Altair Case Studies Victory Through Innovation: Winning the Race and Staying Sustainable with Altair Solutions

	Victory Through Innovation: Winning the Race and Staying Sustainable with Altair Solutions Altair

Victory Through Innovation: Winning the Race and Staying Sustainable with Altair Solutions

Altair

Technology Category	Cybersecurity & Privacy - Intrusion Detection Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Life Sciences
Applicable Functions	Product Research & Development
Use Cases	Manufacturing Process Simulation Structural Health Monitoring
Challenge	Elisava Racing Team, a project of final year students at ELISAVA Barcelona School of Design and Engineering, had the challenge of designing and developing an electric motorcycle to compete in the Barcelona Smart Moto Challenge. The team had already optimized important structural parts of their previous designs, “ERAY” and “Dayna,” but wanted to take their latest design “Dayna EVO” a step further. The team aimed to create a 100% electric off-road motorcycle with an IoT connection and a medical service capability. They sought to improve the bike’s safety, comfort, and structural behavior, aiming for a lighter, simpler bike. To achieve this, they needed simulation tools to generate shapes, predict material behavior, and optimize manufacturing processes for the fully electrified motorbike. Read More
About Customer	Elisava Racing Team was established in 2018 at ELISAVA Barcelona School of Design and Engineering. The team is composed of final year students who took on the challenge of designing and developing an electric motorcycle to compete in the Barcelona Smart Moto Challenge, an international competition held annually in Catalonia. The competition focuses on sustainable mobility, with university teams from around the world competing in an off-road race using self-engineered electric motorcycles. The team has achieved outstanding race results by using Altair solutions to optimize several structural parts of their bike. In 2019, the team won five awards with the electric motorcycle “ERAY” and continued its success in 2020 with the motorcycle “Dayna”. Read More
Solution	The team used topology optimization using Altair® Inspire™ to optimize the design of several structural parts while achieving maximum weight reduction. They began by analyzing the original chassis’ performance. For the aluminum subframe, they applied Inspire to minimize the structural assembly’s weight and used Altair® Inspire™ Print3D to optimize the manufacturing process. To design the bike’s swingarm, they studied three main load cases and performed various iterations with Inspire to generate the geometry with an optimal shape. For the carbon fiber handlebars, they used Altair® HyperWorks® to optimize the composite material by modifying the number of layers to achieve the desired performance. Finally, they used HyperWorks to simulate the new parts and complex assemblies and evaluate their performance in different racing scenarios. Read More Log in to view content
Contents

Technology Category

Cybersecurity & Privacy - Intrusion Detection

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Life Sciences

Applicable Functions

Product Research & Development

Use Cases

Manufacturing Process Simulation

Structural Health Monitoring

Challenge

Elisava Racing Team, a project of final year students at ELISAVA Barcelona School of Design and Engineering, had the challenge of designing and developing an electric motorcycle to compete in the Barcelona Smart Moto Challenge. The team had already optimized important structural parts of their previous designs, “ERAY” and “Dayna,” but wanted to take their latest design “Dayna EVO” a step further. The team aimed to create a 100% electric off-road motorcycle with an IoT connection and a medical service capability. They sought to improve the bike’s safety, comfort, and structural behavior, aiming for a lighter, simpler bike. To achieve this, they needed simulation tools to generate shapes, predict material behavior, and optimize manufacturing processes for the fully electrified motorbike.

About Customer

Elisava Racing Team was established in 2018 at ELISAVA Barcelona School of Design and Engineering. The team is composed of final year students who took on the challenge of designing and developing an electric motorcycle to compete in the Barcelona Smart Moto Challenge, an international competition held annually in Catalonia. The competition focuses on sustainable mobility, with university teams from around the world competing in an off-road race using self-engineered electric motorcycles. The team has achieved outstanding race results by using Altair solutions to optimize several structural parts of their bike. In 2019, the team won five awards with the electric motorcycle “ERAY” and continued its success in 2020 with the motorcycle “Dayna”.

Solution

The team used topology optimization using Altair® Inspire™ to optimize the design of several structural parts while achieving maximum weight reduction. They began by analyzing the original chassis’ performance. For the aluminum subframe, they applied Inspire to minimize the structural assembly’s weight and used Altair® Inspire™ Print3D to optimize the manufacturing process. To design the bike’s swingarm, they studied three main load cases and performed various iterations with Inspire to generate the geometry with an optimal shape. For the carbon fiber handlebars, they used Altair® HyperWorks® to optimize the composite material by modifying the number of layers to achieve the desired performance. Finally, they used HyperWorks to simulate the new parts and complex assemblies and evaluate their performance in different racing scenarios.

Impact #1	The use of Altair solutions allowed the Elisava Racing Team to improve the motorcycle’s parts and create a lighter, more efficient design. They were able to optimize complex assemblies while ensuring maximum performance, comfort, and safety. The optimization of the “Dayna EVO” frame to achieve an optimal package for an electric powertrain also demonstrated that electrification can save costs. The team created a fully electric motorbike that’s suitable for rugged terrain while providing drivers with the speed, comfort, and control they demand in great bikes. “Dayna EVO” is a significant step forward for the ELISAVA team and will help them improve future designs.

Impact #1

The use of Altair solutions allowed the Elisava Racing Team to improve the motorcycle’s parts and create a lighter, more efficient design. They were able to optimize complex assemblies while ensuring maximum performance, comfort, and safety. The optimization of the “Dayna EVO” frame to achieve an optimal package for an electric powertrain also demonstrated that electrification can save costs. The team created a fully electric motorbike that’s suitable for rugged terrain while providing drivers with the speed, comfort, and control they demand in great bikes. “Dayna EVO” is a significant step forward for the ELISAVA team and will help them improve future designs.

Benefit #1	Achieved maximum weight reduction in the design of several structural parts
Benefit #2	Minimized the structural assembly’s weight of the aluminum subframe
Benefit #3	Optimized the manufacturing process of the bike’s swingarm

Benefit #1

Achieved maximum weight reduction in the design of several structural parts

Benefit #2

Minimized the structural assembly’s weight of the aluminum subframe

Benefit #3

Optimized the manufacturing process of the bike’s swingarm

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Overview

Victory Through Innovation: Winning the Race and Staying Sustainable with Altair Solutions

Operational Impact

Quantitative Benefit