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The commercial fan market has been shifting from large custom-designed fan systems to more standardized factory-manufactured units. In response to this trend, AcoustiFLO aimed to develop an efficient small centrifugal fan that could be marketed as a standardized, modular component suitable for packaged air handlers. The concept for this small fan consisted of a centrifugal impeller housed in a vaneless diffuser. However, optimizing the static pressure efficiency of the unit required simultaneous optimization of both the impeller and the diffuser due to their interaction. The engineers at AcoustiFLO found that physical testing was not only cost prohibitive but also failed to provide the necessary insight into the airflow for design improvement. The less powerful CFD software they had been using for simpler design tasks lacked the power to analyze the turbulence and rotational dynamics in the impeller.

Robo-Technology GmbH, a company that specializes in the planning, development, design, manufacturing, and programming of automatic robotic systems, faced a significant challenge. They were tasked with developing an ultrasonic testing system for helicopter parts, which could be up to 6 meters in length. The system required two synchronized 6-axis robots to carry out fast testing movements with high dynamic precision and synchronization. This demanded the highest construction standards, posing a significant challenge for the company. The complexity of the task was further compounded by the need to ensure the rigidity and vibration behavior of the system met the customer's demands.

Trek Bicycle Company, a global leader in bicycle design, manufacturing, and distribution, faced a significant challenge in maintaining its competitive edge in the industry. The company's success hinged on its ability to release innovative products that met stringent strength and stiffness requirements, all while adhering to critical product launch deadlines. A specific challenge was to expedite the market release of a cycle with an assembly composed of an aluminum steer tube bonded with epoxy adhesive into a composite fork that is bolted to the wheel axle. The complexity of the assembly and the need for precision in design and manufacturing posed a significant hurdle in meeting the desired speed to market.

Mohyi Labs, a pioneering company in the field of drone technology, faced significant challenges in the development of their Bladeless Drone. The company was working on a novel Ducted Counter-Vortex Radial Impeller Propulsion technology, but the design optimization process was proving to be a major hurdle. Prior to the involvement of ANSYS, the process required a considerable degree of detective work, relying heavily on indirect methods to deduce the characteristics of the invisible forces at work. While this approach was successful in the early stages, it was time-consuming, significantly increased the difficulty level, and escalated development costs. Mohyi Labs recognized the need for advanced physics simulations to achieve the level of precision engineering required for their project. However, these advanced simulations were, until recently, exclusive to large corporations, academic, and military users.

The Engine NVH Analysis Section at Ford Motor Company is tasked with providing CAE NVH design analysis support to various programs. The types of analysis performed include engine component and assembly modal & vibrational response analysis, engine component and assembly radiated noise analysis, crank/block dynamic interaction analysis, air intake system NVH analysis, and exhaust manifold radiated noise analysis. However, with program timing being regularly compressed, the demand for quick turnaround on design analysis is constantly growing. As the finite element models become larger, they tend to drive the analysis time longer. This creates a need for quick FE models that accurately represent the structures, with the smallest number of degrees of freedom being an absolute necessity. The parts that need to be meshed can range from simple stampings to complex castings of cylinder heads, blocks, and manifolds, to even more complex multi-piece composite intake manifolds.

EADS Innovation Works, a leading global aerospace and defense company, was faced with the challenge of reducing the weight of aircraft parts to achieve cost savings and meet green transportation goals. The load introduction rib (LIR), a critical part of an aircraft’s wing flap, was a particular focus. The aerodynamic loads are transferred through the LIR onto the wing, and engineers needed to analyze the wing flap under conditions of a jammed flap mechanism. This load scenario traditionally required a detailed model of the flap mechanism. To evaluate the failure criteria of a composite LIR, engineers at EADS Innovation Works used an ANSYS Composite PrepPost model and a shell model, and compared the accuracy and workflow efficiency with a traditional solid model.

FMC Technologies India Pvt. Ltd. was faced with the challenge of designing subsea oil and gas equipment that could withstand high pressure and high temperature domains. The equipment had to be qualified per ASME BPVC VIII, Division 3, which requires the cumulative damage on the equipment to be below 1. The increasing depth of oil extraction meant that the structural loading requirements for subsea components were increasing, but there were also space and weight constraints on these components. To reduce over-engineering and promote value engineering, engineers needed to visualize damage distribution in each component. However, ANSYS Structural, the technology they were using, did not have a method to plot damage. The challenge was to develop a customized method using ANSYS’ scripting capabilities.

Turbomeca, a leading producer of helicopter engines, was facing challenges in developing the embedded software that runs the control system for each engine family. The model-based design approach they adopted used simulation tools for rapid prototyping, software testing, and verification. However, this approach required time-consuming manual coding, which could potentially introduce coding errors and inconsistencies between the code and the model. To keep pace with new innovations in helicopter technology and to remain compliant with DO-178B/C standards, Turbomeca needed tools that would help them code more efficiently, reduce errors, and improve code management.

Energomash Group Enterprises, one of the largest manufacturers of power equipment in Russia, faced a significant challenge in their operations. The company, which is engaged in developing and manufacturing equipment for various types of power stations and pumps, as well as operating their own gas turbine plant and developing electric and thermal energy, needed to improve their mesh generation process. The requirements for this process included the construction of qualitative mesh structures that could be adapted for the specificity of the investigated process, integration with the CAD system, and a reduction in the time required for mesh structure construction for typical problems.

DePuy Spine Inc., a leading supplier of orthopedic spinal implants, has been striving to improve the behavior of total disc replacement implants, particularly the CHARITÉ artificial disc. This three-piece articulating device is designed to eliminate pain and maintain motion of the operative segment, offering an alternative to spinal fusion surgery. However, understanding the effect of implant placement within the disc space on the loading of the facets, known to generate pain when supraphysiologically loaded, posed a significant challenge. Traditional studies involving cadaveric testing with strain gauges and pressure sensors were time-consuming, expensive, and often inconclusive. The company needed a more efficient and accurate method to understand and optimize the performance of the CHARITÉ artificial disc.

KTM Technologies was tasked with the development of the KTM X-Bow, a unique super sports car featuring a monocoque made from carbon composites materials. The monocoque, the external skin of the vehicle, provides structural support, marking it as the world's first production car with such a feature. The challenge lay in the use of carbon composites, which, while ideal for their lightweight and high strength properties, presented engineering complexities. The process of engineering composites designs from concept to simulation and manufacturing included countless opportunities for engineers to choose materials, fiber orientation, manufacturing methods, and layup arrangements. The KTM X-Bow monocoque was to be manufactured using over 300 pre-cut composite plies, adding to the complexity of the task. The challenge was to address these complexities in composites engineering to develop one of the world's most exciting and modern sports cars.

TibaRay, Inc. is a startup aiming to design the next generation of radiation therapy (RT) systems for cancer treatment. The existing RT systems face significant challenges, including collateral damage to normal organs, the need for better accuracy/focusing, motion control, and cost and accessibility issues, particularly in the developing world. TibaRay's proposed product, PHASER, is designed to address these challenges. However, the design of PHASER would not be possible without detailed and accurate engineering simulations. One of the specific challenges in existing RT systems is patient motion, which limits treatment accuracy. Although motion management is implemented in existing RT systems to some extent, PHASER aims to deliver the treatment dose so fast that the effects of motion are essentially eliminated. To achieve this, the design of novel RF components is necessary, requiring electromagnetic and thermal simulations.

AMOG Consulting, a specialist service provider to various sectors including marine construction, government organizations, and offshore oil and gas, was facing several challenges. The company needed to accelerate the simulation-to-design process in a high-technology multidisciplinary engineering environment. They aimed to improve quality by utilizing one 3-D CAD model for all engineering disciplines. The company also wanted to provide clients with more robust and advanced designs within their budgets. Another challenge was to create a bridge between CAD hydrodynamic, fluid dynamic, and structural simulations. The need for a streamlined process was evident to meet industry demands for a more robust and optimized product.

Hatch Mott MacDonald (HMM), a leading North American consulting engineering firm, specializes in the design of underground ventilation systems. One of their key areas of expertise is the prediction of fire and smoke movement in these systems. The challenge they faced was the comprehensive modeling and design analyses for existing tunnels and transportation facilities from a fire/life safety and ventilation perspective. The objectives were to provide good environmental conditions for users during normal operation and safe conditions for evacuation in emergency modes. Fire and smoke modeling required a consideration of turbulent, buoyant, chemically reacting flows and a need to assess tenability conditions, based on visibility, temperature, and toxicity. However, physical measurements in such large structures rarely led to an understanding of the subtle thermal mechanisms that control the environment.

The Grand Central Terminal (GCT), a principal hub of the MTA Metro-North Railroad, faced a significant challenge in ventilating its trainshed, one of the largest underground structures in Manhattan. The trainshed, which occupies 2.5 million square feet, was designed long before the advent of air conditioning, and the widespread use of air-conditioned equipment added waste heat into the facility. The existing ventilation, provided by sidewalk grilles and a few small vent shafts, was insufficient for the large area of the trainshed. During summer months, ground level temperatures were typically 15 degrees Fahrenheit above ambient. Previous attempts to improve ventilation had been costly and ineffective. Hatch Mott McDonald (HMM), a full-service engineering firm, was contracted to conduct a preliminary study using computational fluid dynamics (CFD) to understand the current ventilation conditions and the impact of changes made in recent years.

Steven Aguirre, the owner of Billet Designs, a small engineering firm, was faced with the challenge of balancing various aspects of his business, including product design, marketing, order fulfillment, sales, manufacturing, and general product line development. His primary task was to design a CO2 dispenser for a beverage growler, with the aim of creating an optimal product while efficiently utilizing limited resources within a typically short product development cycle. A few years ago, Aguirre had shifted his business model to outsource assembly, order fulfillment, and inventory management, allowing him to focus on product design. He had experience with popular 2-D and 3-D CAD tools, but he needed a more efficient way to create 3-D models and make changes quickly. The tools he had tried were either too cumbersome or inadequate, making speed and efficiency a significant challenge.

Electro-Motive Diesel (EMD), the world’s largest supplier of diesel-electric locomotives, was under pressure to develop the SD70ACe locomotive that meets high standards of performance, reliability, fuel economy, crashworthiness, and operator comfort. The locomotives are expected to operate economically and safely for decades under harsh conditions with minimal downtime. Durability of components undergoing repeated fatigue cycles was a major concern, as most units log more than 1 million miles during the first six years of operation and have a useful life of nearly 30 years, with some major components lasting more than 50 years. Achieving these goals while shortening the development cycle was particularly challenging due to significant time and cost factors associated with running physical tests on such large, complex machines.

The University of Colorado Health Science Center's cardiology research engineers were seeking to gain a deeper understanding of pulmonary arterial hypertension (PAH), a condition characterized by persistently high pressure in the vessels that transport oxygen-poor blood from the heart's right ventricle to the small arteries in the lungs. Over time, the increased load due to PAH can lead to premature heart failure and death. The current clinical methods for diagnosing and evaluating PAH are invasive and only consider the mean flow rate and pressure drop across the vasculature. The challenge was to simulate transient hemodynamics and arterial motion, which required a solution for the coupled solid and fluid domains. The geometry definition was derived from medical imaging, and the constitutive modeling of the vasculature was complex due to hyperelastic materials and complex constraint relationships. Additionally, the fluid boundary conditions could not be simply characterized.

Delta Marine Industries Inc., a leading megayacht builder, faced a significant challenge in meeting the high customization demands of their clients. The company's clientele, purchasers of 100-foot plus megayachts, expected the ability to highly customize the interior design of their yachts. This demand for customization, particularly the freedom to place walls or partitions wherever desired, created structural design challenges by increasing the complexity of the load paths. The non-alignment of pillars made it difficult to determine how loads would distribute across various structural elements. Traditional design methods were inadequate due to the highly nonlinear and difficult to discretize load paths. Furthermore, Delta Marine was tasked with building a megayacht that not only had a luxurious interior and high cruising speed but also optimized weight and structural elements for strength and vibration resistance.

Murray Inc., a global manufacturer of outdoor power equipment, was faced with a significant challenge. The company had a narrow window of opportunity to get its new product, the Power 2 Steer snowthrower, into production before losing business from one of its strategic snowthrower retailers. The Power 2 Steer featured a unique steering system that required a new clutch assembly, the effects of which on stress and deflection levels needed to be evaluated for various components and subsystems throughout the snowthrower. This included the drive shafts, bearings, subframe, and the sheetmetal main chassis. Designing these components for the necessary strength was critical to ensure adequate fatigue life of components without adding prohibitive cost and material. The tight product development schedule left no room for numerous physical prototype test cycles.

Hi-Tech Outsourcing Services, a leading architectural engineering construction (AEC) and industrial services provider in India, faced a challenge in the design of computer storage racks. These racks, used to mount servers or desktops, must provide structural support for computers and comply with Bellcore testing standards, the most common set of safety, spatial, and environmental design guidelines applied to telecommunications equipment. The challenge was to ensure compliance with these standards while also meeting the increasing demand for quick turnaround during product development. The company needed to develop products using fewer prototype tests to deliver a faster time to market, all while ensuring the racks could withstand seismic tests.

Champion Elevators Inc., a Texas-based leader in the design and installation of rack-and-pinion driven elevators, faced the challenge of redesigning cost-effective, yet safe elevators that conform to the stringent building and electrical codes of the high-rise construction industry. The company had to ensure that their elevators met two different sets of standards - regulatory building and electrical codes, and safety standards that are essentially physical properties. After almost three decades in the business, Champion Elevators knew that conformance to building codes was a must. Given the obvious risks, engineers at Champion ran every job through analysis. Assuring safety and conformance to the codes and regulations fell into two very different types of engineering analyses. Safety assurances of the elevator — essentially measuring maximum stresses and ensuring adequate safety margins — was handled with ANSYS DesignSpace® software for finite element modeling and finite element analysis (FEM/FEA) from ANSYS Inc.

Dana Corporation, a leading supplier of parts and assemblies to the automotive industry, faced a significant challenge in designing suspension systems and other assemblies for heavy trucks. The task was formidable due to the heavy loads, harsh environments, and long life requirements of these components. Historically, these components were over-designed and heavier to meet reliability requirements. However, in the current economy, the weight of commercial trucks and its impact on vehicle cost, ride, and fuel economy became a significant concern for both truck manufacturers and end users. The challenge was to design these parts with minimal material yet still maintain adequate strength and stiffness. This had to be achieved while meeting tight budgets and product launch schedules that ruled out building and testing numerous hardware prototypes.

Segway LLC, the company behind the innovative Segway Human Transporter (HT), faced significant engineering challenges in the development of their product. The Segway HT, a two-wheeled, self-propelled scooter, was designed to revolutionize personal transportation. However, the device's compact design required the integration of numerous hardware and software components into a small space. This complexity presented significant challenges for the Mechanical Integrity group at Segway, who were tasked with ensuring that the device's features and functionality conformed to specified performance criteria. The group faced particular difficulties with the Segway HT's chassis, which had to accommodate the weight of an operator up to 250 pounds, house the device's motors, batteries, and electronic components, and be lightweight. The complex geometric configurations of the design made standard mechanical analysis techniques ineffective or extremely difficult to conduct.

RF2ANTENNA, a company specializing in wireless communications and charging, faced a challenge in designing a customized wireless charging system for wearable electronics. The traditional approach of experimental design was deemed time-consuming and costly as it required building different size coils and creating a measurement setup. The specific needs of wearable devices necessitated a custom design, which called for engineering simulations for a reasonably short, cost-effective design cycle. The challenge was to find a simulation software that could integrate a circuit solver with the electromagnetic solvers, to optimize the coil design process.

The continuous casting of steel, particularly when casting different grades in the same sequence, produces transition billets. These billets do not conform to any specific grade and thus need to be downgraded or diverted. The challenge lies in identifying the extent and location of this intermixed zone to minimize production and quality issues. The process of billet casting to convert liquid steel to solid billets is fraught with uncertainties and variables. For instance, the casting speed may change or certain strands may become non-functional, altering the flow in the tundish and changing the transition tonnage. Predicting and optimizing the transition tonnage during the grade change under different plant scenarios is a significant challenge. To better understand and manage this process, a CFD model was developed.

Grantec Engineering Consultants Inc. was tasked with the development of a water quality monitoring float designed to carry a sensor for capturing environmental data. The engineering team faced challenges in minimizing drag and ensuring stability of the float, as well as developing specifications for the mooring system and structure. The original design of the float had a bow that would have been driven below water, primarily due to a moment generated by current loading on the sensor. This posed a significant problem as it would affect the float's performance and the accuracy of the data collected by the sensor.

Plantool Oy, a leading production automation company in the Nordic countries, faced significant challenges in its operations. The company specializes in tailor-made special machines, standard circular saws, system solutions, and production lines for metal industries. However, the custom nature of their machines did not allow for prototypes. Each new order posed a major risk as the initial creation had to be the final product, necessitating perfect design from the outset. Additionally, these special machines often had to be designed from scratch, requiring a flexible design and simulation process. The use of existing 3D models for simulation was crucial, but the company lacked an efficient system to facilitate this.

Ballard Power Systems Inc., a Canadian company that designs, develops, and manufactures zero-emission PEM fuel cell stacks, faced a significant challenge with their MK9 series of cell voltage monitoring (CVM) systems. These systems, used in automotive fuel cell stacks, monitor the voltages produced by cells during operation. However, the company was experiencing CVM chip solder joint failures, which could prompt a false failure signal to the vehicle control unit, potentially shutting down the operation of the fuel cell and even the entire fuel cell engine. This issue was directly impacting the reliability of the entire fuel cell stack. The thermal expansion of the PCB and potting material, which protects the CVM from the environment, was causing deflections that resulted in stress on the solder joints. The company needed to gain insight into the structural load on electronic components during thermal cycling, identify probable areas where excessive stress could cause early CVM chip failure, and identify a potting material that would not exert thermal expansion stress on the CVM components.

India's growing population has led to an increased demand for power. To meet this demand, the country is looking towards renewable energy sources. CSIR-Central Mechanical Engineering Research Institute (CSIR-CMERI) has developed aesthetically pleasing solar cells, known as 'solar artifacts', in the form of umbrellas or trees. These solar artifacts can be placed in commercial or public spaces, providing power while maintaining the space underneath for productive or recreational uses. However, these solar artifacts needed to be designed to fit into the available space and withstand a range of wind speeds depending on their location. The challenge was to ensure that these artifacts would be strong enough to resist damage over a range of wind speeds without sacrificing their aesthetic design.