Femap Case Study- Industrial Machinery

Kotchergenko

Adoption of Siemens PLM Software tools enables company to increase its service offerings; gain competitive edge.

The highest quality technical engineering services

Kotchergenko Engenharia (Kotchergenko) was founded in 1993 to fill a technological gap that existed between machinery and structural design. Since its inception, the company’s plan has been to differentiate itself from the competition through highquality technical engineering services.

To realize a unique service offering, Kotchergenko uses a combination of solutions, including externally acquired state-of-the-art software and internally developed custom applications. These solutions address a wide variety of engineering issues, such as upgrading equipment and investigating accidents involving machinery and structures.

Why Siemens PLM Software

The first market-based product lifecycle management (PLM) system used by Kotchergenko Engenharia was Ansys® software, which wasn’t well-suited to handling the company’s integration requirements at a time when the company needed it to sustain its growth. “The software’s architecture was limited, and its cost was too high,” says Frederico Mol, technology director at Kotchergenko.

Since the software license was about to expire and the company was experiencing a period of notable growth, Mol decided to look for another supplier that could offer a high-quality product capable of being integrated with other internal systems and at a reasonable cost. Mol explains that the company needed to integrate the systems that perform standards-based verification procedures of equipment with its main software.

Given that the company had acquired Femap™ with NX™ Nastran® software last year, it decided to do additional research on Siemens PLM Software’s solutions and discoveredTecnomatix® software. “We thoroughly reviewed Tecnomatix and decided to also acquire licenses a couple of months ago, because we concluded the software would give us new solutions to our portfolio. Not only did we consider Tecnomatix as the best option for us, we also felt comfortable acquiring it, because of our previous relationship with Siemens PLM Software and the great support provided,” concluded Mol.

At Kotchergenko, Femap with NX Nastran is used to conduct structural design calculations through the finite element analysis (FEA) method. A numerical tool for problem solving that is widely used in machinery and structural analysis, Femap with NX Nastran plays a key role in Kotchergenko’s core service, which consists of using simulation tools to verify clients’ machinery and recommending how to increase their production according to the equipment’s capacity, while also taking into consideration various requirements, such as durability, strength and safety. “Since design methods have evolved substantially, manufacturers are under more pressure to improve their products, reducing weight and therefore costs; however, their specifications do not always match market requirements,” notes Mol. “After we conduct our diagnosis, our clients are better prepared to question manufacturers and request changes to match product performance within expectations.”

Vital business component, substantial gains

With most projects utilizing Femap with NX Nastran, the solution has become a vital component in the company’s best practices. “We could have developed such software internally, but this would have demanded a great investment in terms of man hours and effort in an activity that is not part of our core competencies,” says Mol. “Our business is to provide engineering services. For some projects, the systems are designed internally in order to address specific standards that are required by the clients.”

By adopting Femap with NX Nastran, Kotchergenko is generating its models approximately 20 percent faster. The company has also achieved substantial cost savings as well as measurable gains in project quality and reliability. Importantly, with Femap with NX Nastran, the company can easily scale the software to its needs. Six licenses were acquired and more licenses appear imminent as the company is growing rapidly. Last year, the company posted a 77 percent increase in billings.

Adding Plant Simulation for logistics analysis

The Plant Simulation solution in the Tecnomatix portfolio is used for projects that have just started. “Plant Simulation allows us to conduct logistics analysis,” says Mol. “This, in turn, allows clients to assess the feasibility of an operation by doing a simulation with the product, either in transportation, loading, or the processing of the extracted mineral, until it reaches the nearest port for shipping. We had the demand, but we didn’t have the solution to offer; now we are prepared, because we understand the business opportunities at hand.” Mol notes, “Use of Plant Simulation helps increase our profitability as well as improves the accuracy of services provided to both new and existing clients.”

Plans for continuous process improvement, new consulting services

Currently, the entire company routinely uses Femap with NX Nastran, which forms the core of the company’s systems as all the others have to be integrated with this solution. Mol is convinced the tool meets all the needs related to finite element design calculation, and that it can be updated as needed. For Mol, each update is extremely accurate, and always contributes to improving processes.

One of the Kotchergenko’s goals is to increase the number of licenses it obtains from Siemens PLM Software, while it continues to grow. The company’s plans also include offering new consulting services, such as the logistics analysis services enabled by Tecnomatix and, in doing so, it hopes to diversify its client portfolio. Mol notes that the systems also helped Kotchergenko in its International Organization for Standardization (ISO) 9000 quality certification process.

Download The PDF Here

Download The PDF Here

Plans for continuous process improvement, new consulting services

Currently, the entire company routinely uses Femap with NX Nastran, which forms the core of the company’s systems as all the others have to be integrated with this solution.

Mol is convinced the tool meets all the needs related to finite element design calculation, and that it can be updated as needed. For Mol, each update is extremely accurate, and always contributes to improving processes.

One of the Kotchergenko’s goals is to increase the number of licenses it obtains from Siemens PLM Software, while it continues to grow. The company’s plans also include offering new consulting services, such as the logistics analysis services enabled by Tecnomatix and, in doing so, it hopes to diversify its client portfolio.

Mol notes that the systems also helped Kotchergenko in its International Organization for Standardization (ISO) 9000 quality certification process.

Learn more about EDGE plm software:

EDGE plm software is a privately owned Australian provider of software solutions aimed at the Engineering and Manufacturing sectors. EDGE has been providing engineering design centric solutions since 2004 with over 500 customers across Australia and New Zealand. Typical solutions from EDGE would include the provision of software, maintenance, support, consulting and training services.

The EDGE software portfolio includes CAD, CAM, FEA & PDM solutions and EDGE fully supports and offers training and mentoring services on its entire portfolio. EDGE has been a business partner of UGS/Siemens since 2004. EDGE also configures and sells Dell hardware to assist our customers maximise their software investments. Read more about us…

Talk to us now!

Ready to start designing better? Our gurus are standing by.

We can help you to design better & faster in ways you never thought possible.
Talk to us now!

Join Our Solid Edge ST8 Training Courses:

EDGE plm understands the importance and training to the successful adoption of our products. However no two companies are the same and their training requirements often require a different or tailored approach which is why we have developed our flexible approach to training and mentoring.

We offer scheduled classroom-style training, bespoke training to suit customer requirements as well as one to one mentoring for any of our customers around Australia and New Zealand. Our Solid Edge training courses are created with the aim to get participants up to speed with current industry software quickly and effectively, giving you and your company the competitive edge.

Our experienced and qualified instructors run a range of training courses designed to suit your exact requirements, whether this consists of scheduled classroom training at our offices, customised courses delivered at your site, or online sessions.

Please call us on 1300 883 653 or send us an email [email protected] for our latest training schedule or to enquire about specialised training and mentoring services.

Solid Edge Foundation Part 1

This course is the follow on from the initial foundation course. It covers a foundation review, providing an opportunity to revisit and answer any questions from the initial course. It covers Drafting in [...]

Solid Edge Foundation Part 2

This course is the follow on from the initial foundation course. It covers a foundation review, providing an opportunity to revisit and answer any questions from the initial course. It covers Drafting in far [...]

Solid Edge Sheet Metal & Framing

The course focuses on sheet metal design tools, from the creation of simple sheet metal folded parts to the adding of deformation features and the subsequent creation of flat pattern blanks and 2D drawings. [...]

Solid Edge Surfacing

Delegates attending this course must have completed the foundation course or have been using Solid Edge for a minimum of 3 months. This course offers an introduction to the concepts of surface modelling, particularly [...]

Solid Edge Advanced Assembly

This course is designed for users that wish to improve their overall Assembly knowledge and students will be given instruction on how to make full use of the advanced assembly modelling functions for both [...]

Solid Edge Advanced Part Modelling

The course aims to improve the productivity of users when designing with Solid Edge. It includes a knowledge assessment test and sessions aimed at the correct approach to advanced modelling techniques for parts and [...]

Femap 101 Training Course

Talk to us to find more details and the next available course. This course designed to improve the productivity of users when designing with Femap. It includes a knowledge assessment test and sessions aimed at [...]

Read the latest news from our blog:

The End of the Powertrain Bias

Internal Combustion Engine vs. Electric Machine, this seems a famous game these days. Media, politicians, OEMs, car owners - all of them have their arguments and for one or the other reasons, they have their vision of where they place themselves in this fight. There is a lot of emotion and mistrust, misinformation and the claim of misinformation, aggression, and response. Diesel bashing here, pointing to insufficient range, burning batteries and recharging of plugin battery-electric vehicles with mobile ICE devices there.

 

The worrying thing to me is that even in our engineering world you get the impression that you have to choose and you have to choose apriori. It seems that even the world of powertrain engineers has become bipolar, you can either be pro-ICE or pro-E, you can either hug your internal combustion engine or tell the people ICE is dead, you can either tell people there is not enough Lithium on earth or oil, you say a V8 is music or it’s noise, you say too much NOx, Soot or CO2 stems from traffic or from power plants, there’s nothing in between. ICE engineers seem to fear someone takes away their beloved baby, E-guy seem to claim the work of thousands of engineers should go to the trash bin right away.

 

I call this the powertrain bias!

 

Now, honestly, like with many topics I have faced in my life I don’t know who is right and I would claim it’s not easy to tell that for anyone. We live in an increasingly complex world and there are many forces at work, legislation, customer expectation, politics, financial interests and finally human emotions. So, as an engineer, you try to rely on something that should give you the answer: pure science. Then you realize: even numbers can be bend, misinterpreted, miscommunicated. It’s clear that oil won’t last forever and that Lithium doesn’t. It’s clear that some may love the sound of an engine and others love the sound of silence. It’s like with anything – even in science - any party will come up with their study of proving they are right.

 

I truly believe it is this powertrain bias that is the most dangerous thing an engineer can jump onto in a world of incredibly fast-paced change.

 

That said, as powertrain engineers, we should share only one common goal and that is, make the move of a person from A to B as efficient, comfortable and – not to forget - enjoyable as possible thereby minimizing the negative impact on other people. I understand there are multiple trade-offs in this performance function and the weighting of the individual performance factors is a highly individual thing. Yet, we all should agree on one minimum consensus: As engineers, it is our job to push the limits of efficient, healthy, enjoyable and comfortable movement as far forward as we can without limiting ourselves in the design space by a-priori (bias) decisions.

 

 Blog_PowertrainBias_Teaser.png

 

Therefore here’s my call to all of you: Don’t get caught in that romantic vs. progressive powertrain trap! ICE guys, get over it and hug an electric machine, it won’t hurt. E-guys, step back and look at the amazing piece of engineering an IC engine effectively is. Let’s stay engineers in first place, push the Pareto front forward and make the best we can within the range of our expertise. Stay cool and fair when doing so. Get in touch with the other side and understand their reasoning. This is not a call for becoming emotionless, but it’s a call to reconsider what we should be emotional about: And that is creating great engineering value with our powertrain solutions. Here is my scientific study on the topic: In all times, 100% of all cars will have a powertrain!

Blog_PowertrainBias_InfoGraphic.png

 

So let’s all get together at the Simcenter Conference in Prague to celebrate the end of the powertrain bias. With two days of powertrain presentations from ICE to E, from system- through CFD simulation to test the table is all set. Siemens PLM is there to help you, with simulation- and test solutions on the ICE AND the E, there is no either-or in our portfolio, and hey, for those that are already in the middle of it, we have a solution for all you hybrids!

Together, we can make Prague the Woodstock of Powertrain Engineering. Looking forward to seeing you there.

 

With that, I leave it with a

 

“Peace!”,

the first powertrain-hippie on earth

 

 

 

[1] https://about.bnef.com/electric-vehicle-outlook/

[2] https://www.nytimes.com/2017/08/17/automobiles/wheels/internal-combustion-engine.html

[3] study by the first powertrain hippie on earth

 

 

Towards a unified Simcenter solution for electric machine design


Electric motor.jpgHaving a scalable model enables you to use your favorite system simulation tool for various simulation purposes, all along different design stages.

 

If I look in particular at electric machines, the possibilities are numerous:

  • Simple quasi-static machine models are well suited for power budget or energy management assessment.
  • Simple dynamic models are typically used for machine controls development.
  • Non-linear dynamic equivalent circuit models can give more insight into the motor behavior with high current or under fault conditions.
  • You can also include the machine spatial dependency to take into account the effects of the slots or the magnets shape. This will give you access to torsional vibration analysis and winding current distortions. It could help you validate a controller with a very realistic motor model at early development stages.
  • Co-simulation is an interesting solution in case you need to assess imbalance conditions or high frequency dynamics.Various levels of model complexity in Simcenter Amesim.pngVarious levels of model complexity in Simcenter Amesim

On the downside, setting up all those different models require much information which is not so easy to get. Datasheets provide partial data on the main machine behavior. To go further and to fully take benefit of the Simcenter Amesim Electric Motors and Drive solution, this is largely insufficient. To address this challenge, you can use Simcenter Amesim in combination with a finite element tool to obtain a reduced model. This is a major enhancement we focus on to reinforce this Simcenter Amesim solution.

 

Thus, Simcenter Amesim offers co-simulation capabilities with Altair Flux and JMAG-RT. Moreover,  recently released Simcenter Amesim 17 supports the import of reduced Simcenter SPEED models, as you can see in the following video:

 

 

 

What is the value for the Simcenter Amesim Electric Motors and Drive solution users? 

They can now smoothly pass from a finite element model to a system simulation model without spending hours trying to understand the different software conventions, developing or maintaining complex scripts.

   

The link with other Simcenter solutions such as Simcenter SPEED, Simcenter Motorsolve and Simcenter MAGNET will be continuously strengthened in the upcoming Simcenter Amesim versions. 

Neural networks & digital twins change the O&M in the wind industry

Today wind power represents 4.4% of the total generated power. By 2030, this is to increase up to 20%. The challenges for wind turbine manufacturers are wide-ranging: the aerodynamic performance of the blades, reduce weight, keep noise and vibration levels under control, ensure a durable design and improve its overall system performance.

 

The gearbox is the most critical part of the wind turbine. Either you send a technician up the turbine and do a manual check, or you attach sensors to the gearbox and monitor the results remotely on a computer. Both approaches work to anticipate failures and allow turbine owners to schedule for repairs. Obviously, this comes at a price. A high price. Can’t this be done more cost-effective?

 

Predicting the remaining useful lifetime of each wind turbine gearbox

 

Winergy, a global key provider for wind energy in Germany, teamed up with the Simcenter Engineering experts of Siemens PLM Software to estimate the remaining useful lifetime (RUL) of a complete wind park. Let’s be a bit more specific: 78 wind turbines – 35 SCADA channels – historical data stored over 4 years.

 

The Simcenter Engineering specialists tackled this issue by combining 2 approaches:

 

  1. Neural Networks
    The neural network was fed with information from different SCADA channels on the gearbox in combination with service data. Gearbox temperatures were defined as the most representative signals for a possible failure. Next, the neural network was trained on how a turbine reacts in healthy and faulty conditions. Winergy and Simcenter experts used the technique to accurately predict and detect failures early on.

  2. Digital Twin
    A digital twin makes the bridge between a virtual representation and the physical product. It helps to understand and predict product performance characteristics. Wind turbine modeling was combined with physical validation measurements in 1 turbine to validate the digital twin model. The digital twin model is fed with historic loads extracted from the SCADA in order to predict the remaining useful lifetime of the bearings and gear teeth in each gearbox.

 

This combined approach limits the need for physical prototypes, reduces development time, and improves the quality of the finalized product. 

 

Want to know more? Join us next week at the 11th Annual Offshore Wind Europe Conference & Exhibition in London, UK. Wim Hendricx, Simcenter Engineering expert for the Energy sector, will present this application case on November 28 at 9:20 AM.   

 

Wim-Hendricx-Winergy-quote.jpg

 

Interesting links:

 

Conference-banner.jpg

Is this the electric vehicle that we’ve all been waiting for?

Uniti One is an EV that just makes more sense.

I have to confess: I have caught the Uniti fever. It all started last April when Werner Custers and I shot a little movie at the Uniti headquarters in Lund, Sweden, a hip university town about 30 minutes from Malmo. At this point, Uniti Sweden was still oozing that start-up vibe, but, unlike other stories I have followed over the years, the idea of the Uniti One, well, to paraphrase CEO Lewis Horne, it just made sense. Needless to say, I was hooked.

 

 

You probably noticed that Uniti One is a different kind of car. In a way, it is more of a driving experience than an automobile. Sure, it is a completely wired EV with four wheels, but it is designed for the new era of high-tech car ownership that includes things like car-sharing, subscription programs and possibly delivery-on-the-spot autonomous programs.

 

Uniti One Fleet _ Photo by Karl-Fredrik von Hausswolff.jpg

 

Definitely “not reinventing the wheel”

But the cool thing about Uniti is that the team didn’t stop with just reinventing the EV. Everything was up for disruption in the design and development chain. Need your NX model in VR? Just run it through a gaming engine and put on the VR goggles to see what happens. Forget the formal post-design feedback groups. Just put the car in a well-known electronics retailer for a while and ask to-be consumers what they really think. This disruption meant that the team moved fast – really fast.

 

A key secret to the speedy design process was the fact that Uniti adopted the digital twin idea from day one. The working digital twin, based on NX and Simcenter, was one of the main reasons that a very small team of young engineers could prototype three vehicles in four short months.

 

So what’s next?

After its start-up success, the team knew they had to change gears, roll up their sleeves and work on a production-ready version of Uniti One. They also knew they needed some serious automotive experience on the engineering side. This is why Sally Povolotsky recently joined Uniti.

 

As the Uniti Vehicle Development Director, she is working with her team of experienced automotive engineers at Uniti’s new R&D center in the High-Performance Technology and Motorsport (HPTM) cluster located around Silverstone, the iconic British F1 Grand Prix track. With some serious street cred in the EV and automotive industry, Sally knows what it takes to get a car on the roads of Europe and beyond. (See the attached pdf for the full story.)

 

Uniti One _ small _ Photo by Karl-Fredrik von Hausswolff.jpg

 

Save the planet

So with Uniti One shaping up nicely and an Industry 4.0 digital factory vision in place, Lewis Horne and the Uniti team seem to have their new automotive ecosystem literally on the right track towards a workable and sustainable future. From our side, we will definitely keep our eyes on events in the UK and Sweden for you. To be continued…

 

P.S. By the way, if you caught the Uniti fever as well: you can pre-order yours online for 149 euro at uniti.earth.

 

 

 

 

 

Testimonials

“Using Solid Edge with synchronous technology I can actually do many more iterations now that I wasn’t able to do before. And because of that, the cost of the product comes down. The weight of the product comes down. The performance goes up. The warranty is a lot longer. Quality loves it. We love it. The profit margin loves it.”
John Winter , Mechanical Engineering Manager, Bird Technologies
“Siemens’ synchronous solver overcomes the order dependencies that have plagued history-based CAD programs by solving for the explicit and inferred constraints at the same time. The synchronous solver doesn’t use a history tree, but rather holds user-defined constraints in groups associated with the surfaces to which they apply…Ultimately, though, I believe this to be a transformative technology – one that represents an important inflection point in the CAD industry. If you hear someone say ‘that’s nothing new,’ don’t believe them. Synchronous technology is a big deal.”
Evan Yares, CAD Industry Analyst
“Synchronous technology breaks through the architectural barrier inherent in a history-based modeling system,” “Depending on model complexity and how far back in the history that edit occurs, users will see dramatic performance gains. A 100 times speed improvement could be a conservative estimate.”
Dr. Ken Versprille, PLM Research Director, CPDA
Talk to us now!

Ready to start designing better? Our gurus are standing by.

We can help help you to design better & faster in ways you never thought possible.
Talk to us now!