The software is an application-specific extension to the Opera electromagnetic simulation package. It provides a front-end to the simulator that speeds design entry by means of Wizard-style dialog boxes. Users select the style of motor or generator they want to design from a library of all common types, including induction, brushless permanent magnet and switched reluctance motors, and synchronous motors or generators. Then, dialog boxes allow you to enter parameters to define mechanical geometry, material properties and electrical data, and the FEA model is automatically created.

The use of parameterized models and the ability to load and modify previous designs have made it possible for users to perform ‘what-if?’ design investigations. Cobham has integrated a unique optimization tool that makes it simple for users to find the best solution across the design space. While auto-optimization tools are not new, they usually require manual intervention if the globally optimal solution is to be found, and the simulation times involved often make this impractical. The Optimizer selects and manages multiple goal-seeking algorithms including stochastic, descent, particle swarm, and Kriging to eliminate the need for manual intervention.

Setting up an Optimizer run from the Machines Environment is easier. Because most FEA simulations can take as little as a few seconds, the integrated software makes it possible to thoroughly explore the design space. Thousands of simulations can typically be executed within hours, making the perfect solution achievable for all users – without expert assistance.

 The 2D Machines Environment has an extensive library of rotating machine design styles and design components. However, if there are still any unusual features that need to be incorporated in designs, users also have open access to the scripts that generate the models, and can modify them at will to automate proprietary motor and generator design concepts. A library of common material properties is also included in the design software. Again, if users employ any special materials, such as an unusual grade of steel for laminations, then a new menu item can be created. Cobham will also generate custom scripts for users on request. A 3D version of the Machines Environment is available.

Cobham Technical Services

www.cobham.com/technicalservices

3D CAD Tips

Fender chose SolidWorks CAD software – first deployed on the JACKSON and FENDER STRATOCASTER lines and now used companywide – because it is easy to use, includes advanced surfacing capabilities, and integrates well with CAM applications. By deploying SolidWorks, Fender cut production time by 20% across the board, reduced the time required to shape guitar necks by 30%, eliminated many secondary operations, and increased production throughput with improved tooling.

SolidWorks

www.solidworks.com

3D CAD Tips

Concept2 was founded by Dick and Peter Dreissigacker in 1976. Fresh from Olympic training, the two brothers designed and created the first composite carbon fiber racing oars, and went on to prototype the world’s first wind-resistance indoor rower out of old bicycle parts. The Dreissigacker Racing Oars are now used by more than 70% of the rowing community. The Concept2 Indoor Rower has been redesigned and upgraded four times since the Model A was introduced in 1981. Today’s Model D and the recently introduced Model E both build on Concept2′s 26 years of experience in designing and manufacturing rowing machines.

“KeyCreator is integral to our design and manufacturing process,” said Jon Williams, chief engineer of Concept2. “The software enables us to quickly develop, test and iterate conceptual models. KeyCreator makes it easy to communicate those design ideas accurately to our supply chain partners.”

Responding to both customer feedback and rising manufacturing costs, Concept2 decided to evolve its overall rowing system. One area identified for a major design change was the flywheel enclosure. Now in its fifth generation of indoor rowing machines, Concept2 has moved the flywheel from an original unenclosed bicycle wheel to the current three-piece injection molded housing available in today’s Model D &  Model E. Concept2 engineers took advantage of KeyCreator to design current advancements into the Model D.

“When our customers requested greater battery life in the rowing machine monitor, Concept2 designed an efficient, non-contacting generator that powers the monitor as the machine is being rowed.  And when customers wanted a quieter flywheel mechanism, Concept2 used KeyCreator to experiment with different shape housing designs that delivered significant noise reduction,” added Williams.

Accurate exchange of CAD data is vital to Concept2. The Concept2 Indoor Rower has become the standard across the rowing community in part because of the high degree of comparability between scores achieved on individual rowing machines – ensuring that 2000 meters rowed on one Concept2 machine is exactly 2000 meters on another. This standardization has proven significant during races, such as those at the CRASH-Bs (indoor rowing championships).  The accurate exchange of CAD data between Concept2 and its partners guarantees standardization, regardless of which manufacturing plant or assembly plant is building a rowing machine or producing any part.

Concept2 is dedicated to providing the most innovative rowing products and programs to its customers.  That commitment depends on imagination and advancements in technology developed by the engineers using KeyCreator.

Kubotek

www.kubotekusa.com

3D CAD Tips

The team originally planned to build the sculpture with glass fiber composite, but fire codes would have required additional engineering studies to prove it was flame retardant. Additionally, the building was going to be largely enclosed by the time the sculpture was ready for installation, making it impossible to bring the sculpture, which is 14-ft wide and more than 16-ft high, into the building in one piece.

Argent had designed the sculpture as a form composed of hundreds of flat triangles. “The piece lent itself to aluminum as long as we could figure out how to fabricate the pieces,” said Bill Kreysler, who founded the fabrication company in 1982. Working with Argent’s digital renderings, Kreysler’s team translated the design into Rhino software, creating what he calls a semi-monocoque structure with a double-skin of thin aluminum on a thin-ribbed interior aluminum frame. The decorative surface is composed of 1,446 CNC-cut triangles with side dimensions ranging from one in. to three ft. Etched with a numbering system, the triangles were placed using laser-projected grid lines.

“I think that one of the things that is often overlooked in this digital fabrication world is that there’s a sense that because computers are controlling the process, the human element is reduced, but in many ways it’s increased,” said Kreysler, who limited the number of people working on the piece to ensure consistency.

The rabbit’s interior structure was assembled into 14 pieces of varying diameters in the shop, then transported to the airport for assembly. The exterior aluminum triangles are textured with crushed glass to create a velvet-matte surface and float 1½ in. above the interior shell with aluminum standoffs.

Even in the light-filled atrium space the sculpture’s suspension system appears minimal. The concentrated loads coming from seven custom wire rope suspension cables with swage fittings are received by the rabbit’s internal steel armature. Aluminum transverse members then distribute these loads from the steel armature to the monocoque aluminum shell.

Unveiled on October 6, 2011, the new $1.3 billion airport addition is the largest construction project in Sacramento’s history. The rabbit is the centerpiece of the 14 art installations—more than $6 million worth—commissioned by the city’s Metropolitan Arts Commission and planned for completion in the coming years.

Rhino

www.rhino3d.com

3D CAD Tips

“In between my freshman and sophomore years, I became irritated at how cumbersome it was to rotate a model using a traditional mouse. I thought I could get a trackball mouse and program it so when I rotate the mouse it rotates the part on screen. That’s when I came across 3Dconnexion. I ordered their SpaceNavigator right away,” said Ellis.

In 2009 during his senior year, Ellis began researching an aerial robot competition. Five days later, he started the Michigan Autonomous Aerial Vehicles (MAAV) team with 15 members. Within one week, the team kicked off their first quadrotor design for the International Aerial Robotics Competition (IARC). At the end of the first year, MAAV successfully built two quadrotor vehicles capable of manual flight.

“The IARC challenge is to build a flying robot of any type you want. We chose a four-rotor helicopter that can fly through an unknown building completely on its own,” added Ellis. “There can be no communication with the device. The robot follows signs, must avoid detection from security cameras, locate a room, retrieve a flash drive, drop off the decoy, and get out in less than 10 minutes. No one has completed the mission yet, but we are one of the better teams competing. It’s the most challenging mission to date.”

When Ellis started the team, he wanted to get a 3Dconnexion 3D mouse for everyone. “It makes modeling CAD designs so much faster and easier,” said Ellis. IN addition, the team quickly realized trying to fly the quadrotor with a standard joystick didn’t mimic the movements very well and wasn’t intuitive enough for the user. A 3D mouse could mimic the exact movement of the robot. It was at this point the team decided to take matters into their own hands and control flight with a 3D mouse.

“We use the 3Dconnexion SDK to develop a driver to control the quadrotor with the SpaceExplorer and it quickly allowed us to control pitch and roll, zoom control height, and rotation control yaw,” noted Ellis. “In addition, The SpaceExplorer’s Intelligent Function Keys control other commands such as on/off and camera control.”

Today, Ellis is still the head of the MAAV team while also completing two masters in aerospace engineering and robotics. He continues to use CATIA for all of his designing both for the team and his class projects. He also works at a student lab training other students involved in competitions in CAD modeling and machining.

He uses the SpacePilot Pro. “A 3D mouse allows me to easily interact with the model while clicking and drawing in 3D at the same time,” he said.

3Dconnexion

www.3dconnexion.com

3D CAD Tips

The company’s product line includes escalators, moving sidewalks, passenger elevators, sightseeing elevators, and freight elevators. These are produced on some of the most advanced manufacturing equipment in China, including a Salvagnini fully automatic flexible sheet metal production line. Major projects in China include the National Centre for the Performing Arts, Capital Airport and the National Stadium (the Bird’s Nest).

Elevators are electromechanical systems that must fit perfectly into the customer’s building; they are shipped as bulk components and installed at the customer’s site. Thus, most projects are one-off. Management set a goal of standardizing portions of the design process as a way of boosting productivity.

Another factor that previously hampered productivity was the use of multiple CAD programs that could not communicate with each other. “Giant KONE boasts a large number of designers of different ages and different levels of expertise, and their design software varied widely,” says Li Yong of the company’s Information Management department. “Problems were often encountered in upstream and downstream communications and as drawings were modified.” The company also lacked a comprehensive digital solution for managing its operations and product data.

Giant KONE’s original CAD software was 2D, which was adequate when the company had fewer orders, but as the workload grew, the drawbacks became evident. “Sometimes, a design had to be started again from scratch, just to make a simple 5-millimeter change in the dimension of a part,” says Yong. When designing new parts, designers made physical models first, then made drawings based on the models, made a round of physical prototypes from the drawings, and then verified the prototypes.

The chance to make a significant change to the design process came during a project done in conjunction with the National High Technology Research and Development Program 863. Called “Study of the Configuration Management Technology of Large Batch Customized Products and Its Application in the Elevator Industry,” this project was Giant KONE’s impetus to upgrade the design process from 2D to 3D. After investigating and testing a number of 3D solutions, Giant KONE chose Solid Edge software with synchronous technology from Siemens PLM Software. It hired United Digital Systems, Co. (UDS), a Siemens PLM Software platinum partner, to handle the implementation.

“Since implementing Solid Edge, Giant KONE has witnessed remarkable improvements in efficiency,” says Yong. With more than 90% of all products and components now modeled in 3D, it is possible to simulate the assembly of an elevator in Solid Edge prior to manufacturing. Only 2 physical prototypes are now required, down from 5 or 6 in the past. Engineering drawings are more accurate, and they are quickly created from the solid geometry. The average research and development (R&D) cycle for a new product has dropped from a year to 9 to 11 months.

“In working with a variety of parts, components and assemblies during the R&D of a high-rise escalator, Solid Edge with synchronous technology enabled our designers to easily locate problem areas and quickly modify them.” says Yong. “Synchronous technology enables our designers to significantly increase their modeling efficiency.” He explains, “In the past, we got all parts and components ready before assembly. Now, using synchronous technology, we work in a top-down way – first concept design, then accurate design and finally standardization.”

According to Yong, Solid Edge saves the company significant money. Solid Edge Simulation enables the company to improve its design verification process. Yong explains, “We’ve essentially eliminated physical prototypes. We now use Solid Edge for virtual assembly, dimensional simulation and interference checking, thus minimizing material waste and substantially reducing costs. Ultimately, using Solid Edge, we’ve saved ¥3 million.”

Yong adds, “The integration of Giant KONE’s Solid Edge design system with other applications has allowed the company to optimize our product design and manufacturing processes. Barriers between departments have been eliminated; information is immediately shared; and what you see is what you get in a design.”

Siemens PLM

www.plm.automation.siemens.com

3D CAD Tips

Black Diamond’s goal was to combine the two sets of performance criteria in one great-looking boot. “The other free-ride boots out there are made by European competitors with 50+ years of boot-making experience,” explains David Narajowski, director of advanced projects at Black Diamond. “Our challenge was not just to catch up to where they were, but to go beyond and create something much better.”

Black Diamond is a long-time user of CAD and has used its original design software, I-deas, from Siemens PLM Software, to develop many of its successful products. At the time the boot project started, however, the company had decided to standardize on the NX digital product development system, also from Siemens, an advanced design solution that still allows the company to leverage its legacy I-deas data. “Black Diamond’s design engineering centers worldwide have moved from I-deas and other CAD systems to standardize on NX,” Narajowski says. He notes, “Between I-deas and NX, there was a period of time when we tried a mid-range CAD program. But there is no way we could have developed a free-ride boot in a mid-range system.”

One of NX’s main advantages, according to Narajowski, is that it provides both the freeform modeling capability needed to capture the company’s design expertise (through the NX Shape Studio application, offered as part of the NX Mach III industrial design solution) as well as the powerful product design tools needed to turn an idea into a manufacturable product. “This is a perfect combination for BD’s hands-on, chop-shop-inspired, fail-fast-to-succeed-sooner approach to design,” says Narajowski. “Working with NX Shape Studio, we can directly manipulate surface geometry to do things like capture anatomical nuances of the foot. And this functionality is integrated with NX product design tools such as WAVE that let us go from one original conceptual model to three different product families with 10 sizes each.”

Jake Hall, Black Diamond’s lead industrial designer on the project, explains the need for such tight integration this way: “One of the great challenges of designing ski boots is that there is very little separation between performance and aesthetics. Fit, performance and aesthetics are one and the same. This means that engineering, industrial design, and manufacturability must be tied together seamlessly in order to create a successful product. Any apparent seams between the two disciplines would result in poor design.

“Fully integrated engineering and industrial design means that we needed both surfaces and solids as native parametric features within a model,” Hall continues. “NX, and particularly the powerful surfacing features in Shape Studio, provided the hybrid capabilities of surfaces and solids that the project required.”

The tight integration between the NX conceptual design and product design environments was key to optimizing the performance of the boot, a task that involved a lot of actual skiing and hiking in prototypes. “If someone came back and complained of pressure here or a pinch there, we could grab those surface points in Shape Studio and easily make a change,” Narajowski notes. “But those changes are not made in a vacuum. It’s not like we throw the design over the wall from industrial design (ID) to engineering and hope the design intent isn’t lost. We’re also using NX tools and the same geometry we create in NX Shape Studio to analyze the boot’s performance and to design injection molded parts. That is the real strength of NX for us.”

Engineers at the Black Diamond headquarters in Utah worked with their colleagues at the Black Diamond office in China on the design of the boot. The ability to share the workload in an efficient and accurate manner is another important benefit of NX on a project such as the free-ride boot, according to Narajowski. “NX allowed us to break up the model and have more than one person working on it at a time,” he explains. “There would be an ID person working on outside surfaces, for example, while someone else was working on the foot shape or on the cutter for the buckles. People could work on their own parts, and then we could pull them in and automatically update the ‘super part.’

Nearly all of the free-ride boot project was done using Siemens software. The integrated nature of the NX solution made it possible for the design team to go through the many iterations they needed to catch up to and surpass the competition. “Without having all that existing experience, we had to try a lot of iterations. We wouldn’t have been able to go through the iterations fast enough without tools like NX,” Narajowski adds.

The boot has been previewed to the industry, to rave reviews, and sales will begin in time for the next ski season. “As the largest, most expensive, complex development project we’ve ever undertaken, it’s hard to contain my enthusiasm about these boots,” says Peter Metcalf, CEO of Black Diamond. “They represent the best of BD today, exemplifying our design philosophy in terms of innovative product. BD boots will fully meet the demands of today’s free-ride skier. We set out to build a better boot for the skier who wants one boot to rip all terrain and our design team has delivered.”

Siemens PLM

www.plm.automation.siemens.com

3D CAD Tips

The problem: The supplier has provided their customer with their intellectual property from the result of many hours of engineering, design, and analysis. Should another supplier happen upon these files, it will learn much about the product which their competition is proposing. In the electronic world in which we live, collaboration is very convenient. Unfortunately, this means we must be much more careful with the data we share and how we share it.

Solution: Elysium CADdoctor offers a way in which you can protect your intellectual property, allowing you to share only the data you want to share. With CADdoctor’s enveloping functionality, you can:

Provide only the external profile [envelope] of the component or assembly you plan to share. Remove all unnecessary parts from your assembly / product structure. Be secure with the data you share.

Elysium

www.elysiuminc.com

3D CAD Tips

Dassault Systèmes worked with Mougin and his team to simulate the iceberg’s trajectory and its evolution by taking into account data such as variations in ocean temperatures, wind force and direction, sea currents, and boat drag force. They inserted this data into a 3D model of the iceberg to simulate what would happen all along the voyage.

The critical challenge presented to Dassault Systèmes’ engineers was to demonstrate, using virtual technology, the technical feasibility of displacing the iceberg in a controlled manner while reducing its melting. The project, managed by Cédric Simard, Interactive Strategy & Marketing Project Director at Dassault Systèmes, involved a number of steps:

1. Model the iceberg with CATIA based on a cloud of points obtained by scanning a real iceberg with radar.
2. Calculate and simulate the way the iceberg would melt using CATIA Systems and SIMULIA.
3. Simulate the way the iceberg would melt if surrounded by a protective isothermal “skirt” imagined by Mougin to slow the melting process.
4. Calculate how much fuel the boats would consume depending on the winds and currents encountered along the way

Various scenarios were simulated, such as number of boats needed, different departure dates and climate conditions, and the behavior of the boats and iceberg in the event of a storm or turbulence. In addition to enabling the team to visualize these scenarios, the simulation also allowed the scientists to test how to deploy the isothermal skirt around the iceberg.

Dassault Systemes

www.3ds.com

3D CAD Tips

The product development team at PTC came up with the idea of a creating single program that does everything versus offering diverse programs with no connectedness. The strategy addresses its customer base and the trend toward solid modeling for the masses. Creo 1.0 is the result of that concept. The software currently has nine applications including Creo Parametric, Direct, Illustrate, Schematics, View MCAD, View ECAD, Sketch, and Layout.

The company focused on a group of traditional user problems and applied a core of technologies against them, specific roles having options for modeling modes with the click of an app. Simplifying a process that has plagued engineers and designers for decades makes using the software and being productive all the difference. The Creo GUI is much cleaner than the Pro/E GUI. According to those who have used the new product, the GUI strategy is most evident in Creo Parametric and Creo Direct. PTC leveraged the best features from CoCreate and made it easier to use. The company added features to Creo Parametric that will make Pro/E seem like ancient technology. Creo proves that a feature can live in a history-based and history-free environment keeping the parametric relation to features within each if needed.

Another 2011 debut was SolidWorks 2012 that also sports new features to help a more diverse audience. The software has improvements in assembly and drawing capabilities, built-in simulation, design costing, routing, image and animation creation, and product data management. Dassault Systemes says SolidWorks 2012 will help automate design functions, change product development processes, and extend support for collaboration and connectivity. This technology could change how the software is marketed and sold. The product helps users streamline design processes by removing traditional steps.

Autodesk’s AutoCAD 2012 and Design Suite 2012 series are available in a range of offerings including web and mobile applications. Thus more users have access to the technology and can stay connected to their work no matter where they are.  In addition, AutoCAD 2012 and Design Suite 201212 are directly connected to the free AutoCAD WS web and mobility application.

With CAD pretty much saturating the engineering and manufacturing arena, CAD vendors are realizing that pumping out a redressed version of what went out the door at the last launch is not going to work much longer. They have to offer tools that appeal to other audiences. We have seen that starting to happen in the retail, hobby, and jewelry industries where non-engineering types are using 3D programs to crank out new products.

PTC

www.ptc.com

Dassault Systemes

www.3ds.com

Autodesk

www.autodesk.com

3D CAD Tips