White paper

Breaking down silos with Business Process Management

Business Process Management maximizes the scope of SPDM software solutions by ensuring full traceability and interconnectivity in the engineering design processes.


Accelerate aircraft design with collaborative MDO

The added value of combining ESTECO and PACE technologies for a server-based optimization of an EXPEDITE derived preliminary aircraft design.

A detail of Morpheus Hotel building design
Success Story

Balancing multiple disciplines in AEC

ESTECO Technology helped Bouygues Construction automate the simulation process to identify appropriate designs quicker.

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Optimizing kinematics and compliances of vehicle suspension using Adams Car and modeFRONTIER
This webinar presents a methodical way of optimization of Kinematics and Compliances (K&C) performance by linking the models developed in Adams Car with modeFRONTIER for end to end process automation and numerical optimization. Experts from ESTECO and MSC Software explain vehicle suspension systems which are made up of many components including springs, dampers, bushings, hardpoints, etc. Each of these components plays a critical role in Kinematics and Compliances (K&C) of suspension systems. Manually evaluating K&C of a system is also a tedious task considering multiple number of events that must be considered i.e. parallel wheel travel, roll, etc. Thanks to ESTECO's design optimization and simulation process integration and automation technologies, the coupling of Adams Car and modeFRONTIER accelerate and ease the process, leading to an optimal combination of these parameters which results in the desired K&C results for all events.
Getting started with parametric optimization
This webinar showcases how to perform Parametric Optimization in modeFRONTIER. Parametric optimization is a computer algorithm driven automated process that modifies the problem parameters to find the optimum, or Pareto set of optimums, within a predefined design space, taking objectives and constraints into account. This iterative method allows simulation based design processes to be driven to achieve predefined targets, or to minimize or maximize certain performance characteristics. Watch this webinar and learn more about the importance of parametric optimization, the different algorithms used, strategies and some representative industrial cases.
Server-based MDO using an SPDM framework
This webinar demonstrates the benefits of a server-based Multidisciplinary Design Optimization (MDO) approach and Simulation and Process Data Management (SPDM). With a server-based approach, large MDO workflows can be easily managed and collaboration can be stimulated through a modern web interface which is accessible anytime, anywhere. On the execution side, a server-based approach offers many advantages related to distributed execution enabling hybrid compute infrastructures. SPDM is an important aspect of server-based MDO since it manages the ownership, version control and permissions of all the data and models needed to build and execute complex workflows. With SPDM, MDO becomes a team effort instead of an ‘expert-only’ exercise. Workflows can be quickly upgraded or rolled back to a known state, simplifying the debugging and editing process.
Fundamentals of Response Surface Modeling
This webinar explains how to create a response surface or mathematical model that can be used to predict the results of a new set of experiments, without having to execute those experiments. This technique is especially useful for computationally expensive simulations such as 3D FEA or CFD, where runtimes of hours or even days can be reduced to seconds. Watch this webinar and learn more about the importance of response surface modeling in simulation based design, the various algorithms and strategies of implementation.
Accelerate aircraft design with model-based design automation and collaborative MDO
This webinar hosted by ESTECO and TXT company PACE, demonstrates the added value of combining their technologies for a server-based optimization of an EXPEDITE (EXPanded MDO for Effectiveness Based DesIgn TEchnologies) derived preliminary aircraft design. Taking an EXPEDITE-like modern aircraft conceptual design as a baseline, the webinar showcases the advantages of creating a smart, reconfigurable aircraft model with PACE's preliminary aircraft design platform Pacelab APD and integrating it in modeFRONTIER parametric optimization to identify the optimum solutions, based on constraints and performance requirements. Watch this webinar and learn more about how to implement this methodology in an international context, consisting of distributed teams and the extended enterprise.
Enhancing the design process in biomedical industry with engineering optimization
This webinar explores the possibilities of the use of modeFRONTIER and DEP MeshWorks to accelerate the design process in the biomedical field. Medical devices community needs to adopt faster go-to-market strategies to go from conceptual design to market deployment. Virtual engineering and virtual testing become one of the key factors that enable this speed of development. Engineering simulation enables design, development, and analysis of these complex medical devices with great accuracy. Mathematical techniques such as numerical optimization and machine learning further enhance the design process by allowing the identification of robust and optimal solutions in a short time. ESTECO North America and Detroit Engineered Products (DEP), specialized in model parameterization, explain the value of optimization and response surface modeling in simulation-based medical device development.
Success Story
Best performance of blast furnace with material charge optimization
Using modeFRONTIER coupled with Rocky DEM to design a better deflector while saving up to 130 hours of computational time The Arvedi Group turned to the University of Trieste to find a solution to the uneven material distribution inside the hopper of the blast furnace in Trieste, Italy. The Mechanical Engineering Department investigated the problem and used modeFRONTIER to optimize the design of a new deflector ensuring a better distribution of the materials. Exploiting the ESTECO integration and process automation technology they coupled modeFRONTIER with Rocky DEM software to accelerate the simulation process of the material distribution. Using the proprietary algorithms available in modeFRONTIER, they were also able to find the optimal design for a new deflector. ## Challenge The project concerned the charging process of coke coal and iron ore inside the hopper. The different materials formed piles and pitches, leading to a lower performance of the plant. The uneven material distribution inside the hopper caused variations in the temperature profile, gas flow, and gas composition. To solve this problem modeFRONTIER was coupled with Rocky DEM to get a better understanding of materials behavior and optimize the design of the deflector. The integration with modeFRONTIER also allowed to meet the time constraints, reducing the computational time for each simulation. ## Solution This project was developed in two phases. The first phase concerned the calibration of Rocky DEM parameters and the simulation of hopper charge. The second phase consisted in optimizing the geometry of a new deflector for the charging process.For the calibration process, they used the parameters of Discrete Element Method as inputs in modeFRONTIER, such as particle- particle static friction and rolling resistance. The repose angle of simulated material was used as output. For the device optimization, a sensitivity analysis with Uniform Latin Hypercube allowed to run 90 designs and identify the most important design variables. Engineers then optimized three different geometries, taking these geometrical variables as inputs. The outputs were based on the material distribution, calculated by virtually splitting the hopper into 12 sectors and performing statistical analysis on the particles found in each. These values were used to define the two objectives and the constraints of the optimization. They used the ESTECO proprietary pilOPT algorithm to run the three optimization studies. Thanks to the autonomous mode they could evaluate more than 1000 designs in just a few weeks, without having to set any parameters and with remarkable benefits in terms of time. Benefits Thanks to a user-friendly graphical user interface, modeFRONTIER helped automate the simulation process. Without modeFRONTIER, engineers would have had to manually change the geometry of the deflector for every simulation, with significant waste of time. With modeFRONTIER they were able to save up to 130 hours of computational time. Finally, by automating the process, design engineers could launch the optimization and avoid the painstaking process of manually combining the output from multiple applications.
Success Story
IVECO S-WAY truck: perfecting cab design to maximize driving comfort
IVECO relies on ESTECO technology to innovate its simulation-driven product development process. IVECO engineers combine the use of CAD and CAE solvers within modeFRONTIER workflow to automatically execute parametric simulations across a wide spectrum of disciplines: structural calculation (crash, durability, strength), fluid dynamics, NVH (Noise, Vibration, Harshness) and vehicle dynamics. On top of the automated simulation process, they apply optimization algorithms to achieve better vehicle designs with increased performance at reduced production costs. ## Challenge The IVECO S-WAY is a complete transport solution which provides excellent life on board conditions to drivers. With a brand-new cab designed to enhance aerodynamic performance and increase fuel efficiency, engineers at IVECO had to completely rethink the suspension system to improve the comfort standard level. In fact, one of the main challenges of the project was to evaluate the cab comfort before the construction of any prototype. Consequently, they made use of multi-body simulation and optimization techniques to verify the overall behavior of the cab by defining the correct set of stiffness and damping parameters for the suspension elastic components. Solution A 3D truck model was generated in MSC Adams/Car to simulate the behavior of mechanical components (cab body, suspension, actuator, tractor and trailer frame) on different proving grounds as pave, patched asphalt and speed bump. The simulation model was directly integrated in modeFRONTIER workflow to automatically tune the suspension properties, with the aim of optimizing output parameters related to vibration, cab movements and comfort. An initial Design of Experiments (DOE) analysis allowed to identify the correlation between design variables and system responses, with the aim of simplifying the multi-body simulation model to be further validated in the optimization process. Finally, the MOGA-II algorithm, available in modeFRONTIER, enabled engineers to pick the right designs with minimized cab vibration on different paths. Benefits “We took advantage of modeFRONTIER software solution to automatically execute a huge number of simulations and evaluate thousands suspension system designs within few weeks. The Parallel Coordinate Chart enabled us to easily plot several variables and visualize the distribution of the designs in an effective manner. The optimization process led us to achieve up to 10% reduction in cab vibration compared to the baseline. Moreover, the results achieved with modeFRONTIER allowed us to identify specific properties of dampers, springs and bushes that have been considered during the prototype phase of the IVECO S-WAY truck development” said Andrea Morello, Performance Engineer and CAE Senior Analyst, IVECO - CNH Industrial.
White paper
Optimizing the Manufacturing Process to Make Robust Decisions and Reduce Uncertainty
In today’s Industry 4.0-driven market, companies strive to offer the most competitive and valuable solutions while being efficient and reducing costs. Unlocking the advantages of digital transformation is key to face these challenges. Through production process optimization, manufacturers can improve their decision making process to enhance efficiency and quality, while reducing costs and uncertainty. As a case study, this white paper illustrates how out ESTECO technology helped optimize a computer assembly line by: increasing profitability, total throughput and same-day shipment, minimizing work-in-progress, subject to a maximum allowed limit on staff utilization.
Cloud-based optimization of mixer design for Urea/SCR aftertreatment systems
This webinar explains how modeFRONTIER was used to drive CONVERGE in the optimization of a Urea/SCR flapper-type mixer. Meeting NOx (NO + NO2) emissions regulations with aftertreatment system designs that are both effective and economical is critical to successful product performance. The favored approach to satisfying NOx emissions regulations in heavy- and light-duty diesel vehicles is to use a Selective Catalytic Reduction (SCR) device where ammonia catalyzes to reduce NOx. Current industry trends are moving to more compact integrated Urea/SCR systems, which increases the need for an optimum mixer design that may be difficult to achieve with traditional design approaches. ESTECO and Convergent Science during the webinar demonstrate how combining fast and accurate CFD simulation with effective multi-objective optimization of the geometry has the potential to substantially improve the mixer designs and produce high levels of NOx reduction without a substantial backpressure penalty.