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Optimization of Photovoltaic (PV) Mounting Structures – Savings on Material and Cost

Photovoltaic specialist Thesan, a subsidiary of global manufacturer Savio S.p.A, manufactures, and distributes mounting structures, consisting of a so-called Purlin, a Rafter, and a Pole (and Hat), designed to withstand potentially occurring loads from wind and snow, as well as dead loads. Drawing on the Savio Group’s competence in the design of steel and aluminum structures and thanks to a team of over 40 engineers, they are to satisfy every construction requirement of photovoltaic power plants at all altitude and climatic conditions, using any specific fixation requirements. For a recent project requiring optimization of a mounting structure of a medium sized PV field with a power of 5 MW, engineers used HyperWorks. The benefits included reduced material usage, reduced manufacturing and transportation costs and improved competitiveness for Thesan.

Success Story: IVECO Australia

HyperWorks and the Altair Partner Alliance Streamline Testing of Truck Components at IVECO Australia

APEL Extrusions

APEL Extrusions employs die extrusion simulation software to test die extrusion performance. This allows APEL to greatly speed up the design process and test multiple simulations per week.

APWorks Choses OptiStruct for Topology Optimisation for the 3D Printed Light Rider

Despite its skeletal appearance, the Light Rider is an extremely strong yet lightweight electric motorcycle designed by Airbus subsidiary APWorks as a showcase of what’s possible when OptiStruct's topology optimisation is coupled with metallic 3D printing. Written by Tanya Weaver from DEVELOP3D.

Altair Offers Flexibility and Enhancement for Casting Process Design and Optimization

The goal of the project outlined in this paper is to get the optimal gating system (size and position of ingate) to help avoid porosity and other common defects in the produced parts, achieving the final design to begin casting the component.

Haier Redesigns Air Conditioners and Packaging with Altair HyperWorks to Eliminate Drop Damage

Haier Group is one of the world’s largest manufacturers of home appliances and consumer electronics. The company is the leader of its industry in China, where it is headquartered.<br><br> Haier ships its products all across the globe and in more than 100 countries, so well designed product packaging is crucial to the company’s ability to deliver products without damage to even the farthest destinations.<br><br> Download the Case study to see how Altair was able to reduce costs of physical testing and eliminate drop damage using simulated drop testing with HyperWorks.

DECKED

The huge capacity of a pickup comes at the expense of storage. The loading area is often a simple box with no ability to store smaller items safely or secure them from theft. After spotting an opportunity in the marketplace, entrepreneur, Lance Meller, started work on a well-built alternative. Lance founded DECKED with his business partner, Jake Peters, with a shared determination to create an innovative, robust and useful storage solution for both commercial users and private owners alike. The system had to be able to withstand a load of 2,000 lbs, fit it into a wide range of pickup models including those from Ford, GM, Chrysler, Toyota and Nissan and be manufactured for a compelling retail target price. DECKED selected Altair ProductDesign as it needed a partner that was able to deliver conceptual design work along with advanced engineering and prototyping services.

Combining topology optimization with laser additive manufacturing reveals new potential for lightweight structures

Challenge: Development of design and optimization methods to improve components made with laser additive manufacturing methods. Altair Solution: HyperWorks, OptiStruct, Simulation Driven Design Process Benefits: increased material efficiency, lighter and stiffer structures, less user training required, flexible and adaptable manufacturing process

Fully automated in a single process: Optimization and manufacturing of CFRP components

Use of HyperWorks and adapted threestep optimization process for Composite materials integrated in the production process Benefits:<ul><li>process suitable for large volume series</li><li>flexibility in production</li><li>short learning curve for users</li><li>light and yet stiff components </li></ul>

Increasing Robustness and Reliability of a Race Car Engine with AcuSolve

This study is part of Prodrive’s implementation of AcuSolve to enhance its CFD capability after many years of outsourcing these simulations.

Accurate Simulation Modelling of Sports Impact Scenarios using HyperWorks

One of the key research activities within the institute is concerned with the development of enhanced human surrogate models for sports personal protective equipment (PPE) research. Impact surrogates are used to provide a representation of a living human which can then be impacted under injurious loading conditions such as a ball impacting the thigh to understand the response behaviour.

Failure Criteria for Stamping Analysis in RADIOSS

In this paper, several failure criteria are compared in their ability to predict necking point and failure propagation during a forming process. The paper has been presented at the 2014 IDDRG Conference in Paris, France.

Empire/Renishaw

Renishaw and Empire Cycles utilized generative design to conceptualize the world's first metal additive manufactured  bicycle frame. This resulted in a 33% weight reduction of the bicycle.

HardMarque

HardMarque coupled topology optimization with additive manufacturing to conceptualize and refine the design of a piston. The final piston design is 23.5% lighter than the original design. 

Intel Solution Brief: Maximize Performance and Scalability of RADIOSS on Intel® Xeon® Processor E7 v2 Family-Based Platforms

This paper summarizes the findings of a benchmark study with RADIOSS and Intel® Xeon® processors. In the study, Altair benchmarked RADIOSS using a modified crash simulation model on a single-node platform -- RADIOSS was able to easily take advantage of all 60 cores, running the workload 2.75X faster than on a comparable 24-core platform.

Reducing Weld Distortion by 93% with HyperStudy

Gestamp Tallent Ltd is a world class designer, developer and manufacturer of cutting edge, chassis structural and suspension products, body in white structures, modules and systems for the automotive industry. Gestamp used the BMW MINI front subframe tower to demonstrate the weld distortion optimisation approach. The tower is particularly susceptible to distortion due to its tall and thin dimensions. The objective of this optimisation was to minimise the distortion of the tower measured by the displacement of the top of the tower as the weld sections cool. In order to further investigate weld removal optimisation they chose HyperStudy.

Success Story: M.TEC

M.TEC Engineering Continues to Benefit and Yield New Business Due to Advantages of the Altair Partner Alliance (APA)

Assa Ashuach uses solidThinking Inspire to Optimise 3D Printed Stool Design

Industrial Research and product design consultancy Assa Ashuach Studio, design and manufacture lifestyle products and also limited edition studio pieces using new design and production methods to achieve unique forms and aesthetic qualities.

Success Story: HBPO GmbH Achieves Flexibility and Cost Efficiency in Automotive Development By Leveraging the APA

HBPO GmbH optimizes their design process by utilizing multiple products, such as Moldex3D, Total Materia and MADYMO, alongside HyperWorks products for the development of their front end modules.

Altair Products and Partners Offering Assist Commercial Vehicles Seat Manufacturer to Enhance its Development Process

Isringhausen applies DesignLife, Moldex3D, and Total Materia alongside RADIOSS, OptiStruct and other HyperWorks tools to optimize weight and durability of their customized seats while still meeting safety standards.

BiggerBoat Solutions Makes Waves in Auto Industry Using HyperForm to Cut Die Development Costs and Time

When the auto industry crashed in 2008 and the tool shop where Jay Weiner worked closed its operations, he started his own company, called BiggerBoat Solutions Ltd. He carries out metal-forming simulations for major tooling suppliers and originalequipment manufacturers. With 15 years of experience in tooling design, Weiner and his Toronto-based practice offered a service that no one else had perfected but that was crucial to a key process in automotive manufacturing: the simulation-based die design for stamped sheet-metal parts.

Altair Partner Alliance Offers Flexibility and Enhancements in Development Process at Manufacturer of Interconnect Products

Amphenol is one of the largest manufacturers of interconnect products in the world. The company designs, manufactures, and markets electrical, electronic and fiber optic connectors, coaxial and flat-ribbon cable, and interconnect systems. Amphenol was able to use HyperWorks and the APA to access software encompassing the entire development process, all within one platform.

Creating a Virtual Press to Optimize the Extrusion Process

Today's advanced computational tools increase productivity and quality, as well as lower energy consumption in the design and fabrication of extrusion dies.

Simulation Links Welding Data to Structural Analysis Models

A robust modeling process greatly aids the design of lower cost and higher quality welded structures.

Get the Most from Your Casting Process

By applying optimization technology to casting process design, manufacturers can produce less expensive, better-quality parts in record time.

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