MOGA-II, the genetic algorithm included in modeFRONTIER, to minimize catalyst cost and tailpipe emissions. ## Benefits “Our simulation toolchain combined with modeFRONTIER optimization capabilities led to evaluate 500 catalyst system designs within two weeks. Manufacturing and testing few prototypes would have taken us months and significant resources due to the expensive precious metals incorporated and additional operational costs. Despite the large amount of data, modeFRONTIER allowed to quickly rationalize and visualize results in a smart and efficient way. The Parallel Coordinate Chart enabled us to identify the suitable prototype candidates capable to exactly match particular cost and performance targets based on customer preferences. We look forward to demonstrating the benefits of the toolchain for other customer applications” said Dr. Stefan Kah, responsible for Application Engineering Modeling at BASF Catalysts Germany GmbH.

This seminar focus on how metamodelling techniques speed up the search for promising designs by replacing computationally expensive design evaluations or simulations. In 2018, ESTECO joined this NAFEMS Web Seminar talking about how metamodelling techniques provide a global model of some design response, which can then be optimized efficiently. As, in the context of digital transformation, simulation is expected to spread all over the product lifecycle, metamodelling techniques too will be requested to adapt to different types of data and to exploit different types of predictive capabilities.

This webinar presents the new user experience, self-initializing and autonomous algorithms. modeFRONTIER platform guarantees the management of all logical steps of an engineering design process. The workflow formalization and the integration with third party tools enable the automation of the simulation process. A suite of design of experiments and optimization algorithms drive the search for optimal solutions. Picking the right design gets easier with a set of advanced tools for data analysis, visualization and decision making. AGENDA What’s new in modeFRONTIER 2018 Brand new User Interface Self-initializing and autonomous algorithms modeFRONTIER and the VOLTA platform Sharing and managing optimization datasets Case study | Autonomous pilOPT

Research engineers at Dow Chemical were interested in exploring the application of recent advances in engineering optimization using commercial Computer Aided Engineering (CAE) tools for their simulation based design phase. The design of a polymer die, also known as a “coat hanger” die, was chosen as a test case for such an optimization study to improve more than one objective. Polyflow, a commercial Computation Fluid Dynamics (CFD) code, and modeFRONTIER were used to optimize the design of one such coat hanger die. This white paper highlights: how CFD-based optimization can be used to improve the flow uniformity of a coat hanger die while minimizing the pressure drop, how optimal solutions can be identified by increasing the number of geometric parameters that are allowed to change, which are the best algorithms and optimization strategies according with the number of parameters considered.

Imagine if you could examine dozens, hundreds, thousands of design alternatives before committing to a single component. If you could understand the tradeoffs you’re making between weight, shape and capacity? This white paper explores how leading companies are balancing the tradeoffs between components, materials, manufacturing processes and costs to create the optimal product for a particular market niche. Even though physics simulation is still the most frequently used type of optimization, innovators are moving towards agile product development routines. This helps companies make simulation relevant across the enterprise to shape a reliable and effective product innovation framework. Read about how companies like Bombardier, Cummins and Land Rover BAR have been successful in managing the complexity of modeling across multiple domains.

This webinar, cohosted by ESTECO and EXA Corporation in 2017, presents the successful integration of PowerFLOW simulation technology in the modeFRONTIER workflow to provide Ditch Witch® with valuable insight to guide the shroud design on one of its Vacuum Excavators. Watch it to find out how Ditch Witch® have performed multiple analyses, by integrating EXA's PowerFLOW simulation technology into modeFRONTIER workflow, on their equipment to gain a deep understanding of how key design parameters impact performance and manufacturing costs – critical inputs for next-generation machine designs. AGENDA Overview of EXA and ESTECO Focus on Simulation Driven Design Exploration > how to exploit PowerFLOW simulation software into modeFRONTIER workflow Case study > Explore shroud design options to improve machine performance of a FX65 Vacuum Excavator

This webinar hosted by ESTECO, Gamma Technologies, BETA CAE Systems and ThermoAnalytics, presents the successful integration of their technologies in the modeFRONTIER workflow to reduce bumper temperature through coupled simulations for a compact car. Expert engineers from GT-Suite, BETA CAE Systems, ThermoAnalytics and ESTECO will demonstrate the advantages of the integration of their software to reduce bumper temperature in order to prevent car paint peeling. Watch it to find out more about an integrated approach to modify the muffler heat shield properties to reduce bumper temperature by implementing various solvers.

Performing multi-objective inverter cooling system optimization with modeFRONTIER California-based electric car company, Lucid Motors, applies innovative engineering, design and technology to define a new class of premium electric vehicle. Their first Lucid Air all-electric sedan, with up to 400 mile range battery options and 1,000 horsepower twin-motor configuration with all-wheel drive, is to be delivered in 2019. In preparation for production, Lucid Air prototypes are undergoing a rigorous development program. modeFRONTIER has been used - together with other applications - to optimize the design of an inverter with the aim of enhancing efficiency and minimize failure rates. ## Challenge An inverter is an electronic device that converts the direct current (DC) stored in the battery into alternating current (AC) and send electricity to the three phases of the AC induction motors. Overheating is the most critical issue beside vibration, humidity and dust when designing a drive inverter for hybrid and pure electric vehicles. Its efficiency is instead driven by low chipto-coolant thermal conductivity together with temperature balance and low pumping pressure. The Lucid Motors team focused on designing an inverter cooling system that keeps the temperature under control. ## Solution Starting from the conceptual design of a cooling channel with different configurations, engineers at Lucid Motors performed different Design of Experiments (DOE) evaluations and sensitivity analysis using a fully-parametric CFD model with modeFRONTIER, which enabled them to find optimal design candidates for temperature reduction, lowering pressure and minimizing channel size. “After deciding on an optimum channel solution, we went further and optimized the manifold design by including a mesh-morphing step in the modeFRONTIER process integration workflow. The objectives there were to keep pressure variations low and reduce velocity variation”, said David Moseley, Director, Powertrain, Lucid Motors. ## Benefits modeFRONTIER provided an environment to identify inverter optimal designs while enhancing efficiency and minimizing failure rates. The use of modeFRONTIER enabled Lucid engineers to make more power available to the inverter and increase alternative current from 1200 to 1500A. The ESTECO Technology also supported the Lucid Air development in optimizing suspension components and enhancing the thermal performance for the motor cooling.

In this webinar ESTECO and MSC Software present the successful integration of their technologies to explore and improve design solutions for multibody and structural vehicle analysis. Dynamic behavior of a car in terms of handling, steering and ride is influenced by many vehicle body parameters, which also affects the structural behavior of the system. ADAMS and MSC NASTRAN software can be coupled together with modeFRONTIER multi-disciplinary optimization environment in order to efficiently explore the combination of the design parameters and improve the system design.

This webinar, hosted by ESTECO and BETA CAE Systems, focuses on a reliability-based optimization method that statistically increases the safety of free fall lifeboats, which are typically used to evacuate passengers in oil platforms and large transport vessels. Dimitris Drougkas from BETA CAE Systems and Alberto Clarich from ESTECO demonstrate the advantages of the integration of their software in the modeFRONTIER multi-objective design environment for a reliability based optimization of a free fall lifeboat. ANSA software is used to morph the free fall lifeboats mesh by editing its shape and its initial position, and modeFRONTIER is used to automate the simulations performing an optimization under the uncertainties of the operational parameters.