ANSYS ADVANTAGE 1 Table of Contents
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Excellence in Engineering Simulation ISSUE 1 | 2017 SPOTLIGHT ON The DIGITAL TWIN 4 Double Vision Replicating product performance during operation 8 Creating a Digital Twin for a Pump Simulating an operating pump 14 Simulation for the Digital Twin Ecosystem Accurately predicting performance EDITORIAL A NEW ERA IN SIMULATION Combining real-time operational data from working products with digital information about those products enables the digital twin and promises to take simulation into a new era. For over 40 years, engineering simulation has helped engineering simulation to predict the product development teams around the world deliver future performance of that product game-changing innovations, accelerate product within its operating environment. This launches and reduce the costs associated with predictive capability could, for exam- design and development ple, optimize maintenance schedules While the process of creating highly engineered and reduce unplanned asset down- products has never been easy, today’s product devel- time, as well as significantly enhance opment organizations are faced with challenges that operational performance. could not have been imagined 40 years ago. Existing But digital twins have an even products are growing in complexity, with smart func- more important strategic benefit: tionality and more embedded software. Disruptive Product development teams can apply By Ajei Gopal, products are operating in design spaces that have not insights from the twin directly to President and CEO, been explored before. These products are expected their ongoing product development ANSYS to perform in more extreme physical conditions. efforts. Future versions of the product Consumers are demanding bigger and more frequent or process can be designed with new innovations that are delivered affordably. And, in some cases, customers no longer features, new shapes and new materi- demand just a product such as a wind turbine, they demand an outcome like als that directly address any shortcom- kilowatt hours. ings identified through the digital twin process. This promises to radically The good news is that simulation teams to collaborate. Digital prototypes accelerate new product innovation technology improvements provide and digital exploration are easier and and insertion. answers to these growing challenges. faster to employ than ever before. Already in use by leading compa- Simulation software has expanded in But it does not end there. The nies, digital twins represent the future depth and breadth, enabling the mod- Internet of Things (IoT) brings with across many industry sectors. eling of multiple physical forces — it technology and practical cost mod- The use of digital prototypes and electromagnetic, structural and fluid els to install sensors on a vast array digital exploration for increasing product complexity, ever-expanding Simulation is the only way to fully design spaces and the emergence of “ the digital twin propel the use of realize the tremendous value contained simulation into the hands of new within the digital twin. users and develop links with opera- ” tional products. We are on the cusp — as well as embedded software and of products and to stream the huge of a new era that will take us beyond systems using an integrated simula- amounts of real-time data generated. simulation-driven product devel- tion platform. Semiconductors can The emergence of IoT software plat- opment and into simulation-driven now be designed with simulation forms empowers the integration of engineering. leveraging full chip–package–system real-time operational data with all of I hope this issue of ANSYS models so that deficiencies are discov- an organization’s digital information Advantage will help you learn more ered long before prototyping and for that specific product. This enables about the potential of digital twins — sign-off. Improvements in computing the realization of a digital twin. and begin to imagine the enormous capability and the advent of the cloud Simulation is the only way to impact they may have on your busi- have led to the emergence of high- fully realize the tremendous value ness in the not-so-distant future. performance computing (HPC) capa- contained within the digital twin. bilities that streamline and acceler- Field product performance data ate even the largest simulations and (and other relevant information) Creating a Digital Twin Video ansys.com/digital-twin-video empower diverse global engineering can be merged with the results of © 2017 ANSYS, INC. ANSYS ADVANTAGE 1 Table of Contents Spotlight on the Digital Twin 24 4 MANUFACTURING BEST PRACTICES Decreasing Drill Damage Double Vision Researchers use fluid flow and structural The digital twin provides a new layer of analysis tools to analyze process coolant engineering insight by replicating the flow distribution and achieve longer performance of products in operation. 14 cutting-equipment life. SOLUTIONS Simulation for the Digital Twin Ecosystem ANSYS has a full suite of tools to enable a digital twin to deliver accurate, insightful and reliable results that can have a real impact on operation. 8 DIGITAL TWIN Simulation@Work Creating a Digital Twin 28 for a Pump COMMUNICATIONS Technologies now make it possible 18 Tower of Strength to integrate simulation with products TRANSPORTATION Jet Towers used ANSYS AIM simulation to as they exist and operate in the real Comfortable Rail Travel design a line of truss tower modules so world. This enables companies to Siemens engineers use ANSYS software that the company can build and install optimize operations and maintenance, to validate the design of the heating, wireless towers in only one week. as well as further accelerate the ventilation and cooling systems for new-product development process. railway coaches to reduce testing time and cost by up to 50 percent. ABOUT THE COVER A digital twin of a physical product or process can monitor real-time prescriptive analytics 11 and test predictive maintenance DIGITAL TWIN to optimize asset performance. Pioneering the Simulation is vital to the Industrial Internet accuracy of a digital twin. GE Digital is playing an integral role in digital industry by providing companies with valuable insights to manage assets and operations more efficiently. 2 ANSYS ADVANTAGE ISSUE 1 | 2017 46 STARTUPS Winning the Race to 5G PHAZR is developing unique 5G wireless network for mobile and fixed- 40 access applications. This innovative STARTUPS startup leverages ANSYS software to not Wild Ride only speed up its analysis, but provide 32 design agility and flexibility for this The engineering team for a battery- PUMPS cutting-edge technology. powered motorized skateboard employs Pipe Cleaner engineering simulation to quickly make FMC Technologies cuts the weight design changes, predict how changes of a reciprocating pump in half will impact real-world performance and while reducing its footprint and achieve meaningful improvements. increasing its pressure output. Departments 48 NEWS 36 Simulation in the News OIL AND GAS 44 A roundup of news items STARTUPS featuring simulation Ride the Wave Lighten Up A Petrobras engineer uses ANSYS Using engineering simulation, a small simulation to reduce the number of company has developed sturdy, light- experiments required to ensure that weight cargo pallets that are 18 percent vessels can withstand rough lighter than traditional pallets. sea conditions. Join the simulation conversation ansys.com/Social@ANSYS elcome to ANSYS Advantage! We hope you enjoy this issue containing Realize Your Product Promise® articles by ANSYS customers, staff and partners. Want to be part of If you’ve ever seen a rocket launch, flown on an airplane, W driven a car, used a computer, touched a mobile device, a future issue? The editorial team is interested in your ideas for an article. crossed a bridge, or put on wearable technology, Contact us. chances are you’ve used a product where ANSYS software played a critical role in its creation. The Editorial Staff, ANSYS Advantage [email protected] ANSYS is the global leader in engineering simulation. We help the world’s most innovative companies deliver radically better products to their customers. By offering Executive & Managing Editor Art Directors the best and broadest portfolio of engineering simulation Chris Reeves Ron Santillo software, we help them solve the most complex design challenges and engineer products limited Dan Hart only by imagination. Editorial Advisers ACT, AIM, Aqwa, Autodyn, Beamcheck, BladeModeler, CFD, CFD Amy Pietzak Designer Enterprise, CFD Flo, CFD Premium, CFX, Chemkin-Pro, Cloud Gateway, Customization Suite, DesignerRF, DesignerSI, DesignModeler, Tom Smithyman Dan Hart DesignSpace, DesignXplorer, EKM, Electronics Desktop, Elastic Licensing, Enterprise Cloud, Energico, Engineering Knowledge Manager, Eminence, Explicit STR, Fatigue, Fatjack, FENSAP-ICE, Editorial Contributor Cover Illustration FENSAP-ICE-TURBO, Fluent, Forte, Full-Wave SPICE, HFSS, High Performance Computing, HPC, HPC Parametric Pack, Icepak, Maxwell, ANSYS Customer Excellence Ron Santillo Mechanical, Mechanical Enterprise, Mechanical Premium, Mechanical North America Pro, Meshing, Multiphysics, Nexxim, Optimetrics, OptiSLang, ParICs, Pervasive Engineering Simulation, PExprt, Polyflow, Professional, ANSYS, Inc. Professional NLS, Professional NLT, Q3D Extractor, Rigid Body Dynamics, RMxprt, SCADE Architect, SCADE Display, SCADE LifeCycle, Senior Editor Southpointe Suite, Test. SeaHawk, SeaScape, SIwave, Simplorer,