Altair Case Studies Subros Optimizes Product Designs with Altair HyperWorks, Reducing Simulation Time and Prototyping Costs

	Subros Optimizes Product Designs with Altair HyperWorks, Reducing Simulation Time and Prototyping Costs Altair

Subros Optimizes Product Designs with Altair HyperWorks, Reducing Simulation Time and Prototyping Costs

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Sensors - Voltage Sensors
Applicable Industries	Automotive Chemicals
Applicable Functions	Logistics & Transportation Product Research & Development
Use Cases	Manufacturing Process Simulation Time Sensitive Networking
Services	Testing & Certification
Challenge	Subros Limited, a leading manufacturer of thermal products for automotive applications in India, faced significant challenges in meeting product delivery deadlines with agreed quality benchmarks. As a major supplier of AC units to various automotive segments, Subros had to continually upgrade their products to match the evolving designs of vehicles. The pressure of product development timelines was immense, as the launch time of vehicles was crucial for manufacturers. Subros initially used a CAE software tool for simulation to save time in the product development cycle. However, the software was not user-friendly, took a long time to simulate, and was prone to human errors, leading to further delays in product development and delivery. The team needed a robust, quick, reliable, and user-friendly simulation software product to overcome these issues. Read More
About Customer	Subros Limited, founded in 1985, is a joint venture public limited company with 40% ownership by the Suri family of India and 13% ownership each by Denso Corporation and Suzuki Motor Corporation. Subros is the leading manufacturer of thermal products for automotive applications in India, operating in technical collaboration with Denso. The company has grown from a capacity of 15,000 AC units in 1985 to being the largest and only integrated manufacturing unit in India for Auto Air Conditioning systems. Subros manufactures Compressors, Condensers, Heat Exchangers, and all connecting elements required to complete the AC loop. Their product line caters to all vehicle segments such as Passenger Vehicles, Buses, Trucks, Refrigeration Transport, Off- roaders, and Railways. Subros has manufacturing plants at Noida (2), Manesar, Pune, Chennai, and Sanand with an annual capacity of 1.5 million AC kits. They also have a well-equipped R&D Center and Tool Room in Noida. Read More
Solution	Subros turned to Altair HyperWorks to address their challenges. The company has been using the Altair suite of products for over a decade. Initially, Subros used Altair’s pre-processor tool HyperMesh coupled with other industry solvers. As they learned more about the capabilities of the Altair suite, they transitioned completely towards RADIOSS and OptiStruct solver for structural analysis. Currently, Subros extensively uses Altair HyperWorks 14.0, which includes HyperMesh, HyperView, HyperGraph, RADIOSS, OptiStruct, MotionView, MotionSolve, and solidThinking Inspire. The team also intermittently uses Altair AcuSolve, SimLab, and HyperStudy as required. The Subros team uses Altair solutions to carry out various types of analyses to evaluate structural integrity. The software suite has enabled them to perform structural and multi-body dynamic analysis without worrying about errors, positively impacting the product development cycle time and cost of prototypes and samples. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Sensors - Voltage Sensors

Applicable Industries

Automotive

Chemicals

Applicable Functions

Logistics & Transportation

Product Research & Development

Use Cases

Manufacturing Process Simulation

Time Sensitive Networking

Services

Testing & Certification

Challenge

Subros Limited, a leading manufacturer of thermal products for automotive applications in India, faced significant challenges in meeting product delivery deadlines with agreed quality benchmarks. As a major supplier of AC units to various automotive segments, Subros had to continually upgrade their products to match the evolving designs of vehicles. The pressure of product development timelines was immense, as the launch time of vehicles was crucial for manufacturers. Subros initially used a CAE software tool for simulation to save time in the product development cycle. However, the software was not user-friendly, took a long time to simulate, and was prone to human errors, leading to further delays in product development and delivery. The team needed a robust, quick, reliable, and user-friendly simulation software product to overcome these issues.

About Customer

Subros Limited, founded in 1985, is a joint venture public limited company with 40% ownership by the Suri family of India and 13% ownership each by Denso Corporation and Suzuki Motor Corporation. Subros is the leading manufacturer of thermal products for automotive applications in India, operating in technical collaboration with Denso. The company has grown from a capacity of 15,000 AC units in 1985 to being the largest and only integrated manufacturing unit in India for Auto Air Conditioning systems. Subros manufactures Compressors, Condensers, Heat Exchangers, and all connecting elements required to complete the AC loop. Their product line caters to all vehicle segments such as Passenger Vehicles, Buses, Trucks, Refrigeration Transport, Off- roaders, and Railways. Subros has manufacturing plants at Noida (2), Manesar, Pune, Chennai, and Sanand with an annual capacity of 1.5 million AC kits. They also have a well-equipped R&D Center and Tool Room in Noida.

Solution

Subros turned to Altair HyperWorks to address their challenges. The company has been using the Altair suite of products for over a decade. Initially, Subros used Altair’s pre-processor tool HyperMesh coupled with other industry solvers. As they learned more about the capabilities of the Altair suite, they transitioned completely towards RADIOSS and OptiStruct solver for structural analysis. Currently, Subros extensively uses Altair HyperWorks 14.0, which includes HyperMesh, HyperView, HyperGraph, RADIOSS, OptiStruct, MotionView, MotionSolve, and solidThinking Inspire. The team also intermittently uses Altair AcuSolve, SimLab, and HyperStudy as required. The Subros team uses Altair solutions to carry out various types of analyses to evaluate structural integrity. The software suite has enabled them to perform structural and multi-body dynamic analysis without worrying about errors, positively impacting the product development cycle time and cost of prototypes and samples.

Impact #1	The use of Altair solutions has brought about significant operational improvements for Subros. The software suite has enabled the team to successfully carry out various types of analyses to evaluate structural integrity without worrying about errors. This has not only directly impacted the product development cycle time, but has also had a positive bearing on the cost of prototypes and samples. The team feels very confident about their projects after a sustained use of Altair solutions. The software suite always provides resolutions to real-time problems and validates them with experimental results. The team also conducted a weight optimization study that turned out to be very beneficial to the business. The Subros team is quite content with support from Altair and DesignTech teams and only has words of praise for them.

Impact #1

The use of Altair solutions has brought about significant operational improvements for Subros. The software suite has enabled the team to successfully carry out various types of analyses to evaluate structural integrity without worrying about errors. This has not only directly impacted the product development cycle time, but has also had a positive bearing on the cost of prototypes and samples. The team feels very confident about their projects after a sustained use of Altair solutions. The software suite always provides resolutions to real-time problems and validates them with experimental results. The team also conducted a weight optimization study that turned out to be very beneficial to the business. The Subros team is quite content with support from Altair and DesignTech teams and only has words of praise for them.

Benefit #1	Reduced simulation time by 60%
Benefit #2	Reduced prototyping costs by 40%
Benefit #3	Drastically reduced the weight of the total assembly by replacing the higher grade material with a lower grade material

Benefit #1

Reduced simulation time by 60%

Benefit #2

Reduced prototyping costs by 40%

Benefit #3

Drastically reduced the weight of the total assembly by replacing the higher grade material with a lower grade material

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Overview

Subros Optimizes Product Designs with Altair HyperWorks, Reducing Simulation Time and Prototyping Costs

Operational Impact

Quantitative Benefit