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Multiphysics simulation coupled with a design and CAD environment such as Solid Edge allows designers to evaluate the performance of a product or system without the need for physical prototypes. It allows you to test multiple engineering disciplines simultaneously, make design changes and optimize performance, reducing costs and development time. In summary, multiphysics simulation is a powerful tool to improve product quality and efficiency of the development process, reducing development time and maximizing performance, saving time and money for the company. Simcenter FLOEFD™ for Solid Edge® delivers the industry’s leading computational fluid dynamics (CFD) analysis tool for fluid flow and heat transfer. Fully embedded in Solid Edge, Simcenter FLOEFD has intelligent technology at its core to help make CFD easier, faster, and more accurate. It also enables design engineers to frontload CFD, or move simulation early into the design process, allowing users to identify and fix problems earlier, saving time and money and enhancing productivity by up to 40x. Simcenter FLOEFD for Solid Edge provides optional modules for advanced analyses. Three new add-on modules are now available in Solid Edge. Structural module Targeted specifically at the electronics industry, the new structural module is designed for Finite Element Analysis (FEA) of electronics cooling cases, leveraging the SmartPCB FE model. It allows for a direct use of temperature and pressure loads from the CFD simulation all within one simulation run. Using it coupled with electromagnetic and thermal analyses provides true multiphysics simulation capability. To see how this works, watch the video below. Extended Design Exploration (HEEDS) module With this module you can extend the Simcenter FLOEFD parametric study and design comparison functions to drive innovation with design exploration, moving beyond troubleshooting and evaluating designs to discovering better designs faster. The efficient and robust optimization and search functionality of the embedded HEEDS™ SHERPA algorithm leverages multiple global and local search strategies and adapts the search as it learns more about the design space. It doesn’t require specialized algorithmic search expertise and incorporates user intuition with its collaborative search capabilities. The process allows you to identify higher-performing families of designs with minimal simulation time and cost. Electromagnetic (EMAG) module The new Electromagnetic (EMAG) module simulates low-frequency electromagnetic effects of Alternating Current-induced (AC) ohmic and iron losses, as well as permanent magnets and the direct coupled CFD simulation, in order to consider these losses in the thermal simulation of components such as in transformers, bus bars, and induction heaters. For more information, schedule a meeting, and learn all the potential that these tools can awaken in your company!

SIEMENS Digital Industries Software is a company that helps automakers accelerate innovation to develop the next generation of vehicles. The traditional design process for cars has been split into different teams using different tools for design, testing and manufacturing, but this process is no longer adequate in the face of intensifying competition, rapidly changing consumer demands and increasing regulatory requirements. SIEMENS offers an accelerated product development approach with computer simulation and the use of digital twin to address these challenges. With the help of computer simulation, teams are able to test and validate solutions in a virtual environment before moving on to actual manufacturing. This allows them to deliver designs that work seamlessly together to innovate smarter, greener and more sophisticated products at a faster and more effective pace. Additionally, using a digital twin allows teams to maintain a complete view of product development over time, which helps them identify and fix issues faster and collaborate more efficiently.

Artificial intelligence accompanies the development of innovative products, in relation to Siemens Digital Industries products on CAD platforms such as SOLID EDGE and NX , and CAE such as SIMCENTER 3D there are technologies that integrate the use of algorithms based on Artificial Intelligence that help in optimization and product resizing. Currently in the world there is a need to obtain products with lower production costs and a lower environmental impact. From the point of view of creativity, many of the current designs use elements as a source of inspiration from nature in terms of their organic shapes, the perfection of these shapes allows solving problems of complex geometries in parts and also saves on materials that affect the manufacturing process, these shapes can be expressed mathematically and integrated into AI or optimization algorithms that help engineering teams make better design decisions. The images above show a piece that had its inspiration from biomimicry at the Salsão plant and soon after, from a CAD project and continuous optimization processes, a steam valve project was arrived at, given the increasing advances in processes. of manufacturing in the area of ​​additive manufacturing, the manufacture of these complex parts becomes easier, reducing material waste and allowing a shorter time to obtain them. Some of the existing technologies within Siemens Digital Industries platforms to address this scenario are: NX TOPOLOGY OPTIMIZER It is the best known technology in terms of material reduction without affecting the rigidity of the part, this technology is widely applied in castings and can also be integrated into other manufacturing processes such as additive manufacturing. This technology is based on element loads and boundary conditions given by existing geometry axes and contours. As can be seen in the image, a support built by welded plates can be simplified by a simpler model, but which meets the conditions of resistance and functionality of the support. NX LATTICE STRUCTURE DESIGN This algorithm allows defining structural elements that optimize the use of materials in additive manufacturing processes inside the parts. Depending on the geometry of the parts, these structures can support the manufacturing process to avoid dimensional distortions during the process. NX ALGORITMIC MODELING It is an alternative when it comes to parameterizing CAD geometries that allows, from block programming, to insert complex operations on the surface of the CAD solid, as well as generate complex structures using a CAD surface as a base. Starting from a base geometry, the Logic Editor tool is activated , which allows access to a programming interface by blocks and access to libraries with which blocks with parameters can be linked, and thus generate routines between the parameters. This routine is automatically linked to the base geometry with a dialog window that allows controlling the desired parameters in the part. DESIGN EXPLORER – SHERPA SHERPA is a technology available in the SIMCENTER HEEDS product . The basis of this technology is that from parameters it can automate and execute iterative design processes and thus implement boundary and penalty conditions to arrive at optimized designs. This technology has a library of algorithms to be implemented. Obtain design options that can be compared with other results, such as in CAE analysis, from these comparisons, graphically, an optimal range can be established, design and determine which designs meet the requirements established for the project. With these technologies, it is possible to manufacture complex parts with lower production costs and less environmental impact, in addition to being inspired by organic forms of nature. Give these technologies a try and see how they can transform your project.

Are you a foundry company looking to stand out in the market and ensure the success of your business? Then you need to know CAEXPERTS, a strategic partner for the implementation of advanced digital engineering in your business! Through the use of Siemens Digital Industries Software tools, combined with CAEXPERTS expertise in industrial engineering solutions, your company will become more competitive and will be able to add even more value to your end customer, closing more deals and standing out in relation to competitors. With the use of Simcenter 3D, your company will have access to advanced parts engineering, which will allow you to improve the design of parts for your customers and ensure a high technical level of engineering and cost optimization. In addition, with STAR-CCM+, your company will be able to engineer the foundry process, optimizing it to obtain products with higher quality, lower cost and shorter production time. With the implementation of an advanced CAE cell, your company will be able to evolve towards having a greater understanding of how your products work, designing safer, more robust, efficient and reliable parts and foundry processes. And CAEXPERTS and Siemens Digital Industries Software will be committed to helping your company expand its operational excellence, competitiveness and technological vanguard. Don't miss the opportunity to transform the foundry industry into your company, adding even more value to your end customer and ensuring the success of your business. Talk to someone who is an expert on the subject! Get in touch with CAEXPERTS right now and find out how we can be a great technological partner for your company!

One aspect that causes great frustration is when customers design extremely detailed and sophisticated systems, but, after design validation, choose to discard them. Although this is a valid workflow , it is important to reflect on the possibility of taking advantage of all the benefits of the developed model. Why discontinue use of the model after validation when there is an opportunity to continue using it during the design and operation phases of the system? This approach can result in significant time and resource savings, as well as ensuring that the system is always up to date with necessary changes and improvements. Currently, with the evolution of Industry 4.0, making tools and resources available to leverage simulation models far beyond the initial design phase has become essential. In that sense, a connector was developed inside Simcenter Flomaster , which allows you to interact with the hardware and create executable digital twins, based on your original models. With this approach, it is possible to extend the use of simulation models to the operational phase, coupling them to a physical plant or thermofluid dynamic system . This means that a full fidelity model of the thermofluid system can be run in real time as an executable digital twin ( xDT ). With this approach, it is possible to extend the use of simulation models to the operational phase, coupling them to a physical plant or thermofluid dynamic system . This means that a full fidelity model of the thermofluid system can be run in real time as an executable digital twin ( xDT ). But what if the intention is just to create features? If we want to test them comprehensively? With simulation-based capabilities, this is achieved through validation exercises. However, how do you test a connection to physical hardware ? The answer is simple: Create a test installation! The test setup shown at the beginning of this article, while certainly compact and portable, can be used to validate several important operational scenarios. The first is virtual detection, which allows obtaining additional information about the system by simulating the digital twin, in addition to relying on the installed physical sensors. This is particularly important in many situations, for example when measuring something without affecting the value or when the system operates at extreme temperatures and pressures, which can damage hardware sensors . This highlights the fact that hardware sensors are expensive and fragile, and time consuming to install and change. The solution to all this is to install some sensors, and take advantage of virtual detection. This was performed on the test rig as flowmeters are notoriously expensive. So only one was installed directly after the pumps, and then throughout the rest of the system, virtual flowmeters are used in all the complex and winding fluid paths. As can be seen in this Human Machine Interface (HMI), the fluid enters from the left before splitting into three distinct paths. These eventually combine and form a closed loop. Normally, we wouldn't know what the flows are on each of the lines. You could probably guess that it's a third of the main flow for this example, but if you had more rows with variable geometry, how would you know? Also, what would happen if one of the valves didn't open or close? You would believe that there is flow where there is none, which could lead to insufficient cooling and result in more failures. To obtain additional information about the operation of the facilities, virtual sensors that work outside the model within Simcenter Flomaster are added . They have been colored blue on the HMI for easy reference. We can see that there is flow present on lines one and two, and to an operator there would be no discernible difference between a hardware or software sensor. The system is able to respond and match the real plant through changes in the operating point. For example, starting and stopping pumps, opening and closing valves in the system and through leak lines we added to simulate a leak detection scenario. By doing this, the real-time full fidelity model can handle whatever operating point the hardware is running at. This is the main advantage of using a full-fidelity model rather than a reduced-order model. To show this in more detail, watch this short video. Make the most of your models and streamline your design and operation processes, while reducing instrumentation costs and gaining additional insight into your plants. At CAEXPERTS, a SIEMENS technology partner , we are available to help you on this journey, offering our experience in modeling and advanced simulation.

Are you selling equipment by the kilo? Did you know that you can stop selling steel and start selling phosphate! If your company is pricing its equipment based on the cost of raw materials and valuing grandeur over efficiency, it is important to be aware that this business model may be limiting your innovation potential and profitability. The current market is looking for more intelligent, efficient and versatile equipment, not just the heaviest and most imposing ones. It's time to rethink your strategies and explore the advantages that the digitalization of Engineering can bring to your production processes. Through advanced simulation, integrated platforms and efficient process management, it is possible to accelerate your project cycle, reduce costs, improve efficiency and increase the functionality of your equipment. Large industrial sectors, such as aeronautics, automotive and electronics, have been using these technologies for decades, allowing them to be at the forefront of their sectors and offer increasingly efficient and innovative equipment. In the agricultural sector, it is common for the customer to buy robust and heavy equipment, and manufacturers develop bulky and heavy equipment to maximize revenue. However, it is possible to create smaller, lighter and more efficient equipment that perform the same or even more tasks, creating an opportunity for innovation and profitability. Watch the video about the business vision pitfalls that many agro-industries face when avoiding the intensive use of digitization in Engineering. With valuable insights into how to avoid these pitfalls, you can take your first steps into a new era of growth and innovation for your business. At CAEXPERTS, we are ready to help you find innovative solutions that will take your business to the next level. Contact us to learn more about how we can help you optimize your production processes and make your equipment more efficient, economical and innovative. The time is now - let's transform the future together!

Small-to-medium-sized businesses (SMBs) can face several obstacles and challenges, which includes contending with increasing global competition and a large enterprise’s seemingly limitless resources and technological capabilities. Adoption of advanced and digital technologies can be met with resistance due to complexity, cost, and lack of resources. And still, products are becoming ever more complex across all industries as customers demand more personalization as the lifecycle of products is compressing. Other challenges include: Inability to react in real-time to production or design adjustments, which lead to cost overruns, missed delivery and reduced efficiency Lost market share and revenue and inability to grow due to current methods and processes unable to handle complexity Unrealistic customer expectations due to global competition Continued cost of prototyping causing delays, quality issues and increased errors Growing skills gap and a lack of talent Juggling multiple data formats or lack of real-time bill-of-material (BOM) visibility How can SMBs meet these challenges with confidence, and not just survive but thrive? They need easily accessible, affordable solutions that enable rapid delivery of higher quality, customized designs, while reducing development and outsourcing costs. Knocking down perceived barriers There are perceived barriers when smaller companies are either unfamiliar with what new technology has to offer or they perceive it as being too expensive for their smaller-sized business. Companies like Rurok Industries prove otherwise. The founders of Rurok Industries were not satisfied with the bikes they were using. So, they created a business to produce mountain bikes that met their expectation. But developing high-end, precision-engineered products like a new bike is challenging because it requires a comprehensive and costly testing and prototyping process. Rurok Industries uses digitalization to compete in the global marketplace. With the adoption of Solid Edge, part of the Siemens Xcelerator portfolio, Rurok could design, optimize and validate their designs digitally, which reduced development time by 20 percent and minimized prototyping. They were confident in their product development and could invest in the growth of their business. Now they can compete on a global scale. Rurok recognized that their designers worked best whenever and wherever inspiration strikes— making instant accessibility to the latest project data imperative. The conditions were perfect for the team to take full advantage of Siemens Xcelerator Share, a new app in the Siemens Xcelerator portfolio available as a service, that synchronizes data from common CAD software to the cloud. With this next-generation project collaboration tool, Rurok’s various product development teams could view, measure and mark up CAD models in Solid Edge using a simple browser interface. The app then synchronizes the files as they work, making project data accessible to any team member, from anywhere. It became the expressive communications tool they needed to easily describe their ideas while looking at the same design models directly. Even their riders and racers, who had never used PLM or CAD before, could get involved in the discussion.​ Embracing a digital future Businesses of all sizes can manage the complexity and deliver tomorrow’s smart, connected products today. They can outpace their competition with personalized solutions that are quickly adaptable to changing business conditions. Personalized solutions come with a freedom to choose only the capabilities that a business needs. A flexible, open ecosystem allows any business to tap into a vast network of partners and developers, work multiple programs to share data and enables collaboration with their customers and other suppliers. One of the tenets of the Siemens Xcelerator portfolio is its comprehensive digital twin. It creates closed-loop connections between the real and digital worlds with a digital thread across the value chain of product design, production and performance. For SMBs, integrating domains provides a wealth of technological advantages from the ability to reduce the number of prototypes to removing bottlenecks to capturing real time feedback in a closed loop environment. Just this alone can lower the cost of designing and manufacturing better products faster. More and more SMBs are embracing Siemens Xcelerator and its cloud-enabled as a Service, proving they can take hold of the capabilities from Teamcenter, NX, Simcenter, etc. as and when they need them. Each new success story is knocking down perceived barriers. SMBs can thrive on a global marketplace with the adoption of affordable, accessible and flexible digital tools. The agile startup Cox Marine is a British startup that was eager to revolutionize the outboard engine industry. As they developed their outboard motors, they were determined to reinvent a service model that would also accommodate their network of 200 dealers and representation in 100 countries. As a small startup, they faced monumental challenges, such as entering a highly-competitive marketplace with both a product and a matching business model. They had to find relief from the massive costs of technology so they needed to be agile, flexible and scalable because they didn’t have the infrastructure that their larger competitors had. Cox Marine needed to integrate the right digitalization tools to succeed in both product development and to support a growing international business model. By taking a digitalization approach and integrating with the digitalization tools of Siemens Xcelerator, they created their first product, the CXO300 outboard engine. It was more fuel-efficient while also being high-powered, high-performance, more durable and cleaner than most of the outboard motors on the market. Cox Marine uses digitalization to build outboard motors that are high-performance, more durable and cleaner than most outboard motors on the market. “We had to make something as small and light as a car engine, but as strong and robust as a big truck engine. Software plays a huge role in understanding how to optimize and design structures. There are so many elements to consider.” Joel Reid, Global Sales Director Cox Marine Digitalization and customization As the skills gap grows and the struggle to recruit engineering talent continues, every company must be flexible and scalable to meet the needs of their projects. They must have partners they trust, that have experts and domain knowledge they can count on. The flexibility of the Xcelerator as a Service (XaaS) solution means companies can do the same amount, or more, work with fewer skilled technicians. Remote work is not going away, so SMBs can look toward XaaS for secure, trusted cloud-enabled technology without the investment of an internal IT infrastructure. With the flexibility and scalability of XaaS, any company can scale up or down when needed and access their product design at any time, from anywhere and on any device. Imagine it’s a Friday afternoon and a customer calls to make an urgent change on a product you’re creating for them. Because the weekend is upon us, it will be near impossible to talk to your supplier. This causes delays, which holds up production because changes to the design must be made and tested. Because you have the cloud-based solutions and can access a bevy of software and services like simulation and verification software, you can make immediate changes, run tests to verify before going to production, make manufacturing more flexible without losing time, and not have to spend the weekend worrying about this urgent change. SMBs want to thrive. They want to have the ability to compete on a global scale whether they have a handful of employees, or hundreds. To address the main challenges such as shortened cycle time to bring products to market faster, designing more complex and personalized products, protecting their margins and decreasing costs, SMBs need a future-focused approach. Xcelerator as a Service is proving to be the solution to help them remain flexible and adaptable regardless of any challenges that come their way. Xcelerator as a Service: cloud enabled technology for the digital future Do you want to know more and reach new heights with digital engineering?

Model the complexity of battery thermal runaway with ease. Run CFD simulations with energy and cost savings thanks to ARM64 CPU support and increased GPU-enabled acceleration. Accelerate your CFD simulations by over 30% with the SIMPLEC scheme. Document, share and review detailed model information in CFD software . Simcenter STAR-CCM+ 2302 comes with several new features that let you go faster while modeling complexity. Battery thermal runaway setup in minutes CFD simulation of battery thermal runaway. With a dedicated workflow, configuring complex heat release physics is significantly faster and easier with the Simcenter STAR-CCM+ 2302 With the rapid growth of electric vehicles circulating on the roads, new safety rules have been implemented at the national and international level, with new UN safety rules on the use of lithium-ion batteries. This legislation forces major battery manufacturers and users to perform a number of expensive and time-consuming tests to obtain certifications. This leads to an increasing demand for simulation to reduce the cost of testing and make security design cost effective. In Simcenter STAR-CCM+ 2302 , a dedicated workflow was released to accelerate the setup time of thermal runaway propagation simulations for batteries from hours to minutes. Thanks to a focused workflow, you can now handle large batches of hundreds or thousands of cells with ease while maintaining high modeling fidelity. The workflow supports direct simulation of exothermic heat release from “failed” cells with an empirical model and is accessible as part of the Simcenter STAR-CCM+ Batteries add-on . Thanks to its powerful multiphysics capabilities and new dedicated workflow, Simcenter STAR-CCM+ is perfectly suited to study the propagation of uncontrolled thermal events in complex packaging geometry. Simcenter STAR-CCM+ provides a comprehensive solution to better understand this dangerous security event and helps design packages and mitigation measures, thereby reducing the need for costly testing. Easy and accurate modeling of motion with overset meshes With the Simcenter STAR-CCM+ 2302 , you can run cases more reliably with small gaps and motion, thanks to the refined overset region that matches the refinement level of the background region. Warehouse separation, valves, dip coating and many other applications involve moving bodies, with small spaces in conjunction with complex fluid dynamics. To simulate such complex CFD applications, overset mesh technology along with Adaptive Mesh Refinement (AMR) has become a key technology. With the Simcenter STAR-CCM+ 2302 , we make it easy to run these cases by automatically refining the overlay region to match the refinement level of the background region. Small gap scenarios will immediately benefit from the new feature, ensuring valid meshes and guaranteed convergence with no additional user effort. Model new applications involving the drying of wet solid materials Simulating electrode paste drying in an industrial convection oven (part of the battery manufacturing process) using DEM with liquid evaporation is now possible thanks to the extension of evaporation models to DEM phases Many applications in the chemical processing, mining, steel, food and battery manufacturing industries involve drying wet solids. CFD simulation of such systems requires accurate prediction of particle motion and related phase change phenomena. In Simcenter STAR-CCM+ 2022.1 , therefore, we introduced the Liquid-Solid-Gas material for non-DEM Lagrangian particles, allowing to apply evaporation modeling for droplets containing solid materials. This functionality is, for example, successfully used to simulate milk droplets in spray drying. With the Simcenter STAR-CCM+ 2302 , we have extended the capabilities of discrete element method (DEM) particles, allowing you to apply evaporation models to DEM phases. This allows you to model new applications involving the drying of solid materials where DEM is the particle dynamics method of choice, allowing evaporation of liquid components into DEM particles. Thanks to the new feature, you can accurately simulate drying processes in direct convection based dryers such as drum dryers, spray dryers, fluidized bed dryers or indirect conduction based dryers using the discrete element method for the phase wet solid. Best performance for price with ARM support With the Simcenter STAR-CCM+ 2302 , we enable you to run bigger, faster CFD simulations for less cost and energy using Advanced Reduced Instruction Set Computer Machines (ARM) CPU technology. Simulation has become a critical factor in time- and resource-efficient product development. And while CFD simulation consumes significantly less resources than the corresponding physical test, to remain competitive, companies must go one step further. With the ever-increasing volume of simulation-based product designs, to gain a competitive advantage, you must optimize the energy consumption and costs associated with these high-fidelity simulations. Ultimately, a sustainable, cost-effective and energy-efficient digital twin is a differentiating factor and competitive advantage in virtual product development. With the Simcenter STAR-CCM+ 2302 , we enable you to run bigger, faster CFD simulations for less cost and energy using Advanced Reduced Instruction Set Computer Machines (ARM) CPU technology . The technology is currently supported on Linux and is available through different cloud providers such as AWS EC2 instances or the Fugaku supercomputer provided by Fujitsu in Japan. With ARM support, we've added another option to run your CFD simulation on an increasingly heterogeneous hardware architecture landscape . Whether GPU or CPU, local or cloud, ARM or conventional CPUs, Simcenter STAR-CCM+ offers a variety of options to maximize your throughput. Bigger and faster simulations on GPUs Simcenter STAR-CCM+ 2302 comes with a reduced memory overhead on GPUs, allowing you to fit larger models onto a single GPU with immediate performance benefits. Typically, the size of simulation that can be run on GPUs is limited by the available memory (RAM) of a GPU card. Therefore, by reducing the memory footprint of a given simulation, you can fit larger meshes onto a single GPU. This is particularly useful as the most efficient GPU performance is seen when cards are "maximum", which means fitting as many cells as possible onto a single card. To maximize benefits, the Simcenter STAR-CCM+ 2302 comes with reduced memory overhead and improved performance through more efficient use of AmgX, as well as updates to CUDA, the NVIDIA API. In addition to the existing performance benefits of previous GPUs, these enhancements result in up to 40% memory reduction as well as up to 10% runtime performance improvements. As an example, a single NVIDIA A100 with 80GB of memory can now accommodate around 60 million cells trimmed in mixed precision. With these enhancements, we continue our strategy to support fast and efficient CFD simulation on GPUs while maintaining consistency with CPU-based results. Up to 40% faster simulations at no cost In Simcenter STAR-CCM+ 2302 , we introduced a new implicit unstable scheme for the segregated flow solver : the SIMPLE-Consistent one, called SIMPLEC. SIMPLEC allows significant speedup for simulating transient flows while still achieving the same accuracy as SIMPLE. Adding to the benefits of new hardware and massive scalability for high-performance computing, accelerating your CFD simulation through more efficient solving techniques remains the most cost-effective way to go faster. In Simcenter STAR-CCM+ 2302 , we introduce a new implicit unstable scheme for the segregated flow solver : the SIMPLE-Consistent one, called SIMPLEC. SIMPLEC allows a significant speedup for simulating transient flows due to deeper convergence of the solution within the time interval. Thanks to SIMPLEC, you can achieve the same accuracy as SIMPLE with a reduced number of internal iterations per time step. When using convergence-based stopping criteria for inner iterations, there is no need for adjustment when applying the new SIMPLEC scheme. For applications ranging from exterior vehicle aerodynamics through side mirror and HVAC aeroacoustics to aircraft wing icing, SIMPLEC results in a reduction of up to nearly 30% of total turnaround time. All this ensuring consistency of results between the SIMPLE and SIMPLEC approaches. And at no additional cost. Accelerate multiphase simulations without losing fidelity The potential of Implicit Multi-Step to speed up MMP-LSI simulations is illustrated by this gearbox lubrication example. When using 16 substeps, the acceleration is approaching 4x. In applications such as gearbox splatter droplets can break down into smaller and smaller sizes until you can no longer model the very small droplets as Lagrangian particles. At the same time, you still need to model the free surface of the bulk liquid. For such applications, multiphase mixing modeling with large scale interface (MMP-LSI) has become the method of choice. In general, MMP-LSI is relevant anywhere you have Fluid Volume (VOF), but that would be too expensive and a mixture is present. But like VOF, MMP-LSI has a comparatively high cost if you cannot decouple the choice of flow time interval from that required to fulfill the small time interval required for the volume fraction due to numerical Courant constraints. (CFL). To overcome this challenge, we previously implemented Implicit Multi-Step for VOF , where simulations were typically accelerated by 3-4x, and in some cases by up to an order of magnitude. In Simcenter STAR-CCM+ 2302 we are adding the same feature for MMP-LSI. Implicit Multi -Step allows a larger time range to be used for the flow (excluding the volume fraction) by sub-steps the volume fraction multiple times within the flow time range. This separates the choice of flow time interval from that required for the volume fraction due to CFL restrictions. Easily understand a design space using contour plots With Simcenter STAR-CCM+ 2302 , you can now quickly and easily generate performance maps with two independent variables and one dependent variable. For many applications, eg turbomachinery, CFD is a very powerful and cost-effective tool to generate performance maps through automated scans. These maps will give you immediate information about how a dependent variable is performing as a function of multiple independent variables. With Simcenter STAR-CCM+ 2302 , you can now quickly and easily generate performance maps with two independent variables and one dependent variable. This will allow you to add a layer of information to the standard XY chart via contour charts. Interpolation is used to draw the contour lines and the display of external data, say from experiments, is supported via tables. Thanks to the new feature, you will get information about a complete performance map with isolines in just a few clicks. Integrated access to simulation information In Simcenter STAR-CCM+ 2302 , we introduce the simulation guide. The simulation guide allows you to store all relevant information within the simulation file, significantly increasing your productivity. Combined with the simulation model functionality, it will take your productivity to new heights. In today's complex engineering world, efficient collaboration and sharing of relevant information between engineers is more important than ever. For simulation engineers, wasting their time looking for disconnected external resources to get the latest simulation setup documentation or usage instructions for model simulations is a huge productivity burden. For CFD simulations, this entails traceable data and workflow management and the ability to work in an integrated environment, allowing you to access all relevant simulation information quickly and directly. In Simcenter STAR-CCM+ 2302 , we introduce the Simulation Guide. The Simulation Guide allows you to store all relevant information within the simulation file. Having notes or instructions directly in the simulation file increases your productivity as you spend less time looking for information. With a built-in editor, you can add all relevant metadata exactly where it's needed: inside the simulation file. The editor allows you to write text, format it, add images, create tables. As a result, the simulation guide allows you to share, update and review information relevant to the simulation. It helps your team collaborate and build collective knowledge. Along with the model simulation file introduced in Simcenter STAR-CCM+ 2022.1 , the Simulation Guide will take your productivity to new heights: simulation model authors can leave detailed instructions exactly where needed, while model users can now quickly understand setup steps, leveraging streamlined workflow instructions while staying within the CFD environment. These are just a few highlights of the Simcenter STAR-CCM+ 2302 . These capabilities will enable you to design better products faster than ever before, turning today's engineering complexity into a competitive advantage. If you want to learn more about the amazing features of the Simcenter STAR-CCM+ 2302 and how they can help your company run complex simulations more reliably, schedule a meeting with us! Our experts will be on hand to discuss how this tool can meet your specific needs and help you achieve your goals. Don't miss the opportunity to experience the future of CFD simulation!

As shown in this video of a 120 MVA power transformer. An example of a noisy power transformer This noise, known as transformer hum, is so loud that mandatory personnel must wear protective gear at power substations. Close to residential, commercial and medical facilities, the noise is unbearable. It's like using a hair dryer or a vacuum cleaner 24/7! Tables 1 and 2 compare transformer hum to known ambient sound pressure levels in decibels (dB). We can see that the quietest transformer makes a similar amount of noise to a refrigerator. As the rated power increases, so does the noise level, until it is equivalent to that of a vacuum cleaner. Table 1: Ambient sound pressure levels (left). Table 2: Transformer sound pressure levels (right) Consequently, installation of transformers close to people without protective equipment must meet strict noise emission requirements. To avoid over-engineering, the transformer hum does not need to be significantly lower than the sound levels of other local equipment, such as cooling fans. Classification, design, assembly and installation affect the sound level. What causes transformer humming? To understand the sources of transformer hum, we must first look at the structure of a transformer. Figure 1shows a three-phase transformer. Phases A, B, and C (or U, V, and W) are wrapped around one of the legs, corresponding to the red, blue, and green bodies in the image below. The main magnetic flux path is well defined and unidirectional. We apply this advantage to maximize transformer power density using unidirectional (anisotropic) electrical steels. They are cold-rolled grain-oriented electrical silicon steels (CRGO/GOSS/GOES). These are electrical steels designed to efficiently permeate flow in one direction only with even less loss. At the corners, we see that the flow must change direction, forcing it through the unoptimized direction. To handle this, the core is divided into upper and lower yokes, and the three legs use specially designed joints. The transformer joint design,Figure 1 , it's a worthy engineering challenge. Affects losses, noise and assembly. Figure 1: Basic structure of a three-phase power transformer What is magnetostriction? The price we pay for using grain oriented steels is higher noise levels. In general, when a ferromagnetic material is exposed to a magnetic field, it undergoes mechanical stresses that it relieves by changing shape. This shape change due to forces induced by the magnetic field is magnetostriction. The strain is either positive (increases), as in the case of iron, or negative (shortens), as in nickel. Figure 2: The deformation of a transformer member due to a sinusoidally applied magnetic field Ha In Figure 2 , as the applied field increases, the limb (sleeve or leg) undergoes tension and lengthens, which is maximum according to the peak of the field. As the field decreases, the elongation also decreases. In the negative half cycle, the deformation process is repeated, although the field is inverted (disregarding hysteresis memory effects). The magnetostriction, therefore, occurs with twice the network frequency, that is, for each electrical cycle, there are two cycles of magnetostriction. Other permeable transformer elements such as shields, clamps, and tanks also experience magnetostriction due to exposure to leakage (stray) flux. Now we can consider the effects of magnetostrictive forces on the new version 2212 of Simcenter 3D Low Freq EM. Although it happens in all ferromagnetic devices, why is it associated with transformers? Simply because of the core material. Grain-oriented electrical steels permeate more unidirectional flow for the same applied field as non-oriented (isotropic) steels. Isotropic steels are used in rotating electrical machines. Thus, grain-oriented electrical steels experience higher levels of magnetostriction and sound pressure. Is this the only source of transformer noise? In the animation, you can see that the transformer windings are an important part of the transformer. They also experience a force known as the Lorentz or J x B , where J is the surface electric current density and B is the magnetic induction. If you place a conductor between the poles of a horseshoe magnet and place it over two parallel conductors where it can roll freely, complete the circuit using a battery and a switch. Immediately you flip the switch, the conductor will roll in one direction until it is out of range of the magnetic field. In the same way the loose thread is displaced in the images below. He experiences the Lorentz force caused by current flow in the presence of a magnetic field. Animation from The Lorentz Force – YouTube Transformer windings also experience this, as they conduct current in the presence of core, leakage, and winding (self and mutual) fields. Although screwed in, some deformation of the winding structure still occurs, repeating at twice the grid frequency. In addition to noise, Lorentz forces are often the reason for structural winding failure. As is often the case when a system short-circuits and the current increases several times the rated current. Structural elements of the conductive transformer, such as shields, bolts, and fastening systems, are also subject to Lorentz forces. They are exposed to leaks and stray fields, which induce eddy currents, resulting in Lorentz forces. Reducing leakage and eddy fields is an ever-present challenge in transformer design. With our newfound knowledge, let's revisit the transformer joint seen on the right in Figure 1 . It is important to observe the air gaps. They interrupt the flow of magnetic flux by establishing an attractive force between the rungs, as when a gap separates two magnets. This is compounded by magnetostrictive effects and increased flux leakage. The attractive or repulsive force is known as the magnetic force or Maxwell's force. The complexity of transformer joint design is addressed by looking at the EMAG and force contributions. How is transformer noise analyzed? The 1300 kVar reactor seen in figure 3 was simulated in the new version of Simcenter 3D 2212. In the low-frequency EM (EMAG) environment, the magnetostrictive characteristic curve was defined from deformation and magnetic induction. After setting up the EMAG problem, the forces of interest based on the bodies they act on, in this case the core, were requested and extracted simultaneously during resolution. They were then exported to the Simcenter 3D Acoustics solver. Secondary physics-specific geometric and mesh models were derived and associated with the same primary CAD. Consequently, any CAD changes are automatically inherited, saving time that would otherwise be spent manually accommodating any new geometric changes. The field results in figure 3 are the mangetic inductions, the magnetostriction forces and the corresponding acoustic pressure, all in Simcenter 3D. Figure 3: Magnetic inductions , magnetostrictive nodal forces and resulting acoustic pressure of a 1300 kVar reactor courtesy of Baobian Electric Up to this point, we have only examined EMAG noise sources, which apply to naturally cooled transformers. For forced cooling using fans, it is important to consider both EMAG sources and mechanical sources (eg fans) in the noise analysis, as illustrated in figure 4 . Figure 4: A multiphysics power transformer design approach in Simcenter 3D, where different physical attributes are evaluated to verify their performance How does simulation help? Power transformer development is a multi-objective process (cost, time, quality) that equipment manufacturers must get right the first time. This is because in the energy and utility industries, the physical prototype is the product. In these industries, physical iterations are really expensive. Manufacturers must therefore understand transformer behavior as soon as possible. The new version of Simcenter 3D 2212 provides this physics-based view into transformer behavior. This is EMAG, structural and acoustic engineering challenges on a CAD-centric multiphysics platform with traceable workflows. That is, the different physical attributes (EMAG, structural and NVH) are verified, guaranteeing the overall performance of the product. This avoids over-engineering based on a single physics. Maintaining geometric links to a primary reference CAD model propagates geometric changes automatically, keeping simulation results (CAE) up-to-date and ensuring their relevance in product development decisions. Traceability standardizes processes, speeding up workflows, reducing the chances of unnecessary duplication of tasks, and improving collaboration across multiple teams. If you are concerned about transformer hum in your design, CAEXPERTS can help you improve the design of your transformers, reactors and electric motors with advanced digital engineering workflows. We invite you to learn more about our services and request a free diagnostic consultation at the link below.

The heavy equipment industry is facing the need to bring smarter, safer, connected and sustainable products to market faster. For this, it is necessary to abandon the use of slow cycles of iterative product design and isolated tools and processes, inefficient in the delivery of advanced equipment. The proposed solution is the use of a state-of-the-art integrated project platform, which allows: Virtual prototyping: allows you to accurately predict the behavior and functionality of equipment in specific scenarios of your application and in adverse environments, validating even complex autonomous equipment and operations; Simulation Automation (CAE): allows you to do more simulations faster, with automated processes and immediate quantitative feedback on design performance, resulting in rapid innovation and overall cost reduction; Integrated Field Data Analytics: Brings real-time operational data into a closed-loop product development and maintenance system, enabling you to bring products to market faster that meet customer needs and embrace new disruptive trends. Using this integrated design platform results in greater reliability, shorter development times and lower design costs. CAEXPERTS together with SIEMENS Digital Industries Software offers a performance prediction engineering solution that allows you to reliably develop equipment the first time and reap the rewards of rapid innovation.

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