Challenges to Designing Smarter Products

By Matthew

Meeting the Challenges to Designing Smarter Products with ENOVIA

Today’s cars carry more electronics and computing power than the Apollo spacecraft that flew to the moon. One of the leading pressures facing manufacturers today is the increasing market demand for “smarter” products: products that have more functionality are more user-friendly, and more environmental. Therefore, manufacturers are incorporating an ever increasing amount of electronics and embedded software in their products.

Collaboration Design

For example, there has been a dramatic growth of electronic content in the automotive industry. The proportion of electronics in passenger cars in 2007 was around 20%, but this figure is estimated to increase to about 40% by 2015. By 2015 electronic components will become the largest contributor to a car’s overall parts and material costs.

Demand for smarter products is quite the exciting trend that offers a lot of new opportunities for innovation, at the same time there are inherent challenges. Getting it right requires new approaches to developing products. Smart products often consist of an integrated system of mechanical components, electronics, and software. This requires the involvement of multiple engineering disciplines. According to a study by the Aberdeen Group, the best manufacturers seek to improve communication and collaboration across engineering disciples and increase the ability to predict system behavior prior to testing.

In particular there are certain behaviors which have negative impacts on the business of developing smart product:

  • Without significant early collaboration between the electrical and mechanical designs means that problems are addressed downstream when design changes are expensive and time consuming.
  • If the transfer of design constraints between design domains is manual and requires recreating data from scratch then there is unnecessary duplication of effort and risks of data inconsistencies.
  • When the design requires several iterations between the mechanical and electrical domains to stabilize the design, there is the chance that the design could be based on obsolete data which would lead to scrapping and rework late in the process.
  • If there is no automated way to notify the team of changes in mechanical or electrical design constraints, then design changes will be delayed increasing product time to market.

 

Costs Incurred

The impact of early life-cycle decisions on product realization is far reaching. As new products move through the sequential stages of product design to final production, the cost of engineering changes increases tremendously. A mistake that is discovered during the planning and design phase is comparatively inexpensive to fix. But if it is overlooked and discovered later during the process, such a mistake can cost manufacturers several thousand times more. By the time a mistake comes to actual manufacturing, for example, it could cost millions more to fix compared to what it would have cost if detected earlier.

According to Aberdeen Group, Best-in-Class manufacturer leverage PLM solutions to improve communication and collaboration across disciplines. However, the ECAD (Electrical) and MCAD (Mechanical) domains present a unique challenge that requires a unique solution.

Learn how Dassault Systèmes can help. Register here to watch the 10 minute ECAD EXPERIENCE webinar:  http://www.3ds.com/products-services/enovia/resources/enovia-ecad

Matthew J. Hall

Matthew J. Hall

Matthew Hall is the ENOVIA User Advocacy & Social EXPERIENCE Specialist.  You can find him on Twitter at @mjhall. Connect with ENOVIA at @3DSENOVIA

 

SHoP Architects to Deliver Facades+ Keynote and Technical Workshop

By Akio

Learn how SHoP Architects use CATIA 3DEXPERIENCE on Cloud at Facades+

Facades+ New York City is the premier conference on high-performance building enclosures. Architects, fabricators, developers, consultants and design professionals will attend the New York City Facades+ Symposium & Workshops April 16-17, 2015.

 Keynote from SHoP’s Pasquarelli

Gregg Pasquarelli,
Founding Partner,
SHoP Architects

SHoP Architects Founding Principal Gregg Pasquarelli will deliver a keynote at the Symposium.

Since 1996, Pasquarelli has led SHoP Architects as it has set the standard for creative exploration in the field, producing trend-setting designs such as the Porter House apartments and the Barclays Center arena. In 2014, Fast Company named SHoP “Most Innovative Architecture Firm in the World.”

Tweet: Gregg Pasquarelli will deliver the keynote address at #FacadesPlus NYC @FacadePlus @SHoPArchitects @3DSAEC #AEC http://ctt.ec/zdx4I+ Click to tweet: “Gregg Pasquarelli will deliver the keynote address at #FacadesPlus NYC”

SHoP Architects Workshop

Participants will have the chance to join a full day of hands-on instruction by industry experts in small sessions and work with cutting edge technologies in a fast-paced and intensive environment. The innovative SHoP Architects will present the workshop: “Parametric Facade Systems & Logistics Sequencing.” The creation, and documentation of a parametric, unitized facade system using the latest version of Dassault Systemes’ CATIA 3DEXPERIENCE on Cloud. Other processes are used by multi­vender solutions. For more information or to register, visit the Facades+ registration page.

About Facades+

Facades+ is the leading conference on high performance and high design building skins. A robust dialogue encompassing all aspects of building envelopes, Facades+ bridges industry, academia, the profession, operations, and ownership.

The developing technology of high-performance facades has emerged as the key to building systems integration, central to the realization of resilient buildings and a sustainable built environment. We invite you to join the exciting conversation that is Facades+.

Tweet: @SHoPArchitects to Deliver #FacadesPlus Keynote and Technical Workshop | #AEC @FacadesPlus @3DSAEC @Dassault3DS http://ctt.ec/N47M6+Click to tweet this article.


Related Resources

White Paper: Technological Changes Brought by BIM to Façade Design

Façade Design for Fabrication Industry Solution Experience

CATIA 3DEXPERIENCE, the Winning Partner for the DUT Racing Team

By Thierry

Dutch university students from TU Delft had only nine months to design and build a new version of their electric car that they hoped would once again lead them to victory in the 2014 edition of the Formula Student competition.

The team used design and simulation technology from Dassault Systèmes’  3DEXPERIENCE platform to design the DUT14, an electric car featuring numerous improvements over last year’s model.

Global Design Competition

Every year, some of the world’s brightest engineering students pool their talents to design what they hope will be the winning car in the annual Formula Student competition. It is an opportunity for 500 teams from all over the world to put their skills and imaginations to work during their free time, including evenings, weekends and holidays, for a good portion of the school year. In addition to the challenge, it is a tribute to the engineers who founded this competition over 30 years ago. “This international design competition was the idea of the Society of Automotive Engineers who thought that students graduating from engineering school did not have sufficient practical design experience, nor the right project management and team-working skills,” explained Tim de Morée, team leader, Formula Student team at TU Delft in the Netherlands. “So they designed the Formula Student competition to enable them to acquire all three.” Students must design, build, test and drive a formula-type racing car as well as create an associated business plan for potential investors. Contestants’ entries are judged based on a series of tests that include speed, design, safety, reliability, and cost.

Delft University of Technology is a repeat participant in this competition and winner of numerous Formula Student races in the past.

Tim de Morée is this year’s leader of TU Delft’s 86 students team. Once again the students attempted to outperform the other teams in three key races – Formula Student United Kingdom (FSUK), Formula Student Germany (FSG) and Formula Student Austria (FSA) – with their new and improved DUT14. “You may think that after designing 13 cars that we benefit from our past experiences and know-how,” de Morée said. “This is not entirely true since 80% of the team is new to this competition. The other 20% are the few alumni who participated in this year’s adventure providing us with their design and project management expertise.” As a result, de Morée’s team completely redesigned a vehicle from scratch. The four-wheel drive car has four equal motors that enable the car to accelerate even faster and to regenerate energy on all wheels while braking. “This constant reuse of energy allowed us to choose a much smaller and lighter battery package,” de Morée said.

Engineering Firm.com

The team is run like a small engineering company with students working in one of five departments: electronics, powertrain, vehicle dynamics, chassis and aerodynamics. “Team members are responsible for designing a part, for example the steering system or electrical wire harness. Only the most standard parts such as dampers or sensors were purchased from suppliers but we tried to do as much as we could by ourselves.”

The DUT14 was designed and tested using solutions from the 3DEXPERIENCE platform. Every “department” completed its objectives using the 3DEXPERIENCE solutions. For example, students used CATIA for their design work and the analysis and simulation solution SIMULIA to test their design concepts. “This was very beneficial due to our tight schedule and limited resources,” Marinus van des Meijs, chief engineer, said. “We had only nine months to complete the project, of which three were dedicated to design.”

Lighter, More Energy Efficient

One of the team’s objectives this year was to make the car lighter than last year. “With a lighter car we improve energy efficiency and performance when accelerating or braking,” van des Meijs explained. “The DUT14 weighed 155 kg, down from last year’s model, which weighed an already light 179 kg. We owe this success in part to the 3DEXPERIENCE platform and its integrated simulation solutions, which enabled us to test each design iteration with amazing speed and precision. “All five departments of our company shared the same designs so when one group made changes, the others saw the updated design in real-time,” van des Meijs said. “Moreover, design history was capitalized, which allowed us to go back to previous design versions if needed at the push of a button.

Most of all, potential design problems were detected early on and not when we were physically assembling the car, which would have hurt our timing.”

Also new this year were the tires for the DUT14. “We designed them ourselves this time and made them wider, with a smaller outer radius and lighter than last year,” van des Meijs said. “We believed it would improve performance. Here again, without the 3DEXPERIENCE platform we would not have been able to test if our design caused interferences when steering. We were able to look at 55 different design iterations with CATIA before finding the right configuration.

The electrical department used the CATIA Electrical solution to define the wire layout, splice positions and wire lengths. “CATIA helped us to position our wiring in the most efficient way while keeping total mass on par with last year’s model,” van des Meijs said. “It is also important to allow slack where the connectors are and not in the rest of the wire harness. CATIA helped us place them exactly where we wanted. One key value of CATIA Electrical is its ability to quickly produce a precise design for routing. We used the Flattening feature to create the wiring drawings at a scale of 1:1. This made it easier to visualize every detail, which was very helpful,” he said.

CATIA, a Winning Partner

The Society of Automotive Engineers would have been proud to see how the design competition they imagined provides participants with valuable engineering skills. The TU Delft team put these skills to good use winning the championship title at the Silverstone competition and receiving numerous awards at the Hockenheim race in Germany including the Audi ultra-award for best lightweight concept. “It was a heart-stopping few days of ups and downs but we did it,” de Morée exclaimed.

With CATIA we had confidence in our design and in our ability to come up with the best vehicle possible in a very short timeframe.”

Discover the full story in video on 3ds.com

CATIA, the Winning Partner for the DUT Racing team



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