Cybernet Systems is a company

that supports manufacturing with

Computer Aided Engineering

What is CAE? CAE Technology and Market Needs

1 Energy for your innovation

1. What on earth is CAE? Dad, you work at a car company don’t you? When I visited you at work

before, you were sitting in front of a computer…what were you doing?

I was running various simulations with the computer. For

example, what would happen if two cars crashed into

one another. Actually crashing real cars into one another

costs money and is difficult work, but with a computer

we can do it over and over again!

Eh! You crash cars together inside the computer? I didn’t know computers

could do things like that!

That’s right. Because we can do experiments on the computer before

actually making things it also reduces the need for prototypes and

waste/garbage produced, so it’s kind to the environment, too! It also helps

reduce the amount of time from starting the design to when the car is

actually completed. We call these computer-based experiments “CAE.”

CAE? What’s that?

CAE stands for “Computer Aided Engineering.” I suppose it’s a kind of

computer-based engineering support system. It’s used in the design and

development of all kinds of things apart from cars, too, from familiar

appliances and devices like refrigerators and smartphones to things like

rockets and robots!

Dad, that’s amazing! Maybe I’ll write a report about CAE for my free-study

project this year. Dad, please teach me all about it!

Ok, you got it! Now, first of all, let’s take a look at the history of CAE, shall

we? Let’s take a look at how and in what kind of situations it’s used, too!

[Contents] 1. What on earth is CAE?

2. The history of CAE: The birth of computer simulation

3. The process up to completion of a car: In what ways is CAE used?

4. Review: Manufacturing & CAE

5. Benefits of introducing CAE

6. Industries in which CAE is used

7. CAE has many specialist fields!

8. More accurate simulations that consider various specialist fields together, at the same time:

Multi-domain solutions

9. Summary: Things that can be done with CAE & things that we can do because we are Cybernet

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2. The history of CAE:

The birth of computer simulation

ENIAC Computer

1940s

Bell Labs, USA, develops Ballistic Computer

for calculations of ballistic trajectories Spurred on by the breakout of World War II in 1939, the USA

succeeded in developing the world’s first computer capable of near-

instantaneous calculations of the trajectory of shells and other ballistic

projectiles. The computer was named ENIAC.

Development of the Finite Element Method

(FEM)* During the 1950s, a transition was underway for passenger aircraft,

shifting from propeller aircraft (which had been the mainstream until

that time) to jet aircraft. There was therefore a demand for high-

precision oscillation analysis for jet planes which fly at high speeds.

1950s

The birth of general-purpose structural

analysis (3D CAE) software using the Finite

Element Method (FEM) During the 1960s, structural analysis software utilizing the Finite

Element Method (FEM) came to be developed. The ANSYS®

software sold by Cybernet was also created during this time, thanks to

the research efforts of Dr. John A. Swanson, who then worked at

Westinghouse Electric Corporation.

1960s ANSYS Developer,

Dr. John A. Swanson

1970s ~ 2000s

Period of growth and expansion for 3D CAE

(application in a widening range of fields) With improvements in computer performance, the use of CAE became

more typical and widespread. It became possible to model and

analyze fluids such as air and water, and other things such as heat,

light, electromagnetic fields and sound. It also became possible to

model and analyze collisions and falls of objects.

2000s ~

present day

Expansion of the use of CAE during the initial

stages of design and development (the

appearance of 1D CAE) The number of scenes and situations in which CAE is used is

becoming increasingly wider, and is now not only limited to the use of

3D CAE based on 3D design data, but also 1D CAE, which

mathematically simulates the feasibility of performance and

functionality during the initial design and development stages.

*Finite Element Method (FEM) is a numerical technique that subdivides a large problem (i.e. the object being modelled) into smaller,

simpler parts that are called finite elements. The characteristics of these finite elements are expressed using simple formulae and

equations, which are then combined to analyze the entire problem. This technique forms the basis for present-day CAE.

The history of CAE is surprisingly long, and the range of fields in which it is

used is becoming increasingly wider, too. Originally, CAE began with the

idea of first thinking of the design and then simulating whether or not that

shape would work properly. Now, we’ve come to a stage where CAE is

being used even before the design is actually drawn.

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3. The process up to completion of

a car: In what ways is CAE used?

Let’s ask Mr. Tanaka from ABC Automotive about the process leading up to

the completion of a car, and in what kind of ways CAE is used during that

process!

Hello! OK, first of all, let me explain about what kind of jobs are involved in

making a car. There are actually a lot of different jobs involved between the

beginning of the process—when we are deciding what kind of car we are going

to make—and when the cars are actually lined up on sale at the dealership.

1. Thinking of a New Car [planning ~ concept finalization] Planning for a new car begins from between three and four years earlier. We think about changes

in trends and lifestyles, etc., and decide on a general direction for what kind of car we are going to

make.

2. Determining Specifications For example, let’s consider specifications for a car that is geared towards mothers with babies or

small children, which places more emphasis on safety and fuel economy than on speed.

- If we place importance on engine power, the fuel economy will be bad. For

housewives, fuel economy might be more important than engine power,

mightn’t it? What kind of fuel economy and power will we give our engine?

- We want to reduce oscillations (shaking and vibrations) so as not to wake

the baby, too, don’t we? What level of performance should the suspension

have? We also have to consider cost properly, too!

How do you run simulations when you don’t even

know the shape of the car yet?

Because we don’t know the shape, we think about specifications using mathematical models

of the way things move.

It’s a bit difficult. For example, let’s think about the specifications for our engine. For this, we

decided that we should place more importance on fuel economy than power, didn’t we?

We do various simulations by expressing the way the engine will work in terms of

mathematical formulae; for example, how much power we get and how much gasoline is

consumed when we inject this amount of gasoline into the engine with this much force.

These simulations used for designing specifications are called “System Level

Simulations” or “1D CAE.” It’s a bit of a specialist term, but in the Control

Simulation field we sometimes also call it MBD (Model Based Development).

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3. Detailed Design

4. Prototyping & Testing

5. Assembly & Production ⇒ Sale

Wah! There’s strings coming off the car!

Hahaha. Those aren’t strings. We’re simulating

the flow of the air around the car when it’s

moving. The wind whirls around in a whirlwind

behind the car after it passes.

This is a simulation of a touch panel for

a car navigation system. We’re testing

to see how the force of a person

pressing the screen will affect the panel.

Repeating these kinds of virtual experiments (i.e. simulations) allows us to rectify (fix) the

problems that we identify before the prototyping stage. In this way, we can shorten the time

between discovering the problem and finding a solution, and reduce the number of prototypes

we need to actually build.

After conducting many simulations and fixing various faults

and problems, we build a prototype (a test version of the

car) and test it under actual driving conditions. Finally, we

actually drive the prototype around a test course.

What happens if you find a problem at this stage?

That’s a good question! If that happens, we have to go

back to the drawing board to check what was wrong with

the design and then make another prototype. This takes

more time, effort and money. Simulations also play an

important part in avoiding that.

Once we make a prototype and test it, we can collect various kinds of data. We use the

data to check if our simulations were correct, or if there is a disparity (difference)

between the simulations and the actual test results. If there is, we think about why, and

come up with ways of ensuring that we can run more accurate simulations for the next

product that we design.

We prepare for production by thinking

about the order in which we will assemble

the various parts, and about the slight

differences in sizes and positions of parts

that will inevitably occur.

We even have software that calculates and

tells us just how wide a margin of error is

acceptable!

Data provided by: Advantage CFD

Once the specifications are decided, we use software called CAD (Computer Aided Design) to

decide the shape of the vehicle body and various parts. We then run simulations from various

viewpoints to check whether the car will work properly in that shape, and to check the strength of

parts and the impact of heat, etc.

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4. Review: Manufacturing & CAE

What is CAE? CAE is a technology that enables us to reduce the number of prototypes and tests

required to predict and resolve various problems (from various different directions) in

manufacturing a product by running simulated (i.e. virtual) experiments and tests on a

computer and analyzing the results.

By using CAE we can…

1. Check how a product will move/work before we build a prototype

2. Eliminate problems at an early stage in the design process and improve quality

Enables new products to be launched

onto the market at an early-stage

Reduces prototyping and testing costs

Lets us handle simulations for products

for which it is difficult to build a prototype

Performs where high-precision product

design is demanded

Is essential where particular attention is

being focused on safety

CAE is a “trump card” that has revolutionized processes

like R&D, design, manufacture and maintenance; and

caters to the diversifying and increasingly sophisticated

needs of customers.

CAE is also environmentally friendly!

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CAE:

5. Benefits of introducing CAE

Mazda succeeds in development of high economical engine making full use of CAE for SKYACTIV Technology development

Source: Nikkan Kogyo Shimbun, p26, 2014/10/17

Mitsubishi Heavy Industries shortens time taken for analysis in development of gas turbines, etc., (which took around 30 days 5 years ago) to half a day

Source: Nikkan Kogyo Shimbun, p6, 2015/4/7

Asics shortens development times by utilizing CAE in development of soles for running shoes

Source: Nikkan Kogyo Shimbun, p5, 2015/4/27

Konica Minolta shortens time taken for inspection / validation in the development of commercial printers (that originally took 3 months) down to 1~2 days

Source: Nikkan Kogyo Shimbun, p5, 2015/6/29

Nissan and Osaka Prefecture University shorten time taken between analysis of welding conditions for steel sheets of vehicle body and actual production line application to around 1/6 of the original time taken

Source: Nikkan Kogyo Shimbun, p8, 2016/1/22

JAXA and partners reduce noise on airplanes by analyzing airflow and the shape of main wing and fuselage / undercarriage parts of aircraft

Source: Nikkan Kogyo Shimbun, p5, 2016/4/12

So CAE isn’t only used in making things like robots and cars…It’s even used in

making shoes!

It can even be used to do things like analyzing the movement of air when a soccer

ball is flying through the air, and simulating how the ball will move when it is kicked.

It’s also used in the development of things like the printers you use at school, in

thinking of the shape of plastic PET bottles to make them easy to crush. Actually,

CAE technology is used in making lots of familiar things around us.

Image provided by: Dyson Ltd. 7

Pressure

distribution

Flow

lines

6. Industries in which CAE is used Let’s take a more detailed look at what kind of industries CAE is used in. I

wonder what industries you’d like to know more about, Taro… If there are any

that interest you, why don’t you check them out on the Internet!

http://www.cybernet.co.jp/english/products/cae/field/

It makes me really happy to hear that.

OK, let’s take a look at a few more real-life examples.

CAE really is used in all kinds of different places, isn’t it?!

I want to know even more about it now!

“Flute-playing Robot”

Photo provided by: Takanishi Laboratory, Waseda University

■ Robots This is an example from Waseda University. This

robot is controlled using a simulation of the

movements made by a human tongue when

playing a flute, created using a piece of 1D CAE

software called Maple.

This research laboratory also develops other

robots, including a “jaw robot” that doctors can

use for practicing surgery on a human jaw.

This is a simulation of how drops of eye

medicine fall from the bottle when it is

squeezed…because there would be problems

if it all came running out at once!

This example is for the design

of a luxury cruise ship. Based

on the shape of the ship (CAD

design), CAE is used to check

how the ship will deform

(change shape) when the force

of the ocean waves are applied

to it, and what problems seem

likely to occur.

Example: German cruise ship builder Jos. L. Meyer GmbH & Co.

This example is a simulation for the built-in

antenna inside a smartphone. It’s good if

we can check that there is no negative

effect on human users using a simulation,

isn’t it!

■ Pharmaceuticals

■ Smartphones ■ Luxury Cruise Ships

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Automotive

Industrial machinery

Shipping & maritime

Sports

Aerospace

Chemical & materials

Construction & civil

engineering

CAE education &

promotion

Electronics

Energy & environment

Healthcare & foods

Production technology

7. CAE has many specialist fields!

It gets a bit difficult from here. In many cases, the CAE software used differs

between different specialist fields. Let’s take a look at what kind of specialist

areas there are.

1D CAE (MBD)

1D CAE software allows us to perform mathematical calculations to

check whether or not products will perform as expected, during the first

stages of the design, before the shape of the product has even been

decided. I wonder if you remember… If we say it in terms of the software

used at the company where I work, it corresponds to software such as

Maple and the MapleSim software that we use together with it.

Maple is a piece of STEM (Science, Technology, Engineering, and

Mathematics) software. MapleSim is used for the MBD (Model Based

Design) processes used in the automotive industry, so it is also

sometimes called MBD software.

MCAE

MCAE is short for Mechanical CAE. Mechanical means “relating to machines or

physical (dynamic) forces.”

This group of software applications is used mainly after the shape of the product

has been decided to a certain degree, and the CAD design has been completed.

The eye-dropper, luxury cruise ship and internal smartphone antenna examples

shown on the previous page are example applications of ANSYS Inc. software.

Optical Design

These pieces of software are used to simulate the way in which light

progresses (i.e. moves through different objects and media), and are used to

design things such as lenses (for products such as cameras and machines for

manufacturing semiconductors), LED lights and other lighting fixtures, and

backlights such as those used in LCD displays (lights shone behind displays to

make the screen appear brighter).

They are also used in designing things like radars, and lights used in cars.

EDA

Taro, I wonder if you’ve already studied about how electricity works?

EDA stands for Electronic Design Automation. These software

applications are used in automating the design of electronic devices

and things like semiconductors.

They allow us to design electronic circuits and printed circuit boards

so that they will work as designed, and to run simulations to check

that they will actually work properly as intended. It might be a bit

difficult for you to understand yet Taro…

In reality, MCAE is subdivided further into fields such as heat analysis, fluid analysis and acoustic analysis. If you

would like to know more about these, look them up on the internet.

http://www.cybernet.co.jp/ansys/case/

Software: mainly ANSYS (an ANSYS Inc. product)

Software: Mainly CODE V, LightTools and other Synopsys products

Software: Mainly HyperLynx and other Mentor Graphics products

Software: Maplesoft products (Cybernet group development)

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More accurate simulations that consider various specialist fields

together, at the same time

8. Multi-domain* Solutions

Case study 1: Lens design (heat and light)

Case study 2: Oscillations and sound in cars

CAE software is very specialized, so software types are divided between different fields (domains),

such as those used in light/optical, heat/thermal and sound/acoustic analysis. But in reality, multiple

phenomena like these occur and interact with one another, so in order to carry out more realistic

simulations that are closer to actual real-world conditions we need to combine multiple pieces of

specialist software. On the other hand, combining different pieces of specialist software that are

used to analyze different physical phenomena—for which the various software developers who

produce and sell them are different, and for which the units of measurement also differ—is said to

be very difficult.

Using its strengths as a company that has been dealing in CAE software for various different

domains for over 30 years, Cybernet has developed a method for achieving overall simulations by

weaving together different pieces of specialist software. We call these “multi-domain solutions.”

Problem Lens design and structural design are developed through simulations, using optical tools and MCAE

tools, respectively. Even though the design seems to perform as intended during simulations, the

prototype didn’t work as it should…

Cause The cause of the problem was that the plastic lens warped due to the heat of the light source, distorting

the shape of the lens.

Proposal

Typically, optical, MCAE (structural) and MCAE

(thermal) elements are analyzed separately,

using separate tools. We proposed linking these

separate tools together using the Cybernet-

developed software Optimus and running an

integrated, overall simulation.

*”Multi-domain” means an analysis domain that bridges multiple domains, such as heat/thermal analysis and light/optical analysis.

We wanted to reduce the rattling noise produced while a car is moving, but first of all we wanted to

begin by investigating which part of the car we need to fix to reduce the noise…

We ran various simulations from various aspects to investigate the properties of sound sources

(oscillations from the tires and suspension) and different materials used in the car body and tires, etc.,

and combined acoustic and oscillation analysis tools to achieve an oscillation-to-sound simulation.

Techniques for analyzing

materials with different material

properties simultaneously

Techniques for

analyzing sound

and oscillations

simultaneously

Techniques for

analyzing the

whole system

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Problem

Proposal

9. Summary: Things that can be done

with CAE & things that we can do

because we are Cybernet

Issue/Problem Solutions using CAE

1. Cost reduction:

Measures for improving

competitiveness of prices and

increasing profits

(1) Reduce number of prototypes

In the case of cars, prototyping costs for one vehicle model are

over 1 billion yen.

(2) Reduce the number of tests/experiments

In the case of cars, one collision test costs over 100 million yen.

2. Shortening time taken:

Manufacturers that launch their

products onto the market at an

earlier stage enjoy greater

profits/revenues

(1) Shorten testing times

• One example is rusting experiments (where actual real-life

testing) would take too long. CAE simulations cut 10 years down

to one day

• Tests for fatigue due to long-term use can also be carried out in

the space of a few hours

(2) Shorten development times (see page 7)

3. Making environments that are

difficult to test in real life

testable/verifiable by virtual

simulation

(1) Simulations under extreme environmental conditions, such as

in space, ultra-fine/nanoscale environments, ultra-low and

ultra-high temperature, in high vacuums, etc.

(2) Analysis of dangerous phenomena, such as collisions and falls

Issue/Problem Cybernet’s unique solutions using multi-

domain solutions

4. Performance, quality and cost

improvement:

Measures for seeking to differentiate

from competitors by adding additional

value to products

Simulation by multi-domain simulations that analyze according

to the actual phenomena are indispensable.

(1) Solving noise problems inside cars and other vehicles

• 1D CAE analysis, acoustic analysis, ANSYS

(2) Batteries for hybrid vehicles

• Optimization analysis of engine and battery

performance by 1D CAE

• Chemical cell property analysis (numerical formula

processing), thermal analysis and vehicle fuel

economy (1D CAE) analysis for maximal optimization

of batteries

(3) Advanced driving support systems

• Optical analysis and control design technology for

designing headlights that shine in the direction of

motion, even around curves

• Optical analysis for creating digital meters

(speedometers, etc.), navigational displays and HUDs

(heads up displays) that are easy to see and

unaffected by ambient brightness

• Thermal, oscillation, electrical noise and materials

analysis for designing ECUs and light harnesses that

can perform even in cars undergoing heavy vibrations

and high temperature conditions

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Oct 20, 2016 version [Copying and unauthorized re-use are prohibited]

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CYBERNET SYSTEMS CO.,LTD.

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