The Impact of AI on Engineering

As AI continues to evolve, it is likely to have a profound impact on engineering processes and practices. Many of the boring and repetitive jobs could be replaced by AI workflows. This is because the real benefit of AI is the speed at which results can be generated. However, it is still essential to review, check, and improve the data that is produced. This is why I do not see it as a threat to engineers, yet. As I was writing this blog I tried using ChatGPT to write this article and it was interesting to see how AI would write about AI. The results were disappointing, to be honest, and although it gave me some ideas of the topics to cover, I opted to not use the majority of the text that was generated. Much of the text that was produced used too many adjectives, see the example quotation:

“At the forefront of this transformation is SimScale, a pioneer in cloud-based simulation solutions, in collaboration with NAVASTO, their esteemed partner, offering ML-based models that propel engineering simulation to new heights.”

ChatGPT 

Engineers are however going to have to adapt and adjust to the changing environment or risk falling behind their peers and their competitors. There will be an increased importance for continued learning and experimentation with AI-based tools to ensure that the workforce is up to date with the latest developments. Engineers should not be threatened by AI, as if it is employed carefully and correctly it has the potential to make engineers a lot more effective.

A Step Change in Engineering Design and Simulation

The simulation industry has already been going through a state of rapid change and development with the introduction of truly cloud-based engineering simulation like SimScale. However, AI and ML models have the potential to further change and evolve how simulation is used in the product design cycle (McKinsey).

Traditionally, physics-based simulation has been used late in the design cycle to validate designs and potentially reduce the reliance on physical prototyping. However, in a recent report by McKinsey, they highlight from their surveys of R&D leaders in engineering that the business case for using engineering simulation is moving more towards faster-time-to-market and reduced product cost.

Consider an example of a project to design a water pump to a specific specification for a client:

• Two-month window for pump design.
• First month: Design and CAD geometry based on experience and company precedent.
• Second month: If the CFD team has capacity they simulate the design and determine its performance against the specification.
• There may be a couple of feedback looks required for CAD cleanup operations, etc.
• This leaves limited time in the final week or two for design improvements (one iteration) based on simulation results.

Proposed alternative with AI-based ML model:

• Designer uses existing data for AI prediction of pump performance.
• Early simulation-informed design changes are possible as soon as the designer has a concept CAD model available.
• This opens up the possibility for generative engineering workflows that automatically explore design spades or use automated design approaches.
• Shorter design process duration, reducing project overrun risk and late delivery risk.
• Allows for final simulation validation of the design in a shorter or equivalent time scale.

Predictive AI and Simulation

Predictive AI works by collecting relevant data, using algorithms, and training neural networks to build machine learning models that can predict the outcome of an event or scenario that was not observed in the original data.

For engineering simulation: GNN (Graph Neural Networks) are a powerful method. This is because they can use structured node-based data that is very similar in principle to how a mesh works for engineering simulation with FEA or CFD. However, unlike with engineering simulation, the results that are obtained from a GNN prediction of a simulation are obtained in seconds as opposed to hours with incredible degrees of accuracy.

There are of course challenges associated with predictive AI. The quality of the results that are produced are highly dependent on the quality of the input data that is used for the training. For many organizations, data collection and sorting is one of the biggest challenges when it comes to predictive AI models.

In a similar way to how OpenAI made AI accessible to the masses with ChatGPT, SimScale has partnered with NAVASTO to bring AI-powered simulation predictions to the engineering community without the need to worry about data management. See the release webinar here.

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Key Takeaways

1. Cloud-native simulation is leading the “new world” of engineering simulation by eliminating inefficiencies.
2. Purchasing and deploying your simulation tool has never been easier thanks to cloud-native simulation’s accessibility and immediate availability.
3. The cloud-native world enables customizable, online, and on-demand training for new users.
4. No restrictions on who can simulate – SimScale enables the democratization of simulation access, leading to a more diverse, efficient, and enriched design process.
5. In cloud-native simulation, the audit process is streamlined, with a transparent and easily accessible record of who took what action and when.

New World vs Old World: Redefining Efficiency

In contrast to the limitations of the past, cloud-native simulation like SimScale empowers engineers to innovate faster and navigate a streamlined and collaborative engineering design space. One way of looking at this is considering the analogy of a gardening hose.

A twisted hose hampers the flow of water and represents the inefficiencies of the “old world” of simulation. Even when this is untangled, a new kink will appear elsewhere, and without transparency, it’s hard to find where this inefficiency is. The free-flowing spray gun represents the “new world” of simulation, where the inefficiencies are gone, and the flow of water is not only streamlined but also in control, illustrating how cloud-native simulation can increase both efficiency and innovation.

In this article, I will show you how replacing legacy simulation tools with state-of-the-art, cloud-native simulation can streamline your team’s ability to design, innovate, and analyze more efficiently and effectively. You can also see a tabulated comparison at the end of the article.

1. Streamlining Purchasing and Deployment

The process of purchasing engineering simulation tools used to be characterized by long and protracted cycles, creating a considerable delay in acquiring the necessary design insight tools. Conversely, the cloud-native world introduces a revolutionary approach, offering affordability and immediate availability at no cost to kickstart your simulation work. This transformation in the purchasing landscape signifies a shift towards efficiency and accessibility.

Similarly, deployment used to suffer from sluggishness and installation bottlenecks with traditional, on-premise simulation tools. However, the cloud-native world presents a paradigm shift with instant deployment that negates the need for time-consuming installations.

Administrators can still wield control over access, immediately making resources available to anyone, on demand. Users can log in instantly, expediting the onboarding process, and the addition of a new user is streamlined to a simple task of entering their email address.

2. Facilitating Early Simulation Usage

Turning our attention to training and early usage, the old world demands large-scale organization for training sessions, often leading to unapproved training and the looming risk of new users making critical mistakes. On the contrary, the cloud-native world has ushered in an era of online and on-demand training, offering a flexible and customizable approach that can be seamlessly integrated into an organization. Support is not a distant concept; it’s ‘live’ and readily available when users need assistance. Time to answer is no longer measured in days or weeks but in minutes and seconds.

At SimScale, for example, the support system consists of real engineers collaborating with your team in real time, lessening the reliance on automated solutions.

3. Fostering Established Simulation Usage

Legacy simulation tools are fundamentally limited to disconnected, siloed teams, isolated projects on local machines, and data that is hidden and individually owned. Peer-to-peer learning is constrained by individual availability, restricting its effectiveness. However, once a company is fully up and running with its new, cloud-native simulation tool, the collaboration between connected teams is by default fostered, and projects are easily shared with all interested parties at the click of a button. Even in cases where projects require restricted access, there’s an option to form private teams. Administrators retain full access, eliminating the risk of valuable data being lost on a hard drive. Users can support each other within projects, and experts can offer guidance seamlessly within the validation process.

The philosophy of not restricting who can simulate is a cornerstone of the cloud-native world. By front-loading simulations early in the design process, SimScale enables everyone to experiment and learn at the initial stages, producing better designs faster than was previously possible. The democratization of simulation access ensures that input is solicited from everyone, leading to a more diverse and enriched ideation process. Templates, pre-defined by seasoned simulation engineers or SimScale’s own, can further empower new users to contribute meaningfully and confidently, knowing they are working within controlled guard rails. This inclusivity means that, with the support and guidance of experts, everyone can engage in hands-on learning and experimentation.

The transparent usage model in the cloud-native world stands in stark contrast to the old world’s opaqueness. License utilization is crystal clear, providing organizations with the ability to discern their actual needs and optimize costs accordingly. Nobody wants to pay for things they aren’t using, nor should they.

Users’ skill levels are transparently visible, facilitating timely support interventions before errors are made or time is wasted. Simulations linked to real-world projects offer insights into the value they added, allowing organizations to evaluate their tools’ and teams’ effectiveness and identify areas for improvement in subsequent design cycles.

The integration of simulation into the design and approval processes represents a significant departure from the old world’s compartmentalization. With legacy tools, simulation sits outside the process, creating a sequential flow from CAD, through simulatable CAD to results, and finally back to PLM. As a result, design reviews and approvals rely on individual simulation engineers for preparation, limiting access to crucial data. The cloud-native world, on the other hand, seamlessly brings simulation into the design process, allowing anyone to interact organically with insightful results.

4. Efficient Approvals and Audits

In the sphere of audits, legacy simulation tools grapple with questions of who did what and when and the whereabouts of critical data. This often results in team-specific tracking methods that lack standardization across the organization. In the cloud-native world, the audit process is streamlined, with a transparent and easily accessible record of who took what action and when. All data is stored in the cloud, providing flexibility in the organization based on organizational preferences.

The ability to link results from a PLM system with a URL ensures traceability, and the locking of results maintains data integrity and contributes to a comprehensive audit trail. Consistent and easily reproducible reports for each simulation speed up the time taken to interpret results and make approvals far simpler.

Summary

Join the New World with Cloud-Native Simulation

As we navigate the evolving landscape of technological advancements, the cloud-native world’s approach to holistically improving every step, from purchasing a design tool to comprehensive design audits, exemplifies a commitment to efficiency, transparency, and collaborative innovation. This transformative shift promises not only streamlined processes but also a paradigm where technology empowers users across all levels to contribute meaningfully and shape the future of their organizations.

With cloud-native simulation, blockages are removed, and the gardening hose is transformed into a powerful and efficient free-flowing spray gun. By dismantling the barriers of the old world, organizations can leverage the full potential of simulation throughout the product development lifecycle. Cloud-native simulation is not merely a technological advancement; it’s a catalyst for innovation, empowering engineers to explore, experiment, and ultimately, revolutionize product development processes. Get in touch with us below for more information on how SimScale can help you integrate cloud-native simulation into your workflow.

The post Redefining Engineering Efficiency with Cloud-Native Simulation appeared first on SimScale.

Understanding and mitigating the downwash effect is crucial for architects, urban planners, and city dwellers alike. As we navigate the complexities of wind downwash and its aerodynamic underpinnings, we uncover a compelling narrative of urban adaptation. We will discover how strategic design and innovative solutions can tame these gusty challenges, turning potentially unwelcoming urban spaces into havens of calm and comfort. Join us as we explore five key strategies to mitigate the downwash effect, promising a future where urban design harmonizes with the natural elements to enhance the pedestrian experience.

What is the Downwash Effect?

The downwash effect is a wind-related phenomenon commonly observed in urban environments, especially around tall buildings and skyscrapers. This effect occurs when wind strikes the face of these high structures and is deflected downwards, creating strong downdrafts at street level. These downdrafts can significantly increase wind speeds on the ground, leading to uncomfortable and sometimes hazardous conditions for pedestrians. The intensity of the downwash effect is influenced by various factors, including the height and shape of buildings, their orientation, and the surrounding urban layout.

Wind Flow Patterns

The downwash effect occurs when undisturbed high-energy wind from higher up is deflected down towards the ground by a building or structure.
This results in a notably uncomfortable zone at the base of the tall structure. While this effect is frequently observed in regions with towering buildings, it can also arise in lower urban settings. Essentially, under suitable conditions, the downwash effect can manifest in both urban and suburban areas, demonstrating its broad potential impact across different environments.

Recognizing the Downwash effect

One of the key methodologies for comprehending and addressing the downwash effect is the application of Computational Fluid Dynamics (CFD). This sophisticated tool allows architects and urban planners to simulate and scrutinize the intricate patterns of wind flow, pressure variation, and velocity around high-rise buildings. Utilizing CFD, we can effectively visualize how wind behaves in relation to the distinct shapes and configurations of urban structures, pinpointing zones where downdrafts and turbulence are most intense. These insights, derived from CFD simulations, are instrumental in formulating specific strategies that not only refine urban design but also enhance pedestrian comfort in wind-affected areas. As we progress through this article, we will explore how CFD can be adeptly used to identify and mitigate the downwash effect, gradually making its identification more intuitive and straightforward.

Comfort plot

Unlike the cornering and channelling effects, which exhibit distinct patterns in a comfort plot, downwash doesn’t present a unique shape that’s easily identifiable. However, a significant stretch of discomfort, aligned parallel and close to the base of a building, can be a strong indicator of downwash’s influence. This pattern suggests that downwash could be contributing to making the area less conducive for certain activities.

Directional Wind Speeds

Below is a prime example of how directional wind speed results, captured through Computational Fluid Dynamics (CFD), can be instrumental in identifying the downwash effect. The image presents a slice of velocity taken at the base of a building, where the flow dynamics are visible. Using a vector visualization with arrows, we can observe the distinct pattern of wind as it interacts with the building structure. These arrows vividly illustrate the wind’s trajectory: initially striking the building’s facade, then being forcefully directed downwards, and eventually spreading outward at ground level. This graphical representation is crucial in identifying the downwash effect, as it not only confirms its presence but also provides essential details about its direction and strength. Such visual insights are invaluable for urban designers and planners in developing strategies to mitigate the impact of downwash in pedestrian areas.

5 Strategies for Mitigating the Downwash Effect

In the quest to mitigate the downwash effect in urban environments, two particularly impactful strategies stand at the forefront: diverting the wind further up the building and reducing the wind’s energy. These innovative and practical approaches offer promising solutions to the challenges posed by the intense downdrafts created by tall structures.

The first strategy involves architectural and structural modifications to divert wind at higher elevations away from pedestrian zones. This can be achieved through various design elements such as aerodynamic building shapes, strategically placed louvers, or wind-redirecting façades. By altering the wind’s path before it reaches ground level, we can significantly diminish the intensity of downwash experienced on the streets.

The second strategy focuses on dissipating the wind’s energy. This involves employing materials, designs, or additional structures that absorb or break up the wind’s force, thereby softening its impact when it reaches pedestrian areas. Techniques such as incorporating green walls, porous surfaces, or specialized architectural elements can play a crucial role in reducing the kinetic energy of downdrafts.

In the following sections, we will delve deeper into these strategies, exploring how they can be effectively implemented in urban planning and design to create more comfortable and safer pedestrian environments amidst our ever-growing cityscapes.

1. Building Design

By integrating specific architectural features at an early stage in building or site design, we can significantly influence how wind interacts with structures, thereby reducing the intensity of downwash at the pedestrian level.

Key among these architectural interventions are setbacks and stepped building designs. Setbacks involve creating recessed sections in a building’s façade, effectively breaking up the wind flow and redirecting it before it reaches the ground. This not only disrupts the downward trajectory of the wind but also helps in dispersing its energy more evenly across different levels. Stepped buildings, on the other hand, offer a tiered approach where each level acts as a platform to divert and weaken the wind’s downward force. These steps function like a series of barriers, progressively diminishing the wind’s velocity as it descends the building’s height.

Both setbacks and stepped designs are more than just aesthetic choices; they are strategic elements that play a crucial role in the aerodynamic performance of a building. By incorporating these features, architects and urban planners can proactively shape the wind flow around skyscrapers and high-rises, making the areas at their base more comfortable and safer for pedestrians. This approach aligns perfectly with our objective of diverting the wind further up the building and reducing its energy, offering a harmonious blend of form and function in urban design.

The stark contrast between the baseline and setback designs is evident. In the setback design, we observe a marked reduction in high-energy wind reaching the pedestrian level. This is clearly depicted in the streamline images, where the wind’s trajectory is visibly altered, demonstrating less downward force as it interacts with the building’s staggered façade. Correspondingly, the pedestrian comfort images reveal a significant improvement in the areas around the building. The discomfort zones, prominently visible in the baseline design, are noticeably reduced in the setback version, indicating a more pedestrian-friendly environment. These results underscore the effectiveness of incorporating setbacks in urban architecture, not just for aesthetic appeal but for tangible improvements in pedestrian wind comfort.

2. Street-Level Structures

Street-level structures, such as canopies, awnings, and strategically placed barriers, serve as immediate buffers against the downdrafts caused by tall buildings. These structures are designed to intercept and redistribute the wind’s flow, effectively softening its impact on pedestrians. Canopies and awnings, for instance, can provide overhead protection, deflecting the wind upwards or sideways, away from the walking paths. Similarly, barriers like walls, screens, or even sculptural elements can disrupt and break up the wind flow, reducing its velocity as it reaches people on the streets.

This method of intervention is particularly effective because it addresses the downwash effect precisely where it’s most experienced—on the sidewalks and public spaces that thread through our urban landscapes. By integrating these structural elements into our cityscapes, urban designers and planners can create more hospitable and comfortable outdoor environments, enhancing the overall pedestrian experience in areas prone to aggressive downwash effects.

In the baseline scenario, without canopies, the images reveal a more pronounced downwash effect, with streamlines indicating a direct downward wind movement reaching pedestrian level. This corresponds to larger discomfort zones in the pedestrian comfort images, highlighting areas where wind speeds are likely to be uncomfortably high.

Conversely, in the canopy-equipped scenario, the streamline images show a notable diversion of wind flow. The canopies effectively intercept the downward wind, redirecting it horizontally or upwards, thereby reducing the direct impact of downwash on pedestrians. This alteration in wind trajectory is clearly evident and translates into improved pedestrian comfort levels. The comfort images in this scenario show reduced zones of discomfort, indicating that the canopy structures have successfully mitigated the intensity of the downwash effect at ground level.

These results demonstrate the efficacy of canopies as a practical solution for urban areas plagued by strong downdrafts from tall buildings. By incorporating canopies into street designs, urban planners can enhance the pedestrian experience, making city streets more welcoming and comfortable despite the challenges posed by the urban wind environment.

3. Landscaping

Trees and shrubs can act as natural windbreaks, absorbing and dispersing wind energy. When strategically placed, these green elements can significantly reduce the velocity of downdrafts from tall buildings, creating a buffer zone that protects pedestrians from harsh winds. The choice of plant species is crucial here – selecting those that are resilient to wind ensures their effectiveness as a barrier.

Moreover, the arrangement of these green spaces plays a pivotal role. By designing clusters or rows of trees and shrubs in key areas where downwash is most prevalent, we can create a more continuous and effective barrier. This natural approach not only addresses the practical aspect of wind mitigation but also contributes to the aesthetic and ecological value of urban environments.

Incorporating landscaping as a mitigation strategy offers a sustainable and visually appealing solution to the challenges of urban wind conditions. It demonstrates a harmonious integration of nature within our cityscapes, enhancing the overall quality of life for urban dwellers while effectively tackling the downwash effect.

In the scenario with trees added, there is a noticeable change in both the wind streamlines and pedestrian comfort levels. The trees act as natural barriers, disrupting and diffusing the wind’s downward trajectory. This diffusion is evident in the streamline images, where the wind appears to be less focused and more dispersed around the tree-covered areas. Consequently, the pedestrian comfort images show a significant improvement, with reduced discomfort zones, indicating a more pleasant and less windy environment at ground level.

These visual results underscore the effectiveness of trees in mitigating the downwash effect. By strategically placing trees around high-rise buildings, urban planners and designers can create a more sheltered and comfortable pedestrian environment, leveraging the natural buffering capacity of greenery to counteract the challenges posed by urban wind conditions.

4. Urban Planning Considerations

Here, we turn our focus to urban planning considerations, particularly vital during the master planning stage. At this stage, the flexibility to experiment with building positions and orientations offers a unique opportunity to proactively address wind comfort in urban design.

Urban planning considerations encompass a broad range of strategies aimed at optimizing the layout of buildings and public spaces to minimize the adverse effects of downwash. By strategically positioning buildings, planners can influence the direction and intensity of wind patterns in urban areas. This involves careful consideration of the orientation of buildings, ensuring that their placement doesn’t exacerbate wind conditions at the pedestrian level.

Additionally, the arrangement of streets and open spaces plays a crucial role in wind mitigation. Designing streets that are not directly aligned with prevailing wind directions can help in dispersing wind energy, reducing the formation of strong downdrafts. Incorporating open spaces, such as parks and plazas, provides areas where wind can be dissipated before it impacts pedestrian zones.

The effectiveness of strategic urban planning in mitigating downwash is vividly demonstrated through a set of four images, derived from Computational Fluid Dynamics (CFD) simulations. These images compare two scenarios: one where a tall building is positioned on the windward side of a street block, aligning with the prevailing wind direction, and another where the same building is moved to the leeward side of the block. The top row of images illustrates the levels of pedestrian comfort, while the bottom row focuses on the wind streamlines to depict the downwash effect.

In the first scenario, with the building on the windward side, the streamline images clearly show a pronounced downwash effect. The wind, unobstructed by other structures, strikes the building directly and is funnelled downwards towards the pedestrian area, resulting in high-energy wind patterns at ground level. Correspondingly, the pedestrian comfort images indicate a significant area of discomfort, highlighting the intense impact of downwash in this configuration.

Conversely, in the scenario where the building is relocated to the leeward side, there is a noticeable reduction in the downwash effect. The streamlines in these images depict a more dispersed wind flow, as the building is now shielded from the direct path of the prevailing wind. This alteration in wind dynamics leads to a notable improvement in the pedestrian comfort images. The zones of discomfort are substantially reduced, indicating a more pleasant and less windy environment for pedestrians.

These comparative results illustrate the impact of thoughtful building placement in urban planning. By considering the direction of prevailing winds and strategically positioning tall buildings, urban planners can significantly mitigate the downwash effect, enhancing the overall comfort and safety of pedestrian areas in urban environments.

5. Computer Simulations and Wind Studies

The critical role of Computer Simulations and Wind Studies cannot be overstated in the effective mitigation of urban wind phenomena like the downwash effect. In urban design and architecture, Computational Fluid Dynamics (CFD) emerges as a particularly powerful tool. This technology allows for an in-depth analysis and visualization of wind flow patterns, pressure distributions, and velocity fields around buildings and through urban streetscapes.

CFD simulations offer a window into the complex dynamics of wind behaviour in built environments. They enable designers and planners to model various scenarios and assess how different building shapes, orientations, and urban layouts influence wind patterns at the pedestrian level. This foresight is invaluable in predicting and addressing potential wind comfort issues before they materialize in the physical world.

Additionally, these simulations are instrumental in conducting wind studies that inform the design process. They provide detailed insights into how wind interacts with structures, identifying areas where wind speeds may be excessively high or where downwash effects are most pronounced. Armed with this information, urban designers can make informed decisions to optimize building features, landscaping, and street layouts to mitigate these effects.

In essence, the integration of computer simulations and wind studies into urban planning and architectural design represents a confluence of technology and creativity. It allows for the creation of urban spaces that are not only aesthetically pleasing but also comfortable, safe, and harmonious with natural elements. This approach underscores a commitment to enhancing the quality of urban life by transforming wind challenges into opportunities for innovative and sustainable design.

Explore CFD in SimScale

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Conclusion

Addressing the downwash effect in urban design is crucial for creating comfortable, sustainable, and inviting cityscapes. Strategies like aerodynamic building designs, effective street-level structures, landscaping, and strategic urban planning, coupled with the insights provided by Computational Fluid Dynamics (CFD), offer a multifaceted approach to enhance pedestrian wind comfort. These methods demonstrate a harmonious blend of technology, creativity, and practical urban planning. As we continue to evolve our cities, integrating these strategies ensures that our urban environments are not only aesthetically pleasing but also livable and welcoming, harmonizing human experience with the natural dynamics of wind.

The post Building Downwash: 5 Key Strategies to Counteract Urban Wind Discomfort appeared first on SimScale.

In this guide, we’ll look into what magnetic lifting is, how magnetic lifting devices work, and how SimScale improves their design through its electromagnetics simulation tool.

What is Magnetic Lifting?

Magnetic lifting is a method used in mechanical and industrial settings to move heavy metal objects without direct contact. The lifting process is both safe and efficient, particularly when moving large metal items. This technique relies on magnets to create a strong magnetic field that securely attaches to ferrous (iron-containing) materials like steel (not stainless steel, due to its specific metal structure, which makes it non-magnetic).

Smaller magnetic lifting devices can lift between 200 and 400 pounds (~ 100 to 200 kg), suitable for lighter tasks. Larger models are capable of handling hefty loads ranging from 6,000 to 13,000 pounds (~ 2700 to 6000 kg), ideal for more demanding industrial operations. These devices are particularly useful for transporting steel plates, forgings, die castings, and other similar items commonly found in workshops, warehouses, and processing plants.

Types of Magnetic Lifting Devices

Magnetic lifting devices are essential tools in various industrial settings, each type designed for specific applications and capacities. Here are the main types:

Electromagnetic Lifting Magnet

Electromagnetic lifting magnets use an electrical current to create a magnetic field, enabling them to attract and lift ferromagnetic materials. They consist of a coil wound around a ferromagnetic core. When electricity flows through the coil, it generates a magnetic field, allowing the magnet to hold a load securely. The lifting capacity of these magnets can be adjusted by varying the electric current.

They differ from permanent magnets as they require a continuous power source to maintain their magnetic field. Electromagnetic lifting magnets are widely used in industries like scrap yards, manufacturing, and recycling.

Permanent Lifting Magnet

Permanent lifting magnets are built with permanent magnet materials like neodymium or ferrite. These magnets produce a constant magnetic field without needing an external power source. They’re typically used for lifting smaller objects and have a fixed lifting capacity.

These magnets include a block with a main body and a rotor, each containing two magnets. When these magnets are aligned, they generate a magnetic flux that reaches the metal objects to be lifted. One key advantage is their functionality, even during power failures. They’re often found in material handling, sorting, and assembly line applications.

Electropermanent Lifting Magnet

Electropermanent lifting magnets use a mix of permanent magnets and electromagnets to create a magnetic field. Once established, this magnetic field can be maintained without a continuous power supply but can also be turned on or off using an electrical control system. This feature makes them useful when power failure is a concern, such as in steel mills, shipyards, and heavy equipment manufacturing.

When the two sets have the same magnetic direction, the magnet can attract ferromagnetic workpieces. If their magnetic directions are opposite, they cancel each other out, and no magnetic force is generated for clamping. These magnets consist of two magnetic power sources: one set of high intrinsic coercive force (Hci) magnets and another set of low Hci magnets wrapped in electrical wire coils. Changing the direction of the current pulse in the coils can alter the direction of the magnets’ orientation.

Applications of Magnetic Lifting

Here are some examples of magnetic lifting applications in different sectors.

Optimizing Magnetic Lifting Performance through Electromagnetic Simulation

Electromagnetic simulation plays a crucial role in enhancing the performance and efficiency of magnetic lifting devices. Here are several ways in which simulation can optimize magnetic lifting performance.

Detailed Magnetic Field Analysis

Electromagnetic simulations can provide a detailed map of the magnetic field’s strength across the lifting surface. For example, they help in ensuring uniform field strength when lifting irregularly shaped objects like curved metal plates or cylindrical steel rolls.

Through magnetic lifting analysis, engineers can detect areas where magnetic flux leakage occurs, which could lead to reduced lifting efficiency or unintended attraction to nearby metal objects.

Load Capacity Optimization

By simulating various load types, including asymmetric and unevenly distributed loads, designers can optimize the magnetic lifter for a wide range of scenarios, such as adapting the lifter design to handle elongated steel beams safely.

It’s easy to simulate how different ferrous materials respond to the magnetic field, considering factors like:

• Material thickness
• Alloy composition
• Surface condition

Enhancing Operational Safety

Engineers can focus more on operational safety by simulating mechanical stresses and strains on the lifting device under different load conditions, such as analyzing the stress distribution on the lifting arm when lifting near the device’s maximum capacity. Magnetic lifter designers can assess the durability of the insulation and electrical wiring, particularly under extreme conditions like high temperature or humidity.

The multiphysics post-processing results, including electromagnetics and thermal analysis, can predict heat generation in the coils and other components during operation. For devices meant for continuous use, simulation helps design systems that can operate for extended periods without overheating.

Energy Efficiency and Sustainability

Engineers can test how quickly the magnetic field can be altered in response to changing conditions, which is crucial in automated systems where rapid adaptation to different loads is required. By adjusting parameters such as the number of coil turns, wire diameter, and coil dimensions, designers can achieve the desired magnetic field strength with lower energy input.
For example, a simulation might reveal that reducing the wire diameter in the coil while increasing the number of turns achieves the same lifting strength with less electrical power required.

Magnetic Lifting Simulation with SimScale Electromagnetics

SimScale’s electromagnetic simulation capabilities offer a comprehensive solution for engineers and designers working on magnetic lifting devices.

Browser-Based Electromagnetic Simulation

SimScale allows you to simulate the electromagnetic (EM) performance of electromechanical devices without the need for expensive hardware or complex software installations. You can run multiple simulations in parallel directly in your web browser. This approach significantly accelerates the design process, enabling faster innovation and real-time collaboration.

Magnetostatics Tool for Detailed Analysis

The Magnetostatics simulation tool is a core feature of SimScale for magnetic lifting applications. It enables engineers to perform various low-frequency electromagnetics simulations, such as analyzing:

• Magnetic flux density
• Magnetic field strength
• Linear magnetic permeability
• Non-linear magnetic permeability

Simulate Your Magnetic Lifting Machines Using SimScale

Magnetic lifting devices offer a safe, efficient, and contactless method of transport in various industries. SimScale’s Electromagnetic Simulation simplifies the complex task of designing and testing magnetic lifters. Sign up now to start using SimScale, or request a demo to see it in action. You can also learn through our step-by-step tutorial focused on magnetic lifting simulations.

Get started right away with SimScale’s easy-to-use, web-based platform by clicking below—no need for special software or hardware.

The post Magnetic Lifting – Mechanism, Types, and Simulation appeared first on SimScale.

Team Maverick, an aero design engineering team, is dedicated to designing, innovating, fabricating, and testing fixed-wing UAVs. The team is currently engaged in two prominent competitions scheduled for the 2024 season. Initially, they will participate in the SAE Aero Design Challenge (ADC) International taking place in California. This globally renowned competition draws in approximately 75 teams from around the world, offering a platform to showcase aerodynamic innovations and skills on an international platform. The challenge to design UAVs embodies a vision for the future, where engineering prowess meets technological advancement. It is an opportunity for students to leave an indelible mark on the world, shaping the trajectory of UAVs and unlocking their limitless potential.

Additionally, the team is preparing for the SAE Design and Development Challenge (DDC) India in Chennai. This national competition unites around 87 teams from across India, providing a common ground for colleges to test and demonstrate their aircraft’s aerodynamic capabilities. Both competitions present significant opportunities for the team to excel on both global and national levels.

“Efficiency redefined: SimScale minimises computing demands and maximises productivity.”

– Team Maverick

A Look Into Unmanned Aerial Vehicles (UAVs)

Before diving into Team Maverick’s journey, it’s crucial to understand the pivotal role that Unmanned Aerial Vehicles (UAVs) play in modern aviation. Fixed-wing UAVs, often recognized for their likeness to conventional airplanes, rely on wings to create lift while in motion through the air. This design, a common variant among UAVs, has revolutionised industries by offering extended flight ranges and remarkable endurance. These aircraft offer extended flight times and faster speeds compared to rotor-based models.

Available in various sizes and configurations, from compact drones to large reconnaissance units, they cater to diverse sectors like logistics, agriculture, and surveillance. Technological advancements, including AI-driven autonomy and improved battery efficiency, signal an even more integral role for UAVs in everyday operations. As regulations evolve to integrate them into airspace seamlessly, the future of UAVs promises increased efficiency, safety, and expanded applications across industries.

Team Maverick: Aeronautics & Beyond

Team Maverick describes its core objective as providing students with a transformative aerospace experience. Beyond aeronautics, the team focuses on developing project and resource management skills, fostering collaboration, and ensuring industry rules and regulations compliance. With a commitment to contributing to the expansion of the field, the team is devoted to building cutting-edge aircraft for future applications and societal impact.

“We aim to produce technologically skilled, socially responsible, and aesthetically conscious engineers.”

– Rifa Ansari, Team Maverick

Every component of the aircraft they designed underwent extensive study and analysis, considering various aerodynamic parameters like wing lift and drag, empennage characteristics, and the overall aircraft performance. Determining downwash and vortex production by simulating wing behavior was a crucial aspect of their work. Additionally, they employed structural analysis methods to evaluate the strength and integrity of each individual component.

Analyzing Aerodynamics and Structural Integrity with SimScale

The team conducted simulations on various iterations of the wing, empennage, fuselage, and the entire aircraft, assessing different parameters such as takeoff and cruising conditions. To understand the aerodynamic performance of each section of the aircraft and evaluate the airflow around the entire plane, a steady-state laminar incompressible flow simulation was performed. Static structural analysis was carried out to better understand the structural integrity of components and to identify potential failure sites in the aircraft. The online tutorials provided by SimScale were instrumental in establishing the fundamental workflow for their project.

How SimScale Helped Address Challenges

The team encountered several challenges throughout the project, including difficulties with report generation, failure to generate lift and drag graphs, lower result accuracy, and issues with contact detection among multiple components.

“SimScale revolutionizes simulation with its cloud-based platform, eliminating the necessity for costly hardware. Its automated meshing tool generates top-tier computational meshes, while seamless integration with leading design applications, simplifying simulation setup. The SimScale Workbench serves as the hub for creating and overseeing simulations, offering an intuitive interface for defining setups with ease.”

– Rifa Ansari, Team Maverick

To tackle these obstacles, they sought assistance from SimScale support through online meetings, effectively addressing most of the challenges. Additionally, the team leveraged the SimScale forum, where they posted queries regarding the encountered issues, receiving valuable responses that contributed to resolving their simulation challenges.

The simulation results were analyzed and validated with manual calculations and wind tunnel testing. The analysis generated results that were close enough to the practical wind tunnel test. The simulations, employing 32 cores, typically took an average of 120-150 minutes to complete from start to finish. However, for particularly complex geometry simulations, the process required additional time. Lift and drag values were majorly obtained along with the coefficient of pitching moment for control surfaces obtained to determine the hinge moment coefficient. The designed bodies’ total deformation and overall structural strength were evaluated.

The team found the platform to offer remarkable convenience and simplicity. According to them, SimScale’s standout feature lay in its ability to utilize multiple cores, surpassing hardware limitations and significantly reducing time constraints. Team Maverick was particularly impressed by the meshing component, which seamlessly aligned with their desired mesh quality, presenting numerous parameters. Furthermore, the platform’s visual interface for analyzing solutions was not only comprehensive but also visually appealing.

“Through analysis across multiple iterations, SimScale has played a pivotal role in enhancing our project’s overall efficiency. Conducting studies swiftly and seamlessly has minimized both the cost and time associated with building numerous prototypes. In essence, SimScale has been instrumental in streamlining development timelines, cutting costs, minimizing prototype iterations, and amplifying overall efficiency”

– Rifa Ansari, Team Maverick

Next Steps for Team Maverick

On incorporating simulation results into further product development, the team strategises to execute this process in stages. They will soon finalise the entire design by analysing and evaluating various iterations. Specifically, for function-specific requirements, they are investigating the aircraft’s shape and iterating internal structures to guide its form or enhance structural integrity using CFD analysis and structural analysis. Additionally, the team aims to conduct Fluid-Structure Interaction (FSI) and crash analysis to gain insights into the product’s real-world performance.

We’re confident that SimScale’s diverse simulation capabilities will greatly benefit the Team Maverick Student team in upcoming endeavors, and we’re eager for future collaborations. If your team seeks academic sponsorship for optimizing your aircraft’s performance, whether for the SAE Aero Design Challenge or any other competition – make sure to check out our Academic Plan for students who are joining design competitions.

The post Team Maverick: Student Success Story appeared first on SimScale.

The holiday season is in full swing and we would like to reflect on the past year and take a moment to celebrate our employees and their cultural holidays. In today’s post, a couple of colleagues share more about holidays —  their traditions, activities, and importance. Keep reading to learn more about their different celebrations.

Diwali

Sam (Customer Success), how many days is Diwali celebrated?

Diwali is celebrated over five days, with each day having its own significance and rituals. The five days of Diwali are:

1. Dhanteras: This day is dedicated to Lakshmi, the Hindu goddess of wealth and prosperity. People clean their homes, buy new items, and light lamps to welcome Lakshmi into their homes.
2. Narak Chaturdashi: This day is believed to be the darkest day of the year, and it is associated with the victory of good over evil. People fast and pray for the well-being of their loved ones.
3. Lakshmi Puja: This is the main day of Diwali, and it is celebrated by lighting diyas (small earthen lamps) and bursting firecrackers. People also exchange gifts and sweets with their loved ones.
4. Govardhan Puja: This day is dedicated to Krishna, the Hindu god of love and compassion. People build a small hill of cow dung and worship it as Govardhan, the cowherd of Gokul.
5. Bhai Dooj: This day is celebrated by sisters to express love and gratitude towards their brothers. Sisters pray for their brother’s well-being, and brothers offer gifts to their sisters.

Paras (Product), how do you celebrate Diwali?

Diwali is celebrated over 5 days and people like to clean the interior and exterior of homes well in advance. People wake up early, take a bath, and wear new clothes. The exterior is decorated with lanterns, lighting, diyas, and rangolis. The Goddess of wealth and prosperity Lakshmi and the God of Health Dhanwantari are worshiped. Everyone lights fireworks, burns Crackers, meets, and greets each other sharing gifts and sweets. Diwali ends with a ceremony to celebrate the bond between brother and sister.

Kanchan (Product), what are your traditions, and what is important for you during that time?

For me, Diwali is a time for family and friends! It is a time to clear out the clutter from your life and bring in freshness and prosperity. It’s also an excuse to indulge in LOTS of eating and visit friends and neighbors with food.

Diwali for us is also about traditions — making atte ka halwa for the evening prayer and making rangoli (color-filled drawings on the floor). We aren’t an overly religious family but we still love keeping up with these traditions because it keeps us connected to our culture, to who we are.

For example, Diwali has always been a time for deep cleaning of the innermost corners of our homes. Cleaning and decluttering usually start a month before the actual festival and is a LOT of work but so satisfying! Right before Diwali, my mother-in-law and I either prepare or order Indian sweets and delicacies. Typical dishes include laddoos, mathi, namak para, mohanthal, kaju katli, dry fruits like almonds, dates, etc. We also share our good fortune by bringing gifts and sweets for our house helpers and apartment support personnel. On the day of the main festival, we have a nice leisurely brunch and in the afternoon, all the women and girls gather around to make ‘rangoli’, color-filled drawings on the floor in front of the main door. My daughters, since they were old enough to participate, love this part and have to be bathed right after. Men of the house keep themselves busy putting up flower garlands on the doors and hanging up lanterns and decorations. 

As evening descends, we dress up in our fine Indian traditional clothes (making sure they aren’t too flowy as there will be lighted lamps all around the house and can be a fire hazard). We also prepare one final sweet dish (“atte ka halwa” made from wheat flour) to be offered to the Goddess Lakshmi as we pray together in the late evening. In my childhood, we used to burst firecrackers out on the street till late at night. But now we are more environmentally conscious and refrain from smoke and noise-producing firecrackers. The day winds down with more delicious food for dinner, maybe visiting some neighbors to exchange good wishes, and falling asleep to lights sparkling in windows all around the city.

Smriti (Engineering), true or false? People set off fireworks for Diwali.

True. There are lots of varieties of crackers. Diwali is the Hindu festival of lights with its variations also celebrated in other Indian religions. It symbolizes the spiritual “victory of light over darkness, good over evil, and knowledge over ignorance.”

Christmas

Taylor (Marketing), what are your holiday plans for Christmas?

I am flying back to the United States over Christmas. I am looking forward to the time with family, delicious food, and hopefully, there is more snow than in Germany. On the 24th, I will celebrate with my grandparents, aunts/uncles, and cousins from one side of my family. On Christmas morning I will open gifts and celebrate with my immediate family. In the afternoon I celebrate with my other set of grandparents, aunts/uncles, and cousins. I will be there for just over a week, so I will work remotely from Michigan for a few days before and after Christmas.

Jon (Product), are you celebrating with your family?

Yes, we will celebrate together! As SimScale employees, we are lucky enough to have the freedom to move countries and we did that this year. We moved from Germany to the UK in August.
Our son asked if we could stop inviting everyone over at Christmas and have a small party to enjoy our new home. So this year, we will do just that and have a few days with just the four of us. Then, we will visit our wider families and then friends for New Year’s Eve. For the record, I don’t like celebrating New Year’s Eve — I prefer to treat all days as valuable. Plus…I need my beauty sleep

Elisabetta (Engineering), do you have a ritual every year?

For me, Christmas morning always means cooking with my father (and trying not to be too late with all the preparations). Our little ritual is to put on some jazz music and occasionally one of the thousand Bublé’s Christmas songs.

Kerrigan (Sales), what are your favorite Christmas traditions?

As the holiday season approaches, my family and I eagerly look forward to the cherished candlelight service at the Biltmore House in North Carolina. This yearly tradition has evolved into a heartwarming ritual, consistently filling us with the festive spirit of Christmas. Yet, the true joy lies in those precious moments spent with family. Introducing new ways to embrace family time enhances the season’s delight, creating a warm and delightful atmosphere surrounded by the presence of our loved ones.

Stefano (Engineering), what is your favorite holiday food?

For Christmas lunch in Bologna, we usually eat tortellini in broth (a typical handmade stuffed pasta in the area between Bologna and Modena) as a first dish, then the tradition is to eat trotter and cotechino with lentils. It is said that lentils bring luck and money.

As dessert in Italy, we have special Christmas cakes called Pandoro (from Verona) and Panettone (from Milan), sometimes served with warm eggnog. The main difference between Pandoro and Panettone is that the latter has candied fruit inside, but the bread has a different taste. I personally prefer Pandoro.

Obviously, wine can’t be missing. I like strong red ones, like Sangiovese, Chianti or Amarone. With dessert a Spumante or Brachetto or, even better, Passito di Pantelleria.

Eid al-Fitr

Ali (Customer Success), what are you celebrating on Eid al-Fitr?

Eid ul Fitr is one of the most important festivals in the Islamic calendar. It marks the end of Ramadan, a month-long period of fasting, prayer, and reflection. The festival is celebrated with great enthusiasm and joy by Muslims all over the world.

Eid ul Fitr is a time for family, community, generosity, and gratitude. It is a time to forgive and thank, to strengthen relationships, and to help those in need. The festival is celebrated in different ways in different countries, but the underlying message of love, peace, and harmony remains the same.

In Pakistan, Eid ul Fitr is celebrated with great fervor and enthusiasm. The preparations for the festival start well in advance, with people decorating their homes, buying new clothes, preparing special dishes, and donating to the poor. The day starts with a special prayer, followed by a family get-together and a feast. People exchange gifts and sweets, and children receive gifts or money from their elders as a token of love.

One of the most important aspects of Eid ul Fitr is charity. Muslims are encouraged to give to the poor and needy and to share their blessings with others. In Pakistan, many people donate money, food, and clothes to the less fortunate, and organizations set up special programs to distribute food and other essentials to those in need.

Eid ul Fitr is a time to celebrate the end of Ramadan, to reflect on the blessings of life, and to renew our commitment to our faith and our community. It is a time to come together, to share our joy and happiness, and to spread love and kindness to all those around us.

Japanese New Year

Paul (Engineering), how does Japan celebrate the new year? Is it quite different from the Chinese New Year?

In Japan, the New Year, or Shōgatsu, is primarily a family-centric event, often celebrated with grandparents. For those who rise early, the day begins with the year’s first sunrise, known as Hatsuhinode. It symbolizes the start of a new beginning, reflecting hope and renewal.  The New Year’s breakfast features “osechi-ryori,” a range of symbolic dishes served in special layered boxes called jubako. Each dish in osechi carries its own meaning, representing wishes for health, fertility, etc. Mochi, made from pounded sticky rice, is another important element of the New Year’s feast, symbolizing strength and togetherness.

Breakfast is usually followed by a visit to a local shrine, a tradition known as Hatsumōde, where prayers are offered for good health and prosperity. After the conventional celebrations are concluded, many people eagerly make their way to nearby department stores to partake in the exciting tradition of acquiring ‘Fukubukuro.’ These are specially curated bags, their contents unknown, offered at significantly discounted prices.

Paul, do you have a Christmas tree in your house? 

While personal Christmas trees are rare in Japanese homes, the holiday spirit thrives in public areas. Shopping centers and city districts have stunning Christmas tree illuminations, enveloping the surroundings in a festive mood. For those keen on a traditional Christmas tree, IKEA is one of the very few options to get one, so large lines of Europeans can be seen buying the real deal. In our family, we embrace a different approach: my wife and kids paint a large Christmas tree on several pieces of paper, which we then assemble and display on our wall. On the evening of December 24th, my kids even find something nice below the tree.

Thank you all for your great contributions! We are so excited to have you on the team! 

Here at SimScale, we have more than 130 employees from over 35 nations, with over 45 languages spoken. No wonder that so many different holidays are celebrated by our colleagues.

Now all that’s left for me to say is Happy Holidays from the entire SimScale team!

Stay tuned for more insights into SimScale and see what the team has been up to on our @lifeatsimscale Instagram feed. Want to start your own SimScale story? Make sure to keep an eye on our careers page for possible openings!

The post Home for the Holidays — Let’s Celebrate! appeared first on SimScale.

The automotive industry today is led by consumer perception, understanding, and expectations. With sustainability, AI, and efficiency being the reigning themes in almost every discussion, consumers are becoming increasingly aware, inquisitive, and critical of the vehicles they are purchasing, especially the younger, technically savvy generations. This is enabling particular technologies to rise in popularity and drive the market for at least the next decade.

These emerging technologies have led OEMs, and in turn Tier 1 suppliers, to buckle down and rush to optimize their processes so as not to miss out on market share. As consumer behavior gradually changes, vehicle sales are changing, too – determined by product quality [1], sustainability, purchasing experience, and brand. Moreover, these changes have gone further upstream to impact the design, manufacture, and supply of automotive parts and systems. That is why Tier 1 suppliers are racing to increase engineering efficiency and accelerate innovation.

This is where digital solutions like engineering simulation can play a significant role. And by leveraging the power of cloud computing and AI, the impact of cloud-based simulation on innovation and engineering efficiency can be significant. But let us first take a look at the automotive industry today and find out what trends and technologies are driving the market today.

The Four Trends Driving the Industry: ACES

As we are stepping into a new age of technology led by AI, digitalization, and sustainability, the automotive industry is going through a major transformation. Industry leaders are venturing into new avenues of design and manufacture, incorporating cutting-edge software and digital solutions that can help them keep up with the competition and the ever-growing demand.

As a result, multiple trends have emerged, which not only stem from technological advancements but also consumer perception of and willingness to adopt these technologies. The Center of Automotive Research (CAR) calls these trends ACES, which is an acronym for autonomous, connected, electric, and shared vehicles. Although we have seen major developments in other application areas, such as Hydrogen vehicles (which we will cover in another article), the ACES trends seem to have taken the lead, according to industry experts.

“[ACES] will enable new mobility paradigms, new companies, and new business and revenue models that have the potential to alter the way consumers interact with vehicles.”

Center of Automotive Research (CAR)

1. Autonomous Driving

Autonomous vehicle (AV) technology has emerged as a transformative force in the automotive industry, driven by advancements in AI, sensors, and connectivity. Not only will AV change the way cars navigate the roads, but it will also have a significant impact on the design, manufacture, and supply of components and systems.

“15% of new cars sold in 2030 could be fully autonomous.”

McKinsey & Co. ^[2]

AV will result in a shift from traditional automotive components to advanced sensor systems, computing platforms, and communication devices, which would primarily impact Tier 1 suppliers. As vehicles become more autonomous, the demand for sophisticated sensors, such as LiDAR, radar, and cameras rises exponentially. Tier 1 suppliers need to adapt their product portfolios and the manner by which they design their products to meet the evolving needs of OEMs. For this, they must find solutions that would enhance their engineering efficiency and boost their innovation.

2. Connectivity

The advent of vehicle connectivity has made it possible to process data from a wide range of sensors located at the edge and in the cloud. As a result, the volume of data that connected cars are expected to generate will increase as autonomous driving increases.

“Data traffic from connected vehicles is expected to be over 1,000 times the present volume, exceeding 10 exabytes per month by 2025.”

T-Mobile ^[3]

As such, mobility will change as connectivity is further enabled, especially with the advent of machine learning (ML) and edge AI applications.

3. Electric Vehicles

EVs are arguably the most impactful and pivotal trends in the automotive industry today, marked by a departure from traditional internal combustion engines towards cleaner, sustainable alternatives. The electrification of vehicles is driven by a growing global emphasis on environmental sustainability and the need to reduce carbon emissions. As governments worldwide implement stringent emission standards, the automotive landscape is witnessing a surge in EV adoption.

“Over 55% of all new car sales could be fully electrified by 2030.”

PwC Autofacts ^[4]

With lower battery costs, increasingly available charging infrastructure, and growing consumer approval, EVs will continue to have a strong impetus in the market in the near future. This includes its hybrid, battery-electric, plug-in, and fuel-cell-powered vehicles. In order for automotive suppliers to succeed with EVs, they need to leverage partnerships, especially with service providers that are leading the technological landscape. They need to invest in solutions that enable them to accelerate their innovation and production.

4. Shared Mobility

Motivated by efficiency, sustainability, and social inclusivity, shared mobility has begun to take shape over recent years. Although consumers by large still want to hold on to their private vehicles, many are gradually embracing the concept of shared mobility. In other words, mobility becomes an on-demand service in the form of car sharing, ride sharing, or mobility as a service (MaaS).

“40% of consumers expect to commute using shared mobility services in the next 5-10 years.”

Ericsson ^[5]

This not only is economically viable, especially with the introduction of autonomous vehicles, but it could also lead consumers to become consistently aware of technological advances, given the short life cycles of shared mobility solutions. This would put pressure on OEMs and, in turn, Tier 1 suppliers to augment the upgradability of the vehicles and their technological features.

Race of the Decade: How to Lead the Auto Supply Market

With EVs, AVs, connectivity, and shared mobility driving the automotive industry, suppliers are required to innovate faster while increasing engineering efficiency in order to maintain their competitive edge.

To achieve both requirements, suppliers and OEMs need to transform their engineering workflow, starting as early as the design stage. This can happen by fully digitalizing the design and engineering system and enabling teams to collaborate quickly through multiple design iterations. As such, teams should leverage simulation as a decision-making catalyst that underpins the whole design process.

Here at SimScale, we believe simulating early and broad can transform the product design process as it would inform design decisions efficiently rather than merely validate designs at the end of every cycle.

“The key advantage of using SimScale for us is to extract fast design insights at the early stages. We can then arrive at a final design faster and have more confidence when moving to the physical prototyping stage.”

Massimo Savi, ITW

First to Cloud-Native Simulation Wins

In order to accelerate new product introduction while lifting engineering efficiency on legacy products, OEMs and automotive suppliers must iterate through design runs more quickly and efficiently. For that, they need to incorporate digital solutions that can minimize costs and maximize the speed of sound decision-making. Therefore, those who adopt cloud-native engineering simulation will be one step ahead of the competition.

“Companies that invest 25% of their R&D budget in software applications are rewarded with strong growth.”

PwC Autofacts ^[4]

With SimScale’s next-generation simulation that leverages the power of cloud computing and AI, automotive suppliers can circumvent the long lead times and siloed approach of legacy simulation. They can employ aggressive simulation by utilizing parallel testing, which can reduce lead time from weeks to minutes.

Contact us below for more information on how to adopt cloud-native simulation in your workflow, or visit SimScale’s Product Overview section to have a look for yourself.

The post The Automotive Race to Innovation & Efficiency appeared first on SimScale.

Pelton turbines are characterized by their distinctive spoon-shaped buckets that efficiently capture the momentum of high-velocity water jets in high-head hydroelectric projects. But what differentiates the Pelton turbine in the spectrum of hydroelectric technologies? And how are current technological advancements, particularly cloud-based simulation platforms, revolutionizing the design, optimization, and operational processes of Pelton turbines?

This article delves into the intricacies of Pelton turbines, tracing their origins, understanding their mechanics, and exploring the role of advanced computation simulations, such as those offered by SimScale, in enhancing their performance.

Understanding Pelton Turbines

What is a Pelton Turbine?

A Pelton turbine, also known as a Pelton wheel turbine, is an impulse turbine uniquely designed to convert the kinetic energy of water into mechanical energy. Unlike its counterparts – the Francis and Kaplan turbines, which are reaction turbines suited for lower-head and higher-flow applications – the Pelton turbine operates efficiently in high-head, low-flow conditions typical of mountainous terrains. It achieves this by directing high-velocity water jets at a series of buckets mounted around the wheel, known as the runner, capturing the water’s momentum with remarkable efficiency.

Historical Background and Modern Applications

Invented in 1880 by Lester A. Pelton, the Pelton turbine has become a cornerstone of modern hydropower technology [1]. With the global installed capacity of hydropower reaching 1330 GW in 2021 and expected to grow significantly by 2050, Pelton turbines are at the forefront of this expansion [2]. They are renowned for their high efficiency, which can reach up to 92%, and continue to be refined for even greater performance.

In modern applications, Pelton turbines are not just confined to large-scale hydropower plants. They are also instrumental in small-scale installations, particularly in remote and mountainous regions where their high-head, low-flow operation is optimal. Furthermore, they are increasingly integrated into smart grid systems, contributing to a more responsive and sustainable electricity network. Pelton turbines also play a pivotal role in managing environmental flows, ensuring that water usage for power generation balances ecological and human needs.

Key Components of a Pelton Turbine

• The Bucket Design: The buckets of a Pelton turbine are its defining feature. They are engineered to split the water jet, ensuring maximum energy transfer from water to the turbine and allowing for efficiencies to remain high, even when operating at part load.
• The Nozzle: The nozzle, or injector, is responsible for regulating the water flow rate. It is designed to maintain high efficiency across a range of operating conditions, ideally keeping Pelton turbine efficiency above 90% until the flow rate is reduced to 20% of the design flow rate [3].
• The Runner and Casing: The runner, with its mounted buckets, is enclosed within a casing to protect and streamline the operation. The turbine’s axis configuration, whether horizontal (with up to two injectors) or vertical (with as many as six injectors), affects the load distribution and efficiency. The design also includes a deflector for emergency shutdowns or to prevent damage.

Pelton turbines are adaptable to horizontal and vertical axis configurations, with the choice impacting the turbine’s load distribution and potential for energy loss due to friction and windage. Their ability to operate efficiently across a wide range of conditions makes them a versatile choice for hydropower installations, especially in areas with high heads and low flows, such as aqueducts or ecological flows from dams.

How Pelton Turbines Work?

Pelton turbines derive their efficiency from the basic principle of impulse, where pressurized water is directed through a penstock and expelled via a carefully sized nozzle to generate a high-speed water jet. The turbine wheel, featuring strategically positioned double-cupped buckets, efficiently captures and redirects this water jet. Upon impact, the water undergoes a rapid change in momentum, transferring its kinetic energy to the turbine wheel and inducing rotation. The rotating turbine wheel is connected to a generator, converting the mechanical energy into electrical power. This synchronized process ensures continuous and reliable power generation.

The hydraulic efficiency of a Pelton wheel turbine is typically calculated using the following formula:

$$ Hydraulic\:Ef\!ficiency = \left(\frac{Mechanical\:Power\:Out\!put}{Hydraulic\:Power\:In\!put}\right) × 100 $$
It is also referred to as the Power Coefficient and is expressed as follows:
$$ \eta = \frac{P_t}{P_w} $$

where \(\eta\) is the hydraulic efficiency, \(P_t\) is the turbine power output, and \(P_w\) is the water head (unconstrained water current).

This formula quantifies the efficiency of the turbine in converting the hydraulic power of the incoming water into mechanical power. The mechanical power output is the electrical power generated by the turbine, while the hydraulic power input is the energy carried by the water jet.

Pelton turbines, with their distinctive design and efficient water-to-wheel energy transfer, often yield hydraulic efficiencies in the range of 85% to 90%. This means that a significant proportion of the water’s kinetic energy is successfully harnessed to produce electrical power. Yet, this efficiency may drop or fluctuate depending on influencing factors, such as windage, mechanical friction, backsplashing, and nonuniform bucket flow.

Advancements in Pelton Turbine Design Through Simulation

The integration of engineering simulation technologies, notably Computational Fluid Dynamics (CFD), has transformed the design and analysis of Pelton turbines. This innovative approach allows for the detailed modeling of water flow dynamics within the turbine, providing engineers with the insights needed to enhance efficiency and precision in turbine designs. As we delve deeper into the specifics, we will explore how Pelton turbine simulation serves as a crucial foundation for design refinement, performance prediction, and, ultimately, the realization of more sophisticated and efficient Pelton turbine systems.

Engineering simulations are pivotal during the early stages of the design cycle of Pelton turbines, acting as virtual proving grounds. They enable the testing of various design concepts, material choices, and operational conditions without the need for physical prototyping. This stage is essential for pinpointing potential design flaws and implementing improvements, thereby conserving time and resources.

Optimizing Pelton Turbine Designs with CFD

CFD simulations offer a robust framework for tackling fluid flow challenges, allowing for the creation of three-dimensional models of Pelton turbines. These models provide a window into the intricate interactions between water jets and turbine buckets, facilitating the optimization of bucket design, nozzle placement, and runner shape to achieve high turbine efficiency.

This is where a simulation tool like SimScale CFD plays a key role. Not only does this tool provide accurate simulation capabilities, but it also offers parallelization by leveraging cloud computing and storage. In other words, multiple simulations can run in parallel without limitations imposed by hardware constraints. This saves significant time during the design process and enables design parameterization and efficient testing. More on this is discussed below.

Dynamic Visualization and Performance Forecasting in Pelton Turbine Simulation

A key benefit of CFD simulations is the dynamic visualization of water flow through the turbine blades, offering more than just static imagery. Engineers can track the formation and impact of water jets on the buckets, observing the resulting flow paths. This dynamic analysis is crucial for identifying and rectifying inefficiencies. Furthermore, simulations enable turbine performance prediction across a spectrum of conditions, allowing engineers to anticipate real-world functionality and ensure the most efficient and dependable operation of a Pelton turbine.

Cloud-Native CFD to Accelerate Pelton Turbine Innovation

SimScale’s Subsonic Analysis for CFD Simulation of Pelton Turbines

In Simscale, the most useful CFD analysis type to simulate Pelton turbines is Subsonic Analysis. The Subsonic analysis type introduces an automated and robust meshing strategy tailored for fluid flow applications like Pelton Turbines. This approach generates hexahedral cells optimized for the underlying solver, significantly reducing mesh generation times. The resultant high-quality mesh requires fewer cells to achieve comparable accuracy, leading to faster convergence. It is important to note that this efficiency may come with a reduction in the feature set.

Key features of the mesher include body-fitted Cartesian meshing, cells suitable for finite volume discretization, and a highly parallelized meshing algorithm for rapid processing.

The Subsonic solver in SimScale is a Finite Volume-based CFD solver, employing a segregated pressure-velocity coupling mechanism. It stands out for its ability to simulate both incompressible and compressible flows, accommodating laminar or turbulent conditions all in one place. It also offers versatility by supporting both steady-state and extensive transient analyses. As for turbulence modeling, the analysis relies on the Reynolds-Averaged Navier-Stokes (RANS) equations, employing the k-epsilon turbulence model for closure and proprietary wall functions for effective near-wall treatment, making it particularly suited for Pelton Turbines.

Enhancing Pelton Turbine Design with SimScale’s Predictive Analysis

SimScale’s simulation capabilities bring a new level of sophistication to the design and optimization of Pelton turbines. Across numerous projects hosted on the platform, SimScale users are harnessing the power of cloud-native CFD simulation to enhance the operational efficiency and reliability of these turbines.

One such project studied the water flow within a Pelton turbine, mapping velocity magnitudes throughout the turbine’s buckets. This analysis provided a detailed visualization of flow dynamics, enabling the identification of optimal flow conditions and guiding improvements to the turbine design for increased energy conversion efficiency.

In another study, the focus was placed on understanding the pressure distribution within the turbine. The simulations executed in SimScale offered a three-dimensional perspective on the pressure loads the turbine blades endure, which is fundamental for assessing the turbine’s structural integrity and ensuring its longevity under high-stress conditions.

Through these projects, SimScale has proven to be an invaluable tool for predictive analysis that is vital for the refinement of turbine designs. It enables engineers to virtually prototype and test their concepts, iterate designs with accuracy, and achieve a level of detail that significantly reduces the need for physical prototypes. Try it for yourself now by clicking on “Start Simulating” below. For more information about SimScale’s CFD tool, check out our Fluid Dynamics product page.

The post Pelton Turbine: Working Principle, Design & Simulation appeared first on SimScale.

For this reason, over the last two years, the ESG task force (i.e., a group of people from different departments who volunteer time during the quarter to work on environmental, social, and governance projects) has focused our efforts on raising awareness and taking small steps towards becoming a mature organization in terms of sustainability.

One example of this work was the focus group we held in September, led by Darren Lynch. In this meeting, we brought together different members of the SimScale team to discuss a very relevant topic: how does remote working impact our carbon footprint and what can we do to improve the situation?

Doing this type of activity is very important because while we know that remote working can be sustainable, we must identify potential pitfalls and act on them proactively. By understanding the environmental impact of our remote working practices, we can make informed decisions.

At the end of the session, we wanted to have a series of recommended actions to address the pitfalls we identified throughout our meeting… and we found them!

Some of the issues identified that negatively affect the environment when working remotely are:

• Central heating in home offices
• Travel to the head office for events
• Generation of plastic waste

Talking openly during the focus group helped us to share solutions that some of us were already implementing and to discover new ones during the brainstorming. Some points of agreement we came to were:

1. Zoned heating will allow us to stay warm during working hours in our dedicated office/room. Instead of centrally heating rooms that are not in use, the heating can be turned on an hour before moving to those other rooms.
2. Find and use more zero-waste shops. These places stock products but not in an individually packaged form. Encouraging shopping through these means would generate better consumption habits and a reduction in the use of unnecessary plastics.
3. Purchasing energy-saving electronic devices would also help to reduce electricity consumption during the working day. During breaks or at the end of the working day, it is important to switch off or put equipment on standby to avoid unnecessary consumption.
4. Encourage remote meetings and in case of travel, use the sustainability guidelines recommended by SimScale.

This was the first of many open talks SimScale employees will be holding on sustainability and what more we can do to care for our planet. We highly recommend that you take the time to talk about these issues with colleagues, family, and friends because while individual efforts are crucial, collective actions amplify the impact.

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In this article, we will delve into the intricacies of drafting in racing, shedding light on how it works and the speeds at which it is most effective. We will also highlight the effects via a small CFD study using the SimScale simulation platform to visualize and capture the effects at different trailing distances.

What is Drafting in Racing?

Drafting refers to a strategic racing technique where a vehicle closely follows behind another, taking advantage of reduced air resistance or drag created by the lead vehicle. This aerodynamic phenomenon allows the trailing vehicle to experience a decrease in wind resistance, enabling it to achieve higher speeds or improve fuel efficiency compared to running independently.

Drafting is also interchangeably referred to as slipstreaming. Effective drafting requires a delicate balance between proximity to the lead vehicle and maintaining control, as getting too close can result in turbulent air and compromise stability.

How Does Drafting Work?

Drafting exploits a key principle of viscous, bluff-body fluid dynamics called “Boundary Layer Separation.” This phenomenon occurs when the airflow over an object loses its ability to follow the contour of the object’s surface and separates away from it, creating a turbulent and chaotic wake. This turbulent wake leads to reduced pressure or a vacuum region on the rear of the vehicle, creating a drag force that acts against the vehicle’s motion and necessitates additional energy to overcome. The net effect is a reduction in fuel (or electrical energy) efficiency or, in the case of a race car, a reduction in top speed.

When a following vehicle slips into this turbulent wake, its nose augments this wake, and the tandem vehicles will start to behave more like a longer, single aerodynamic body. Depending on the distance between the vehicles, the wake of the first car can be nearly eliminated. The corresponding pressure changes reduce the drag force on both vehicles compared to when traveling alone (raised rear pressure on the lead vehicle and reduced nose pressure on the trailing vehicle).

Thus, the overall convoy experiences significantly reduced air resistance, enabling it to achieve higher top speeds and more fuel efficiency with the same power output. Adding more cars into the drafting situation (as is typical at the Indianapolis 500 or on a NASCAR superspeedway, such as Daytona or Talladega) can further amplify the effect for the whole platoon. Also, drafting can be used by a trailing car to gain a short closing boost, which can be exploited to “slingshot” with momentum to overtake the lead car upon braking and corner entry, as is common in F1.

Other Effects of Drafting

Dirty Air

Drafting can also cause a very pronounced aerodynamic force balance shift. When you hear a race car driver say that they were in “dirty air” or had the “air taken off of their nose,” they are referring to this shift in aerodynamic force balance. In essence, the center of pressure (or neutral moment point) moves front to rear (and possibly laterally and vertically) in response to the net change in pressure due to the draft. Too much of a shift rearward for the trailing car results in an understeer condition. The lead car may see the opposite effect, with a reduction in rear spoiler or underbody downforce, leading to an oversteer condition.

Overheating

Aerodynamic performance is not the only consequence of this “dirty air.” Getting adequate air cooling can often be a big issue for the following car. Drivers are constantly pushing hard and putting mechanical components, like the engine and brakes, to their thermal limits. When the total pressure (or ability to do work) of the air is greatly reduced to the trailing car, it starts to affect all of the cooling systems, which are designed for “clean” airflow; the radiators would not be able to work sufficiently, the airflow going through the brake ducts would be insufficient, and EV battery cooling would be suboptimal, etc. All of that causes overheating, and the drivers have to generally back off to manage those systems.

At What Speed Does Drafting Work?

The effectiveness of drafting hinges on multiple factors, including the overall velocity of both the lead and trailing vehicles, the spacing between them, and the shape of the vehicles involved. Drafting is most potent at higher speeds, generally exceeding 50 mph (80 km/h). At these velocities, the aerodynamic forces become more prominent, and the advantages of drafting become more pronounced.

Let’s take a closer look at the drag force equation below. Here, we can see that drag is proportional to the velocity squared, so a pair of race cars traveling 200 mph (~ 320 km/h) see 16x more drag than one at 50 mph (80 km/h) highway speeds. This greatly magnifies the drag change due to drafting.

$$ D = \frac{1}{2} \rho V^2 C_D A $$

where:

• \(D\) is the drag force acting on the car,
• \(\rho\) is the air density,
• \(V\) is the relative velocity between the vehicle and air,
• \(C_D\) is the drag coefficient,
• \(A\) is the reference surface area of the vehicle.

The overall aerodynamic shape of the vehicles and any aerodynamic devices (splitter, spoiler, wings, etc.) also greatly affect their drafting ability. Race vehicles can often be very dependent on the performance of these discrete aero components, so augmenting the airflow they feel can have an abrupt and often undesirable effect on the handling balance. This is especially true when cars are cornering and grip-limited. Here, you will often hear the drivers complain about the ‘dirty air’. Motorsports-sanctioning bodies are always exploring aerodynamic packages and overall car designs to limit this sensitivity, as it hampers competition and overtaking.

In addition to the vehicle shape and features, the ground clearance and underbody design elements (such as the diffuser) are also critical drivers of drafting performance. The low pressure suction produced by the underfloor is very sensitive to the airflow ingested and expelled. When a car is trailing another in the draft, the lead car effectively uses up the energy of the oncoming air and leaves much less to drive the underfloor performance of the trail car. Again, this can have detrimental effects on the handling balance and reduce the maximum grip the trailing car has available when cornering.

Simulation Analysis: Analyzing Aerodynamic Drafting Using CFD

To gain deeper insights into the intricate dynamics of drafting, engineers have turned to computational fluid dynamics (CFD) simulations, usually instead of wind tunnel experiments. This choice is often driven by the high costs of wind tunnels, but in this case, the overall physical size limitations of most wind tunnels prohibit multi-car testing.

CFD provides a platform to accurately predict and analyze how tandem cars will behave as they approach one another. A map of various relative positions can be explored to understand the handling effects, and steps can be taken to optimize drafting performance. Furthermore, engineers can understand why these changes are happening by visualizing the airflow, which would accelerate the cars’ development and inform design changes. This powerful tool empowers engineers and designers to foresee the performance of their designs under different conditions and optimize them before hitting the track.

Aerodynamic Drafting in SimScale

On the SimScale platform, there are two different CFD modules that could be employed to simulate external vehicle aerodynamics and assess drafting performance. The Incompressible module utilizes the computationally efficient and practical finite volume approach (FVM), using the Reynolds Averaged Navier-Stokes (RANS) k-w SST turbulence model, which is prevalent in industry. The other approach leverages the advanced Incompressible Lattice Boltzmann Method (LBM), which can quickly solve high-fidelity, transient turbulence utilizing the power of GPUs.

Generally, LBM is the better option with regard to accuracy (particularly in the rear wake), scalability, and geometry robustness. Nowadays, DES and IDDES turbulence modeling (as is deployed in the LBM solver) is considered state-of-the-practice for accurate external vehicle aerodynamics simulations. However, if a quick early screening is all that is required, a simplified model using the Incompressible RANS approach still has merit.

A drafting study was conducted in SimScale using the geometry from the 2019 Formula 1 regulations, as shown in Figure 5. This geometry was imported from a dirty .stl surface mesh directly into the platform. The poor quality of this starting geometry is not an issue for the LBM module, as it is able to handle non-manifold surface mesh geometries in this format.

A single-car simulation was first conducted to get baseline values for drag, lift (downforce), and lift balance coefficients and a corresponding surface pressure plot. This “virtual wind tunnel” CFD simulation was conducted at 180 mph (~ 290 km/h) and assumed a rolling road and spinning tires via a rotational wall velocity. Force coefficients are summarized in Table 1 below.

The vehicle was shown to have a relatively high drag coefficient (\(C_D\)) of 0.805, which is expected for a race vehicle. The downforce was much lower than would be expected for an F1 racer, with a \(C_L\) of only -0.945. Also, the aerodynamic balance is heavily biased towards the rear, with a 14 to 86% front/rear balance. These differences are mainly driven by inaccuracies in the CAD model, particularly around the aero devices, ride heights, and interior structures. This serves to highlight the sensitivity of aerodynamic design.

For this study, it is more interesting to explore the aero differences once an identical second car is introduced into the draft, at a trailing distance of 1 wheelbase (~ 3.5 m). This is shown in Figure 6. The tandem pair is still traveling at 180 mph (~ 290 km/h), so this would be akin to slipstreaming down a straightaway just prior to deciding to overtake under braking.

Here, we can assess the aerodynamic force and moment changes due to the drafting effect. In this scenario, the lead and trail cars see a -0.066 and -0.180 reduction in \(C_D\), respectively. This is a drastic drag reduction of more than 22% for the following car, compared to when traveling alone! When viewing the frontal surface pressure, it becomes apparent that the trail car will exhibit much less drag, as it sees much less overall static pressure to act against the forward motion. This is very evident on the wings, engine, duct inlets, and even the tires.

As a consequence of less activation of the aerodynamic devices (particularly the front and rear wings and the rear diffuser), the tandem cars experience an overall reduction in downforce. This is especially true for the trailing car, which sees its downforce cut down by more than half! It would be imperative for this driver to slip past the lead car and get into some fresh air under braking into the corner.

There is so much more that could be explored in this drafting CFD study, including the reduction in duct inlet flow, the effect of drafting distance, and the effects of stepping slightly out of the draft (just to name a few). You may try that for yourself and explore these effects by accessing, copying, and running this “F1 2019 Drafting Study” project in SimScale.

With its online CFD toolset, SimScale enables engineers and designers to easily simulate aerodynamic cases like this one early in the design process directly in their web browser without the hassle of hefty hardware and expensive prototyping. The scalable high-performance computing platform in SimScale enables automotive and motorsports aerodynamicists to quickly and easily conduct vehicle drafting CFD studies. Try it for yourself by clicking the “Start Simulating” button below.

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