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modeFRONTIER helped the team meet multiple structural constraint and significantly reduce the rocket weight. Since the early 2000s, the Hybrid Propulsion Team at the University of Brasilia has been a pioneer in the development and test of hybrid rocket engines and small sounding rockets. By following a system design approach based on the multidisciplinary optimization technique, the Team has developed a conceptual hybrid rocket motor, attaining a valuable technological option for the reentry maneuvering system of SARA, the reusable satellite designed by the Brazilian Institute of Aeronautics and Space. ## Challenge Solid and liquid rocket propulsion systems are traditionally considered the most convenient technological solution for deboost motor systems. Owing to the improvements in solid fuel regression rates, hybrid propellant rocket engines represent a valid alternative. The team analyzed three different propulsion settings, combining the paraffin as solid fuel with cold gas fuel, thereby responding to the SARA reentry procedure requirements. The final design should meet both the geometric constraints, linked to total mass limitation and the performance indicators for the mission: deboost impulse should produce a deceleration ranging from 235 to 250 m/s and the motor burning. ## Solution The Team took in account the key parameters impacting the performance of the hybrid engine: grain configuration, combustion efficiency, oxidizer tank pressure and nozzle configuration together with geometrical configuration. The two-step sensitivity analysis performed with modeFRONTIER - dedicated tools led to the selection of the variables showing significant dependencies with design constraints and objectives. These key elements were brought together to build a workflow capable of both preserving the simplicity of hybrid propulsion systems. This automatic framework drove the search for the geometric configuration, yielding to the higher mass reduction for each of the three configurations. “The routine piloted by the modeFRONTIER® workflow helped generate, evaluate and select design alternatives along the optimization process, resulting in lighter engines than the liquid and solid motors previously studied.” said Manuel Nascimento Dias Barcelos, head of the Hybrid Propulsion Team. ## Benefits modeFRONTIER streamlined the design effort conducted for the hybrid propellant engines based on liquefying fuel (solid paraffin) and two different gas fuels: H2O2 and self-pressurizing N2O. The estimated mass of the reentry system for the cases addressed in the study varied from 22 to 29 kg, lower than either liquid bipropellant or solid engines formerly proposed. “The optimization process discussed in this work can be considered an essential tool for the preliminary phase design of hybrid rocket propulsive systems”, concluded Manuel Nascimento Dias Barcelos.

Optimal Design of an Unmanned High-Altitude Solar-Powered Airplane In recent years the development of High Altitude/ Long Endurance (HALE) solar-powered unmanned aerial vehicles (UAVs) has been gaining importance. Such aircrafts could serve as “pseudo satellites”, with the advantages of being closer to the ground, more flexible and less expensive when compared to common satellites. Using a combination of a solar array and batteries and without requiring sophisticated assisted take-off systems these UAVs could potentially cover a 1,000 km diameter area and process about 425,000 cell phone conversations while sustaining long endurance flights. ## Challenge Stability and control are critical issues in any aircraft design, more so in this case particular care was paid to this problem especially considering that the airplane flies at altitudes of up to 17km. Another concern is how to identify the best setup of battery packs and power system in order to comply with aircraft standards and regulations. The researchers of the Brazilian Instituto Tecnológico de Aeronáutica worked on the enhancement of a light-weight solar-powered UAV model, featuring a rectangular wing with a conventional tail connected to the wing by means of a boom and two engines located on the inner wing. The baseline airplane gross weight was 30.1 kg and the battery fraction, impacting the overall weight, was very high. With this in mind, the researchers sought the best configuration of selected parameters - geometry, aerodynamics, structures, stability, weight and systems. The multi-objective optimization was concerned with maximizing the available electrical power while reducing the gross weight of the airplane configuration. ## Solution The multi-disciplinary workflow built with modeFRONTIER took into account the stability constraints and the area of solar panels, which could not exceed the dedicated portion of the wing. The objective of the optimization was to minimize weight and maximize the power surplus. The wing area range could vary between 30 and 60 m2, and after 40 generations with 30 individuals each, the MOGA-II algorithm returned a group of feasible designs. The best configuration featured a 50% expansion in wing area, admitting a larger solar panel resulting in a considerably higher power availability with a slight increase in aircraft weight. ## Benefits The choice of modeFRONTIER as the optimization tool provided researchers with a large variety of configurations in less than one day’s computation. For each design solution, engineers identified the strengths, weaknesses and typical values of the variables in order to introduce the improvements sought. “The disciplines of aerodynamics, structures, stability, weight, and systems were all considered and integrated in a modeFRONTIER workflow, capable of providing a relatively simple resizing, but highly realistic airplane”, said Bento Silva de Mattos of the Instituto Tecnológico de Aeronáutica. This case study clearly demonstrates the added value achieved by combining optimization and simulation. With only a few semi-empirical mathematical models and data obtained with the computations and the application of simple theories, it was possible to reach the optimal design and verify the consistency of the solution.

This webinar, hosted jointly by ESTECO North America and Powersys Solutions, demonstrates how modeFRONTIER can optimize the Finite Element Design of an Interior Permanent Magnet (IPM) Electric Machine JMAG model through the direct integration node coupling the two tools.

Optimized heating plate dramatically improved long-term DSSC performance TRE (Tozzi Renewable Energy), a producer of renewable energy, was looking to improve the long-term stability of its photovoltaic Dye-Sensitized Solar Cells (DSSC) - widely considered the next generation solar cells - under development by TRE start-up company Daunia Solar Cell. Compared to the current generation, DSSCs are cheaper to produce, work well in low-light conditions and are suitable for most engineering applications. They are particularly well suited to architectural applications where aesthetics are important, offering design choices that were previously unavailable (i.e. color and transparency). However, the issue of unconfirmed long-term DSSC stability was standing in the way of satisfying stringent manufacturing certification standards. ## Challenge In terms of commercialization, stable performance over time is crucial. With long-term stability dependent on the quality of the sealing process and the quality of the sealing process dependant on uniform heat distribution over the heating plate surface, one of the main objectives was to improve thermal uniformity. Using modeFRONTIER optimization software, TRE was able to change the heating plate design and achieved optimal thermal distribution, guaranteeing an effective sealing process. ## Solution The solution involved a two step process. In the first step, ANSYS Workbench was used to create a CAD (Computer Aided Design) model representing the initial heating plate configuration based on experimental data. This data was the basis for an FE (Finite Elements) model, required for performing transient thermal analysis. This served to find the materials that would perform best in the optimization run and reach the optimization objective. This procedure was necessary to establish the right setup and validate the computation procedure based on the real reference model. The second step involved deploying the modeFRONTIER optimization platform to modify geometric parameters, increase the thickness of the insulating refractory and the dimensions of the heating coils. modeFRONTIER simulations generated over 250 candidate designs before pinpointing the best design and the optimal time required for the heating process to achieve proper sealing ## Benefits modeFRONTIER thoroughly explored the design space before converging to the optimal heating plate configuration which now distributes heat evenly across the entire surface, directly impacting sealing process quality and ultimately improving long-term DSSC stability. Furthermore, by automating the entire design optimization process with modeFRONTIER, TRE successfully managed to improve the quality of the heating plate, saving both time and money. As Alessio Antonini, Technology Manager of Daunia Solar Cell says, “Thanks to modeFRONTIER, the operator no longer needs to take a trial and error approach to simulations, but rather can use the “artificial intelligence” of the optimization method to automatically seek and find the best combination of input parameters”.

The optimization platform helped the BMW team create a reliable transient cooling system model When it comes to reducing fuel consumption, one effective strategy is to improve the performance of an engine’s transient cooling system. The Diesel Engine Development Department at BMW used modeFRONTIER to optimize engine parameters related to the cooling system and to support the validation steps for the newly updated thermal model, in this way determining an accurate framework for comparing and optimizing different cooling packages. Challenge In order to identify better configurations for the transient cooling system of the six cylinder/225kW diesel engine, the team of BMW engineers developed the air side and coolant circuit model using Kuli, supported also by 3D-CFD simulations. To validate the model, measurements were taken of two different driving cycles and load step on the test bench. After comparing the coolant heat balance for oil and water circuits in the vehicle and on the test bench, results showed significant differences, even for very similar engine operating points. In particular, the wind speed impacting the crankcase, the oil pan and the cylinder head beside the actual thermal conditions under the vehicle hood are difficult to precisely determine on the test bench, affecting the reliability of related transient cooling simulations. To increase confidence in the reliability of such simulations, the engine model was refined to reduce measurement divergence observed during validation tests. ## Solution The coolant circuit and the air path models represented in the engine model included two main groups of key parameters requiring enhancement: five heat transfer coefficients and four heat capacities. modeFRONTIER allowed the engineers to set up an effective optimization workflow that was capable of automatically interacting with the Kuli engine model and detecting the optimal configuration for the nine parameters. Günther Pessl, Head of Simulation at BMW says that “the easy-to-build integration between the two software enabled faster identification of the best heat transfer coefficients and thermal inertia in the engine analyzed.” When transferring the test bench model to the real vehicle model, some parameters indicated fluctuations during the validation cycles, especially oil temperatures which showed the biggest deviation during the hill climb. “Thanks to the optimization loop performed on the hill climb cycle, the engine parameters were refined, resulting in a significant improvement in accuracy measured on the Miramas BMW test track” says Günther Pessl. ## Benefits modeFRONTIER helped the BMW team create a reliable transient cooling system model, compliant with new testing guidelines and accurate enough to be reused for comparing and optimizing different cooling packages. The software contributed to a significant reduction in oil temperature and coolant side model errors and improved related temperature trends. Additionally, the automation capabilities of modeFRONTIER together with its powerful optimization algorithms, enabled automatic fine tuning of the parameters that supported and shortened the model validation steps.

This webinar, hosted jointly by ESTECO and Optimal Solutions, provides a demonstration of the new interface between the **modeFRONTIER and Sculptor, including some relevant case studies where the direct coupling has been used.** Agenda: Introduction to ESTECO and modeFRONTIER Introduction to Optimal solutions and Sculptor Test case introduction The new interface between modeFRONTIER and Sculptor Test case: DOE and Optimization studies and results for F3 Race car

Bottero innovates with optimized high performance mold-motion Leading in the glass industry is Bottero’s declared ambition. The recent launch of E-MOC, a family of mold opening and closing mechanisms (MOC), has challenged the hollow glass industry. E-MOC introduces a completely new cooling concept, granting the possibility to achieve the proper temperature profile, according to the type of process required for the application field. Challenge “The innovative idea behind E-MOC design is the result of our R&D team’s work: numerous constraints were limiting the possibility of changing the machinery design, so modeFRONTIER, the multi-objective optimization platform, came to our help”, says Marcello Ostorero, Structural and Fluid Dynamics Simulation Department Manager at Bottero. The mechanism had to be equipped with a universal mold holder providing efficient cooling and, when mounted, it had to be readily accessible and installable on both new and existing machines. The optimal system performance called for a smooth and precise mold motion, with fast closing time, and maximum closing and clamping forces. ## Solution The complexity of the problem was tackled with modeFRONTIER within two optimization cycles. The aim of the first one was to minimize mold motion oscillations. The results were then used to conduct a sensitivity analysis, which revealed the piston center movement as the most important variable for mechanism stability, but the geometrical constraints did not allow the piston to maintain the optimal trajectory. This unexpected obstacle was bypassed by replacing the single large piston with three smaller ones. In the second optimization cycle modeFRONTIER guided the model adjustments to minimize mechanism lability and oscillations, while keeping constant the newfound optimal values of component geometries and of piston center movement. ## Benefits “Due to the intricate nature of the required mechanism, the systematic optimization approach proposed by modeFRONTIER was the only way to obtain a functioning high-performance design”, says Ostorero, “modeFRONTIER managed to find a fine balance between a high number of rigorous constraints and adjust the model geometry to the most important mechanism specifications so as to increase its efficiency and quality, while successfully driving a number of software, each solving a single aspect of the problem, integrated in a single workflow”.

Multidisciplinary collaboration made easy at Airworks Engineering Airworks, a multidisciplinary company for mechanical engineering, was facing the challenge of improving efficiency in the conversion of wind energy into electrical power by optimizing the whole assembly of a wind power unit rotor. ## Challenge Experts in wind power unit, specialists in CAD (Computer Aided Design) and CFD (Computational Fluid-Dynamics) professionals from different organizations were involved in a complex design scenario and needed to collaborate by effectively sharing a different kinds of information and resources. Engineers from the University of Trieste prepared the parametric CAD model and set up CFD simulations, while Airworks took care of aerodynamic performance calculations of the wind rotor blade, and subsequently performed optimization analysis with modeFRONTIER, the multidisciplinary optimization platform. The need for a common platform to share results emerged rapidly, and was successfully tackled with SOMO software solution (now evolved in VOLTA SPDM enterprise platform). This enabled the seamless execution of inter-organizational simulation workflows. ## Solution With SOMO each partner of the simulation workflow was able to contribute to the project providing its own high level of collaboration. The CAD expert generated the geometry of the blades providing a parametric model and the CAD solution used to update it, while the CFD expert set up the aerodynamic simulation model, which used the geometry to evaluate the rotor aerodynamic performance. Both simulation workflows were made available to partners in a shared repository. Then the wind power unit expert was able to integrate his performance evaluation software into an automated multi-disciplinary workflow. Ultimately he used the workflow to evaluate the power efficiency of the system and to optimize it in a complete range of environmental conditions. ## Benefits Through the entire process, simulation data and engineering knowledge were effectively managed and shared through SOMO, allowing a faster process and a considerable resource-saving”, says Stefano Picinich, Airworks Engineering Managing Director. With the set up of the optimization workflow, Airworks professionals were able to explore and evaluate new parametric geometry, leading to innovative designs, analyzed by the decision-maker via the post-processing tools. The considerable result was of a wind turbine design with an outstanding power coefficient and an annual energy production increase of respectively 1.26% and 0.47%.

In this webinar, experts from CN and ESTECO gives a short presentation of the two software packages and demonstrate the process of integrating a TurboOPT II model with modeFRONTIER. Watch the webinar to learn more about the following 3 test cases: Axial fan blade section optimization using AxCent® and Pushbutton CFD® analysis Centrifugal pump multi-disciplinary optimization (MDO) with CFD and at design and off design conditions MDO of a compressor third stage impeller using CFD and FEA analysis

Improvements in weight, aero-dynamics and brake distribution led to a lap time reduction ranging from 0.19 to 0.50 seconds Polestar Racing has been using modeFRONTIER in different steps of the development of the “Polestar Performance” concept. The software is used both as a tool for driving the aerodynamics, multibody and structural analysis process, and to improve the real lap time simulation. In 2012 Touring Car Team Association (TTA) championship, Polestar Racing won the first prize for the Drivers, Teams and Manufacturers categories with their innovative car design. ## Challenge The 2012 season of the Racing Elite League run by TTA introduced new rules leaving little room for engineering design changes. Therefore, the Polestar Racing vehicle model had to be modified without considering the chassis design parameters, which were previously the core of the optimization analysis. Design simulation acquired an even greater importance as the best combination of the Front-to-Rear weight, aerodynamics and brake distribution in less time (track testing was limited to three days) became the new target. ## Solution The simulation tools used - Adams.Car by MSC Software and the Lap Time Simulation (LTS) in-house code - were easily integrated into the modeFRONTIER optimization workflow, to optimally tune the Front-toRear weight distribution parameters. “Considering the limited amount of time we have had for testing in this championship” – says Per Blomberg, Manager of Chassis Development – “this kind of interrelated parameters study would not have been possible without the capability of modeFRONTIER to extend the simulation analysis ”. Improvements in weight, aerodynamics and brake distribution led to a lap time reduction ranging from 0.19 to 0.50 seconds. ## Benefits In only a few hours of simulation time modeFRONTIER piloted the evaluation of parameter combinations that might have never been tested, leading to enhanced configurations. The optimization framework initially set up for the TTA championship can be promptly adapted to the typical circuits of the STCC championship. Repeating the study considering different conditions is now “something that we can do even overnight on a weekend race , once we have completed the trial session and gathered some data about the track model”. Similarly, it is rather easy to run a new optimization cycle even with modified conditions, such as the driver, tires, and so forth: once the relevant parameters in the LTS vehicle model (e.g. engine or track model) are set, modeFRONTIER performs a robust sensitivity verification of the output (lap time) in relation to different vehicle parameters.