Femap Case Study- Medical Devices

Biotec

With Solid Edge and Femap, dental implant manufacturer opens up new markets.

The Smile System

Biotec Srl was established in 1998 as a subcontractor for the production of medical devices. Based in Povolaro di Dueville, near Vicenza, Italy, the company decided to invest in the development of an advanced dental implant program under its own brand.

“From a strategic standpoint, we realized that subcontracting was not a long-term vision, so we gathered the entire production under the Biotec brand and, in 2009, we undertook a new project to re-launch our business, involving all areas from technology to marketing,” says Dr. Andrea Peloso, managing director of Biotec. “That’s how the ‘btk’ brand was born, propelling Biotec into the business of cosmetic surgery and dental implants. With its three letters, the new brand maintains an association with the company’s name and, at the same time, sums up its core values: biocompatibility, technology and know-how.”

Fittingly, the company’s tagline is “the smile system™.” Biotec employs about 40 people, and has doubled its headcount in the last three years. Sixty percent of the business comes from Italy and the rest is generated from Southern Europe, the Middle East, North Africa and Eastern Europe. New markets are opening at regular intervals from Libya to Russia, often requiring long certification procedures before products can be marketed. In some cases, the waiting period can be up to two years.

“Powerful, intuitive and fast”

A dental implant is not a simple product: It has small dimensions, needs to perform multiple functions and is used by demanding doctors.

“In recent years, doctors have shown increasing interest in design,” says Peloso. “They know about technology and ask to be involved. It’s great to have their help developing high-tech and innovative products provided that we have tools that enable us to design concurrently with physicians, showing them the conceptual prototype of an implant as well as the final product.” To meet these new requirements, Biotec management decided to adopt product lifecycle management (PLM) technology in 2010, and chose Solid Edge® software from Siemens PLM Software. Solid Edge provides advanced computer-aided design (CAD) technology for accelerated product development, faster revisions and better data re-use.

“We selected Solid Edge because it is powerful, intuitive and fast,” says Igor Piccoli, research and development (R&D) manager at Biotec. “Many design tools require long preparation and setup, whereas we often design entire product families, so we need a very dynamic and flexible approach. We must have all the features of parametric CAD in intuitive and easy-to-use software. Solid Edge fits that description.”

Deploying the right tools

To develop products, the Biotec team collaborates with a number of medical and industry professionals, who represent valuable sources of experience, information and documentation. The company also partners with universities, especially their bio-engineering and the medical/surgery departments.

“We collect needs and requirements from all the partners, and they are recorded in one or more specification sheets and then transferred to our product development team,” says Piccoli. “These specifications enable us to analyze technical feasibility and provide the foundation for initial sketching and drafting on the PC (personal computer). “Until a few years ago, we used 2D software, which was inadequate for developing assemblies; it didn’t allow is to take into account proper matching and interference among parts. The final output was a two-dimension drawing, which had little practical use.”

In 2010, things changed with the adoption of 3D CAD, which sped up initial sketching and enabled Biotec to analyze the feasibility of a solution in detail. “The values of technology and know-how are hot-stamped in our btk brand, and we can support such values only by selecting the best tools and partners,” says Peloso. “On one hand, we expand our knowledge through official partnerships with universities and key industry players; and on the other hand, we deploy tools that help our engineering and manufacturing staff develop and design specific products.

“It is essential for us to have a common tool in order to interact with all applications and processes – design, production and surgery.” That’s where Solid Edge comes in.

Marking a turning point

With Solid Edge, Biotec engineers can utilize a unified language inside and outside the company from early in the development process. The technical drawings, which require specific knowledge and expertise, have been replaced by the mathematics of 3D models. From such models, the 2D drawing is generated. The 3D model is the starting-point for all operations downstream.

“In the past, the 2D draft was handed out to the machine operator and converted into a machining program, with consequent issues in terms of cycle time and interpretation,” says Piccoli. “Now, with a unified and advanced technology source, we have eliminated all transitions, conversions or translations that caused an inevitable waste of time and input errors.”

The adoption to Solid Edge was a turning point for the company’s renovation and expansion project under the new btk brand. Before 3D was deployed, using solids-based design versus surface modeling, Biotec manufactured mechanical pieces rather than anatomic parts.

“Without an accurate digital model, we couldn’t achieve specific shapes and curves on machine tools,” says Piccoli. “Using Solid Edge, we can translate model geometry into machining programs through our CAM (computer-aided manufacturing) tools. With this approach, we have achieved part compliance, virtually eliminating idle time on the machine tools. As we machine one work piece, we prepare another program offline, which enables virtually uninterrupted production.”

Biotec found that with Solid Edge, the company is able to effectively collaborate with surgical teams, who now receive the implant geometry directly from the manufacturer to program and guide operations in the dentist’s office. This is possible because Solid Edge can handle a wide range of data formats, including Parasolid® software, IGES, STEP, DXF and DWG.

“The clinic provides the patient’s 3D model, which we integrate with our dental implant to simulate and plan the surgical operation,” notes Piccoli. “The 3D geometry is also used to prepare documentation, deliverables and the physical prototypes of our implants.” In this scenario, the synchronous technology of Solid Edge helps Biotec engineers suppress or simplify complex features or geometries very quickly, without having to re-build the history of the model. With synchronous technology, users no longer have to choose between constraint-driven or history-free modeling, no longer have to be a programmer to re-use a model, and no longer need to worry about using data from multiple CAD systems.

“The benefits of Solid Edge with synchronous technology are amazing,” says Piccoli. “We also manufacture some mechanical equipment internally, and the use of synchronous technology delivers huge benefits when we design sheet metal for the support of parts to be submitted for heat treatment. We have created shapes that would be hard to imagine utilizing a traditional environment.”

Download The PDF Here

Download The PDF Here

Femap serves as the starting point

To implement a full-featured design system, Biotec uses Solid Edge with Femap™ software, finite element analysis (FEA) technology from Siemens PLM Software.

When designing very small parts like the pins of dental implants, an accurate analysis of stress and load distribution on the mechanical components and on the jaw bones is needed.

“Performing an analysis is mandatory, unless you are willing to spend a long time on mechanical tests, which would be difficult due to the tiny dimensions of our products,” notes Piccoli.

Today, Femap is frequently the starting point for the design cycle at Biotec, not only for mechanical engineering, but also for the identification of the geometric shapes that guarantee the best fit for the patient’s anatomy.

“We try to collect as much information as possible to bring our simulation as close to the real thing as we can,” says Peloso. “Recently, we faced the challenge of having to make an ultra-short implant.

Femap played an essential role as short implants don’t seem to offer adequate load distribution at first sight.

The simulation with Femap was confirmed by physical tests and indicated that with accurate design and suitable geometries, even better load distribution can be achieved with few spirals.”

Part of the team

Biotec’s designers are supported by the Siemens PLM Software partner CCSteam, the value-added reseller (VAR) that worked with them throughout the implementation process.

“I have been in touch with CCSTeam for eight years, including the period when I worked in a different company,” says Piccoli. “When we selected the design and development technology, we also considered service and support.

CCSTeam has always been very supportive; whenever we have a problem, they respond to our needs and take action in real time.

“For instance, during the latest training course, we found some critical concerns that were resolved immediately, because we had established a very efficient input and feedback process that delivers quick and practical solutions.

We think of the CCSTeam staff as part of the team, rather than suppliers.”

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…

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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 [...]

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Simcenter Amesim 2019.1: top 4 reasons to upgrade


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We are proud to introduce Simcenter Amesim 2019.1

 

With this version, we accelerate the software delivery model to provide access to new enhancements every 6 months, while maintaining focus on the technical excellence.

 

The latest release helps you build digital twins faster and earlier in the design cycle by democratizing access to system simulation. By further extending Modelica® support and integration with other Simcenter solutions, version 2019.1 enables you to set up a unique toolchain throughout various development phases and teams.

 

Among many other enhancements, new capabilities in Simcenter Amesim 2019.1 focus on the 4 main areas:

  • vehicle electrification,
  • aircraft systems performance engineering,
  • controls engineering
  • system simulation efficiency and ease of use.

Find out top 10 functionalities in 3 minutes:

 

 

Let us walk you through the major new capabilities in these 4 areas.

 

 #1 Vehicle electrification

 

  • Simcenter Motorsolve model import
  • Simcenter Battery Design Studio import for equivalent circuit battery models
  • Ready-to-use air cooled battery pack demonstrators

Many industries, such as automotive, aerospace, off-highway and marine, are making the shift toward e-mobility. After introducing the capability to import from Simcenter SPEED in the previous release, the latest Simcenter Amesim version reinforces its integration with other Simcenter solutions that support electrification challenges.

 

Simcenter-Amesim2019.1-Simcenter-Motorsolve-import.png

 

Using the same app for linear and nonlinear variants, you can import permanent magnet synchronous motor (PMSM) parameters from Simcenter Motorsolve to test your machine in the vehicle context earlier in the design cycle. 

 

Find out more in this blog post.

 

 

Moreover, battery equivalent circuit models from Simcenter Battery Design Studio can be imported into Simcenter Amesim 2019.1 to obtain a shared battery model. You can visualize parameters of the imported model before using them in Simcenter Amesim. For more details, read this article

 

New demonstrators allow you to easily re-use the complete battery pack model based on geometry, identify critical temperatures for controls design, apply a documented methodology for model reduction as well as integrate the reduced battery model into your vehicle energy management analysis.

 

 

#2 Aircraft systems performance engineering 

 

  • Upgraded CAD import capabilities for fuel systems
  • Enhanced postprocessing apps and scaling tool for aircraft engine and gas turbine
  • New rotorcraft engine demonstrators with the recuperated cycle and series hybrid variant

To support the aerospace industry, the latest release of Simcenter Amesim comes with upgraded CAD import Simcenter-Amesim-2019.1-CAD-import.PNGcapabilities that enable users to easily create rib submodels and generate all the required tank and rib data files. Therefore, you can drastically reduce the time required for creating data files and organizing your output files. Moreover, the new rib submodel allows users to account for flowing areas, speeding up parameterization while improving accuracy.


By using the enhanced postprocessing apps and scaling tool when exploring new gas turbine configurations, users can easily derive scaled performance maps starting from reference maps and looking at the surge margin.

 


Users can benefit from two rotorcraft engine demonstrators that are derived from a validated engine model. The first derivative is a recuperated engine cycle and the second is a series hybrid variant assessed during an oil and gas mission.

 

 

#3 Controls engineering

 

  • Extracting a nested signal bus
  • New tool for proportional–integral–derivative (PID) controller calibration
  • New real-time components for thermal and valvetrain systems

With the industry shift towards connected, software-intensive, complex products, Simcenter Amesim 2019.1 offers a large set of new or enhanced capabilities for controls design and validation to enable you to simultaneously optimize the mechanics, electronics and software as an integrated system.

 

You can now use signal buses to manage data transfers between physical subsystems. This redesigned capability facilitates visualization of all data flowing through any given bus component and simplifies information propagation across nested buses.

 


In addition, the latest release comes with a new tool for PID controller calibration, which is associated with two demos for speed and position control. Hence, you can visualize closed-loop step response and check the robustness with stability margins. 

Whether you are a system designer who just wants to quickly make the PID controller work, or a control expert interested in stability margins, find out the step-by-step process in this article

 

 

Additionally, new real-time components of thermal and valvetrain systems will allow you to greatly reduce CPU time and run hardware-in-the-loop (HiL) simulations.

 

#4 System simulation efficiency and ease of use 

 

  • New Modelica compiler and full Modelica Standard Library (MSL) v3.2.2 support
  • Model conversion from hydraulic to thermal-hydraulic domain
  • Two-phase flow thermodynamic cycle analysis app 
  • Valve builder

To boost the efficiency of your system simulation activities, Simcenter Amesim now offers you full MSL 3.2.2 support and greater openness thanks to Modelon’s compiler, which is integrated into this Simcenter Amesim version. You can easily couple Modelica and native Simcenter Amesim library components: Using Modelica Editor enables you to automatically import Modelica models into Simcenter Amesim and get the best of both.

 

 

Moreover, existing hydraulic models can be converted into thermal-hydraulic models with one click while maintaining model structure and parameters. 


With a new app for two-phase flow thermodynamic cycle predesign, within just a few seconds you can assess steadystate cycle performance by adapting your design points from predefined cycles. Watch how this app works in the demo here. 


Finally, the latest improvements in valve builder functionality allow users to create pilot-operated directional valves and connect them to the hydraulic or pneumatic pilot stage, as well as integrate nonreturn valves into the design of your directional valve to avoid unnecessary volumes and dynamics.

 

 

Stay tuned

 

Those are only a few of the major capabilities introduced to Simcenter Amesim 2019.1. For instance, a large set of capabilities has been introduced for shipbuilding as well as for internal combustion engine vehicles helping automotive manufacturers to meet the RDE standard. 

 

Want to know more?

- Don't miss our blog posts and how-to articles

- Contact your local Siemens PLM office

- Upgrade your Simcenter Amesim license

 

 

Turning up the heat: ensuring efficiency in high temperature processes

Humans have used fire for thousands of years. From cooking meat to make it easier to eat and digest, to firing pottery to make watertight containers, to managing grass or moorlands through controlled burning, fire has been a vital tool for many aspects of human existence. These days, combustion is used in many industrial processes. These may be less visible to the general public, but are essential to produce materials and products used by everyone on a daily basis. Coal burners, dryers and kilns, and steel furnaces are just some of the areas where high temperature processes and combustion are used.

 

GettyImages-178607562.jpgIndustrial gas furnaces are used in many chemical processes

Today, process engineers must ensure these high temperature processes are as efficient as possible: inefficient processes lead to costly and excessive energy consumption, with the potential of excess emissions and non-optimal product yields. The use of Computational Fluid Dynamics (CFD) to virtually investigate high temperature processes is now an established design tool in many industries, including the process industry, but are you using it to its full potential?

 

This on-demand webinar takes a look at recent advances in simulation capabilities in Simcenter STAR-CCM+, which make simulation and optimization of combustion processes even easier. Our technical experts will cover:

  • Recent advances in CAD maneuverability for geometry setup
  • Different reaction modeling approaches available in Simcenter STAR-CCM+
  • Combining CFD and design space optimization for intelligent geometry optimization

HighTempSim_1980x1080.jpgOptimize burner geometry via simulation

Successful use of simulation is enabling process engineers to reduce design costs and create innovative, efficient designs. Join us to learn more, and discover how CFD can help to optimize your high temperature processes.

Simulation Automation

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There’s no doubt about it: simulation is delivering value in product development.

 

Some are avoiding multiple rounds of prototypes. Some are reducing the cost of goods in products. Some are making designs both lighter and stronger simultaneously. Some are coming up with more innovative designs that work functionally. Overall, many companies are reaping the benefits of applying simulation early and throughout the design cycle. And if there are any issues with simulation, it’s that managers seem to want more.

 

So how can an engineering team get more productivity out of their analysis tools? One clear answer is automation. It removes repetitive tasks from users hands, allowing them to concentrate on the value-added aspect of simulation. It also promotes standard best practices across a company. Here are some capabilities that do just that.

 

Macros

 

One of the most simple, yet valuable, ways to automate a simulation process is to leverage macros.

The idea is straightforward. A user can record a sequence of user interface interactions, such as selecting menu options or entering values. This sequence of actions is then mapped to a trigger, often a specific combination of keyboard keys or mouse buttons. Then, whenever the users want to initiate that sequence of actions, they simply hit the trigger.

 

This approach provides the most value when applying repeated actions within the same model. It reduces repetitive work for the user. However, it also eliminates any potential human error likely to occur in a heavily repeated action. Furthermore, executing macros happens very quickly, far faster than the sequence of actions could be executed by hand. Lastly, macros are an opportunity to apply analysis standards across a company.

 

In all, macros allow users to avoid repetitive work, reduce human error, accelerate their simulation processes, and distribute analysis standards.

 

Templates

 

Where macros automate repetitive tasks within a simulation model, analysis templates automate entire sets of tasks by offering an accelerated starting point.

 

Analysis model templates include standards that should be included in all simulations of that type. For some cases, a template might include a parametric model of a pump that has already been meshed to the correct level of detail. For other cases, a template might include standard loading cases based on data collected from physical tests. For yet others, a template might encompass all of the standard materials and their properties that are officially approved by a company.

 

Templates, however, do not just apply to entire models. Loads and boundary conditions can be applied as templates. Solver selections, method selections, and their corresponding parameters might be included in a template.

 

The value in templates is also straightforward. Templates simply allow users to avoid creating everything from scratch. They start their process several steps farther than a clean sheet. But just as importantly, templates are another way to distribute best and standard practices within a company.

 

Simulation Workflows

 

A different kind of automation builds on top of templates. Simulation workflows apply the concept of workflows to simulation.

 

The idea here is that each analysis template requires several inputs to be run. Once those are provided, the simulation can be solved, producing a number of outputs. With simulation workflows, the outputs from one analysis is fed as inputs to another analysis. This chain of simulations can be used to connect disparate types of engineering physics that are interrelated. For example, a fluids dynamics analysis of a wing would yield loads that are then passed on to a structural analysis of the internal stringers. In another example, a complex combustion analysis of a turbine engine would pass temperature fields to a structural analysis of a turbine blade.

 

Such simulation workflows can be used to automate very complicated analyses, but they can also provide guidance to novice users as well. They simply ask for standard inputs and produce standard outputs that can be interpreted.

The value here is more advanced than in other cases. Expert users can automate an entire complex simulation process. Novice users get guidance on how to complete a range of analyses, ranging from the simplest to incredibly complex. Both use cases deliver value.

 

Application Extensions

 

The last, but not least important, means of automating simulation is through application extensions.

Here, a company will build out new functionality by coding software extensions to an analysis application. This is done using an Application Programming Interface (API) toolkit, which often is an externally available version of the code used to build the analysis application by the software provider.

 

This toolkit can be used to build brand new functionality on top of the solution. This functionality can dramatically automate simulation processes and procedures. It can add completely new interfaces such as dialog boxes and menus. It can tweak or modify how the application prepares models and passes them to solvers.

 

The toolkit can also be used to integrate with specialized homegrown simulation tools. Doing so allows data and other information to be passed back and forth between the applications. This is applicable when the company is dealing with custom calculations, ranging in complexity from programmed spreadsheets to their own internal software.

 

The value here is strong. Companies that seeking new ways to automate the simulation process has an opportunity to build it the way they want with the API. Companies with custom applications for specialize calculations can wrap their work into the simulation software.

 

Recap

  • Companies that are looking to get more value out of simulation can look to automation, which comes in a variety of flavors.
  • Macros allow users to record and then execute a sequence of actions through a trigger. This is of value to users repeatedly applying the same actions within an analysis model.
  • Templates allow users to accelerate their simulation process, applying and reusing prior analysis work.
  • Simulation workflows stitch the output of one analysis to the input of another, enabling the automation of several interconnected simulations.
  • Application extensions add new capabilities to existing tools by coding with the software’s API toolkit. This is an opportunity for automation or integration with a company’s custom analysis application.

Automation can provide a lot of additional value to companies already leveraging analysis. What has your experience been with simulation automation? Let me know your thoughts in the comments.

 

Siemens PLM provides a range of capabilities that directly address automation of modern simulation processes. For more details on how FEMAP addresses these needs, download our complimentary eBook.

Electric vehicle NVH challenges: The mindset and tools you will need

 

 

The question of the day is – would you buy an electric vehicle (EV) today?


Maybe. Although, during the upcoming years, you are more likely to answer: “Yes!”. Let’s face it. Avere, the European association for electromobility, estimates that there are already 1 265 441 passenger electricity powered cars driving around the Europe, using 161 426 public charging points. And both numbers will increase in near future. Countries world-wide are introducing the mobility visions promoting and supporting electric cars (e.g. Electromobility in Germany: Vision 2020 and Beyond,etc.). According to Bloomberg New Energy Finance, 55% of all new car sales and 33% of the global fleet will be electric by 2040.

 

Electric car development hits bumps in the road


However, there are also some important bottlenecks that cause reluctance to switch to electric cars. One of the most important is the driving range of the electric vehicles. The EV development teams strive to reduce the vehicle weight to increase the driving range. But reducing weight of the vehicle chassis and body is not given! Finding the optimal balance between vehicle weight and performance attributes, such as durability, NVH, ride and handling, becomes more important than ever. Yes, you need to increase the driving range, but on the cost of reduced durability performance that could lead to earlier vehicle damage. Also, reducing vehicle weight can deteriorate handling performance. It means your vehicle may lose stability when performing certain driving maneuvers.


Here is another engineering dilemma - how do you balance the vehicle body stiffness while keeping up with the right NVH characteristics? At Siemens Simcenter, we recognize these challenges and we aim to provide our customers with solutions for different vehicle development teams to tackle all these problems and help to find optimal lightweight vehicle conditions without loss in performance.
What are the other electrical cars development shifts?

 

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Electric vehicle noise in the spotlight

The trend towards electrical vehicles poses both challenges as well as opportunities for car developers. The absence of the internal combustion engine (ICE) changes the signature of the interior cabin noise dramatically. The most obvious game changer is the fact, that the withdrawal of the traditional powertrain unveils the other noise contributors or make them more audible and prominent. In 2011, G. Goetchius (Leading the Charge – The Future of Electric Vehicle Noise Control, Sound & Vibration) estimated the noise contributors in ICE vehicles and predicted the noise morphology in the electrical ones. According this publication back then, in the traditional ICE vehicles, the biggest noise contributor is the powertrain followed by the road, wind and ancillary system noise. While in electrical vehicles, the road noise and wind are the most dominant noises. And what’s more, the new structure reveals noises that were originally masked by the combustion engine (such as ancillary system - whine gears, steering rack, air conditioning system, wipers, ABS module, pumps etc.).

 

EV vs ICE vehicles NVH challenges.jpgEV vs ICE vehicles NVH challenges

 

Without any surprises, the structural changes in electric vehicle noise will need new engineering approaches to optimize the NVH performance with appealing sound quality.
Here are three strategies you should focus on to make the ride in your electrical vehicle to sound as a symphony.

 

Act on the present noise source

Firstly, you may need to find the noise root cause and act on it. Depending of the origin of the noise source, different NVH analysis techniques are required. Reducing wind noise, for instance, happens most effectively in wind tunnels. These allow to effectively isolate the wind noise from other noise sources and find the most effective measures to reduce this annoying source. However, as these tests are extremely costly, it is crucial to test with extremely efficient measurement techniques. The use of industrialized testing processes based on large beamforming arrays that allow identification of the exterior noise sources, and use this data to decide what to test next, becomes more and more a reference.

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Road noise needs to be handled with effective and reliable techniques, such as transfer path analysis (TPA). This technique allows to pinpoint the noise critical paths on the chassis and car body contributing to the interior noise. To be able to handle the complexity and closely spaces loads of suspension systems, more advanced techniques such as strain-based TPA becomes another necessary building block.

For other auxiliaries, the key information can be provided by wide toolset of NVH tests and analysis techniques. And again, for many of these subsystems the traditional transfer path analysis (TPA) can help to identify the component or structure causing the noise issue.
Acting on the noise source, however, does not always provide solutions early enough. In case it is not too late in the vehicle development cycle, the responsible team can proceed with component design adaptations and improvements. But in real life, there are situations, when design adaptations are impossible or cause conflict with other attributes (such as weight, durability, etc.). Or often, the results of the TPA leads to pragmatic and expensive additions of damping and trimming to the vehicle. The disadvantage is that damping material increases the vehicle weight - which will directly reduce the vehicle range, add extra cost and prolong the vehicle assembly. What’s more, this strategy is limited and doesn’t offer an optimal solution in all the cases.

 

Master the electric vehicle sound quality including active sounds

There is good news. The shifted noise structure of the electric vehicle brings an option to add new noises. This opens an opportunity to create new and pleasant driving experience for your customers. From this perspective, sound quality engineering is the key tool to develop high-performing sounds within the vehicle. This technology is currently gaining ground in the automotive industry.
It all starts with the acquisition of realistic sound data, including for instance binaural recording. Secondly, to be able to analyze the acquired sounds, you can proceed with audio replay, using different filtering and analysis through different sound quality metrics. And finally, you shall organize a Jury testing, which is based on subjective audio perception. Sound quality engineering combines objective analysis metrics with subjective analysis. This strategy will provide you with detailed insights to find answers to questions like – what do the customers like to hear? What sounds do they prefer in different corners of the world?

 

Simcenter Testlab Neo Jury testing.jpgSimcenter Testlab Jury testing for EV NVH development

Another application, where sound quality is currently gaining importance, is the exterior artificial sounds generated by the acoustic vehicle alerting system (AVAS). This system warns pedestrians of an approaching vehicle. Developing new exterior warning sounds is something of a novelty. Different countries around the globe currently impose new certification requirements for electrical cars. Car producers need to design and certify warning sounds that the electrical cars must exceed traveling at low speeds.  Anc at the same time, automotive OEMs are highly concerned about the perception of the new vehicle sounds. Designing new artificial sounds that reflect the brand DNA requires the right toolset for sound quality engineering.

 

Speed up vehicle development time by blending simulation and testing together

To keep up with the market, automotive OEMs need to react fast and develop advanced vehicle models rapidly. This creates the need to take control of the vehicle NVH performance as quickly as possible, earlier in the development cycle ever. This translates into the demand to be able to predict the component or subsystems behavior before integrating them into the vehicle. In practice, this also leads to introduction of new technology that merges the simulation and physical testing together throughout the vehicle development cycle. While in the past simulation and testing where two separate worlds, the future evolves more into hybrid approaches. This concept can drastically impact and improve the development time.
Component-based TPA is one example (here you can find a related white paper). The compelling combination of test and simulation enables the NVH engineers to predict the final vehicle NVH performance before assembling the first full prototype. In a nutshell, this technology enables you to predict a component or subsystems behavior prior to integration. Consequently, it enables the dream to create a virtual vehicle prototype by assembling different components (e.g. electrical engine, suspension system, body, etc.). Component-based TPA is very powerful concept not only because you may get an accurate prediction of the vehicle NVH behaviour in development stage, when implementing design improvements is still easier. But also, the component-based TPA enables you to work with a standardized platform to virtually assembly countless vehicle variations with much lower time investments.


Another example is the trend to combine 1D simulation and test in a more hybrid approach, so called Model-based system testing (MBST). With MBST technology, the use of physical component in combinations with 1D models becomes more and more the industry standard. 

 

Simcenter EV NVH testing.jpg

 

These are the key trends in NVH testing that will drive electrical vehicles development in near future. Besides, it is important to realize, that is not only the product changing. It is also the OEM’s frame-work that will change soon too. There will be new requirements and expectations that team members will have to fulfil and skills the engineers will need to learn.
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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
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