マグナ・インターナショナル・ジャパン List of Products and Services

Our company offers a comprehensive "contract service for electric vehicle development" that supports everything from concept design to the design of various structural components, as well as prototype production and functional testing for electric vehicles such as BEVs, FCVs, HEVs, and PHEVs. In addition to commercial vehicles, we have extensive development experience with special vehicles such as fire trucks, agricultural machinery, and construction equipment, collaborating with our engineering team based in Austria. Based on our rich know-how, we can provide flexible business proposals tailored to various requests. 【For those facing such issues】 "I am considering electrification but don't know where to start." "I am struggling with component selection that meets the performance requirements of the vehicle being developed." "I am having trouble selecting compatible products due to mismatches in the output or application of electric components." "I want to support electrification with specifications that differ from standard vehicles, such as special vehicles." ★ We are currently offering free materials that introduce specific business contents such as functional development and prototype evaluation. You can view detailed information by clicking the download button.

• Mechanical Design
• Prototype Services
• Contract measurement

As the electrification of the automotive industry accelerates, the development of EVs and FCVs requires advanced technology and extensive experience. Magna Powertrain and ECS leverage years of vehicle development expertise and electrification technology to provide prototype and development services for EV/FCV vehicles tailored to customer needs. By supporting all phases of development, from vehicle design to testing and mass production preparation, we strongly assist our customers' electrification strategies. 【Use Cases】 - Development of new EV/FCV models - Electrification of existing vehicles - Development of vehicles equipped with electric powertrains - Production of demo vehicles and prototypes - Testing and evaluation 【Benefits of Implementation】 - Utilizing expertise and experience in electrification development to achieve shorter development times and cost reductions - Supporting high-quality vehicle development and smooth transitions to mass production - Leveraging the latest technologies and know-how to support competitive electric vehicle development

• Prototype Services

Are transportation companies considering the introduction of electric vehicles (EVs) and fuel cell vehicles (FCVs) to respond to environmental regulations, reduce fuel costs, and strengthen their competitiveness? However, vehicle development requires specialized knowledge, technology, and significant time and costs. At Magna Powertrain ECS, we support our customers in solving their challenges by providing EV/FCV vehicle prototyping and development services based on years of experience and proven results. 【Usage Scenarios】 * Transportation companies want to introduce EVs/FCVs to reduce environmental impact, cut fuel costs, and enhance competitiveness. * They wish to engage in the development and manufacturing of EVs/FCVs as a new business. * Specialized technical support is needed for the development of vehicles for specific applications. * They aim to improve the efficiency of vehicle development and reduce costs. 【Benefits of Implementation】 * Compliance with environmental regulations and reduction of CO2 emissions. * Reduction of fuel costs and lower running costs. * Strengthening competitiveness and creating new business opportunities. * High-quality vehicle development and shortened development periods. * Acquisition of specialized knowledge and technology, and human resource development.

• Prototype Services

In the logistics industry, reducing environmental impact and cutting operational costs are urgent challenges. Magna Powertrain and ECS leverage years of vehicle development experience and the latest technology to provide prototype and development services for electric vehicles (EVs) and fuel cell vehicles (FCVs). Logistics companies considering the electrification of delivery vehicles are encouraged to utilize our services. 【Usage Scenarios】 - Logistics companies are considering the electrification of delivery vehicles. - They aim to reduce environmental impact, cut operational costs, and limit CO2 emissions. - They are exploring the introduction of EV/FCV delivery vehicles as a new business initiative. - They lack specialized knowledge and technology focused on the development of EV/FCV vehicles. 【Benefits of Implementation】 - Reduced environmental impact: CO2 emissions can be significantly reduced compared to conventional gasoline or diesel vehicles. - Lower operational costs: Electricity and fuel costs can be minimized, leading to substantial reductions in running costs. - Enhanced competitiveness: The introduction of environmentally friendly vehicles can improve corporate image and build trust with customers. - Creation of new business opportunities: The introduction of EV/FCV delivery vehicles can generate new business opportunities.

• Prototype Services

In the construction industry, there is a demand for reducing environmental impact and improving energy efficiency. The electrification of heavy machinery significantly contributes to addressing these challenges, while also requiring different technological developments compared to traditional gasoline engine vehicles. Magna Powertrain and ECS leverage years of vehicle development experience and electrification technology to provide prototype and development services for EV/FCV vehicles in heavy machinery development. 【Application Scenarios】 - Electrification of heavy machinery at construction sites - Reduction of environmental impact and energy efficiency - Suppression of noise and exhaust gases - Development of new electric heavy machinery - Electrification modifications of existing heavy machinery 【Benefits of Implementation】 - Reduction of environmental impact and CO2 emissions - Decrease in fuel costs and control of running costs - Improvement of the working environment through noise and exhaust gas suppression - Strengthening competitiveness through the development of new electric heavy machinery - Performance enhancement through electrification modifications of existing heavy machinery

• Prototype Services

The electrification of agricultural machinery significantly contributes to reducing environmental impact and improving work efficiency. However, the development of EVs and FCVs requires specialized technology and know-how. Magna Powertrain and ECS provide strong support for the electrification of agricultural machinery through their "EV/FCV Vehicle Prototype and Development Services," based on years of vehicle development experience and achievements. 【Usage Scenarios】 * Reduction of environmental impact through the electrification of agricultural machinery * Electrification for improved work efficiency * Introduction of electrification technology in new agricultural machinery development * Electrification modifications of existing agricultural machinery * Electrification towards the automation of agricultural machinery 【Benefits of Implementation】 * Reduction of environmental impact: Decrease in CO2 emissions and suppression of air pollution * Improved work efficiency: Better fuel economy, reduced noise, and shortened work time * Acceleration of new agricultural machinery development: Shortened development period through the introduction of electrification technology * Enhanced performance of existing agricultural machinery: Performance improvements through electrification modifications * Adaptation to automation: Smooth transition to automation based on electrification technology

• Prototype Services

This is a service that provides total support for the development of electric vehicles (EVs) and fuel cell vehicles (FCVs) for medical institutions. Compared to traditional gasoline vehicles, EVs/FCVs have a lower environmental impact and excel in quietness, contributing to consideration for hospitals and patients, as well as the realization of a sustainable society. However, the development of EVs/FCVs requires specialized technology and know-how. Based on years of vehicle development experience and achievements, our company offers optimal solutions tailored to our customers' needs. 【Usage Scenarios】 - Electrification of ambulances in medical institutions - Consideration for hospitals and patients through reduced environmental impact and improved quietness - Strengthening competitiveness through the introduction of new technologies - Contribution to a sustainable society 【Benefits of Implementation】 - Contribution to hospitals and communities through reduced environmental impact and improved quietness - Providing a comfortable transportation space for patients - Differentiation and strengthening competitiveness through the introduction of new technologies - Contribution to the realization of a sustainable society

• Prototype Services

In the development of public agency official vehicles, do you face challenges such as reducing environmental impact, cutting fuel costs, and introducing the latest technologies? Magna Powertrain and ECS offer prototype and development services for electric vehicles (EVs) and fuel cell vehicles (FCVs), providing optimal solutions tailored to your needs. 【Usage Scenarios】 * Electrification of official vehicles (patrol cars, fire trucks, ambulances, etc.) * Reduction of environmental impact and fuel costs * Improvement of vehicle performance through the introduction of the latest technologies * Reduction of operational costs * Simplification of maintenance management 【Benefits of Implementation】 * Reduction of environmental impact: Decrease in CO2 emissions and control of air pollution * Fuel cost reduction: Significant savings in fuel costs compared to gasoline and diesel vehicles * Introduction of the latest technologies: Achieving improved vehicle performance and safety by adopting the latest electrification technologies * Reduction of operational costs: In addition to fuel cost savings, a reduction in maintenance costs is also expected * Simplification of maintenance management: Electrification eliminates the need for complex mechanisms such as engines and transmissions, making maintenance easier.

• Prototype Services

In the research and development of electric vehicles (EVs) and fuel cell vehicles (FCVs) at universities and research institutions, vehicle prototyping and development are crucial processes. However, if there is a lack of expertise, equipment, or development experience, the progress of research and development may be delayed. Magna Powertrain and ECS support the efficiency and acceleration of research and development by providing EV/FCV vehicle prototyping and development services based on years of experience and proven results. 【Application Scenarios】 * Research and development related to EVs/FCVs at universities and research institutions * Development and verification of new EV/FCV technologies * Education and practical training for students * Vehicle development using the latest technologies * Vehicle development aimed at reducing environmental impact 【Benefits of Implementation】 * Smooth vehicle prototyping and development is possible even with a lack of expertise and equipment * Support from experienced engineers achieves efficiency and quality improvements in development * Upgrading the level of research and development by introducing the latest technologies and know-how * Accelerating development towards practical application * Contributing to the reduction of environmental impact

• Prototype Services

To startups developing innovative mobility services: Magna Powertrain and ECS provide prototyping and development services for EV/FCV vehicles. The electrification of vehicles leads to reduced environmental impact and the creation of new business models, but it requires advanced technology and extensive experience for development. Our services accelerate your electrification development by supporting all phases of development, from vehicle design to prototyping and testing. 【Use Cases】 - Development of new EV/FCV vehicles - Electrification modifications of existing vehicles - Development of autonomous driving technology - Development of mobility services - Development of new business models 【Benefits of Implementation】 - Shortened development time - Reduced development costs - High-quality vehicle development - Introduction of the latest technologies - Strengthened competitiveness

• Prototype Services

With the evolution of power electronics products in the automotive industry, the strength analysis of printed circuit boards (PCBs) has become increasingly important. However, evaluating the vibration durability of PCBA with complex structures has been a time-consuming and costly process using traditional methods, hindering efficient development. "FEMFAT MELCOM" is a strength analysis software for printed circuit boards developed to address these challenges. 【Usage Scenarios】 - Vibration durability evaluation of printed circuit boards in the development of automotive power electronics products - Structural analysis during the design phase of power electronics products such as inverters and DC-DC converters - Optimization in the strength design, material selection, and manufacturing processes of printed circuit boards 【Benefits of Implementation】 - Significant time savings and cost reductions compared to traditional testing - High-precision prediction of the vibration durability of PCBA with complex structures - Early detection of issues during the design phase, contributing to improved efficiency and quality in product development.

• Structural Analysis

The lightweight design of power electronics products in the aerospace field is essential for improving product performance and fuel efficiency. However, there are concerns about insufficient strength of printed circuit boards due to weight reduction. FEMFAT MELCOM efficiently conducts strength analysis of printed circuit boards and predicts strength deficiencies in the design phase, contributing to improved product reliability and shortened development time. 【Usage Scenarios】 - Design and development of power electronics products for aircraft and satellites - Concerns about insufficient strength due to lightweight design - Streamlining strength verification in the design phase 【Benefits of Implementation】 - Early detection of strength deficiencies in the design phase, contributing to improved product reliability - Reduced development time due to shortened analysis time - Enhanced product performance through improved accuracy of lightweight design

• Structural Analysis

The increase in system components and the corresponding importance of E/E development require an appropriate development process. This relates to a system architecture that ensures the achievement and tracking of development goals, creating a more detailed E/E architecture for low-voltage and high-voltage systems. At the engineering center in Steyr, we advance development from E/E architecture to the development of harnesses and wiring diagrams, taking safety measures into consideration while formulating component specifications. Based on this result, the integration of hardware according to the requirements of components and the entire vehicle has become part of our engineering capabilities. *For more details, please refer to the PDF document or feel free to contact us.*

• Prototype Services
• Processing Contract
• Other process controls

Are you looking to efficiently conduct strength analysis of printed circuit boards (PCBs) used in power electronics products? "FEMFAT MELCOM" is a software package that predicts defects on printed circuit boards incorporated in power electronics products such as inverters through simulation. By forecasting issues like cracks in solder joints due to vibration and thermal loads, and the expansion and cracking of multilayer ceramic capacitors (MLCCs), it contributes to improving the efficiency of product development and enhancing reliability. 【Usage Scenarios】 - Development of power electronics products - Fields such as automotive, aerospace, and industrial equipment - Strength analysis, thermal fatigue analysis, and vibration fatigue analysis of printed circuit boards - Reduction of analysis time, improvement of analysis accuracy, and optimization of design 【Benefits of Implementation】 - Reduction of analysis time: Automation features significantly reduce model creation and analysis time. - Improvement of analysis accuracy: Detailed models and analytical methods yield more accurate analysis results. - Optimization of design: Based on analysis results, improvements and optimizations in design can be made. - Efficiency in product development: Early detection of defects during the design phase contributes to shortening development time.

• Structural Analysis

The diversification of propulsion systems, the increase in thermal requirements due to high-voltage systems and fuel cell propulsion systems, necessitates new thermal system solutions to achieve development goals. Therefore, variations in the functional and mechanical implementation of various different thermal components and system specifications are required. Based on thermal simulations, we create specifications for customized systems and components and align them with our suppliers. With a deep understanding of the system, we mechanically implement components from concept to mass production. *For more details, please refer to the PDF document or feel free to contact us.*

• Prototype Services
• Other process controls
• Thermo-fluid analysis

We have extensive experience in developing cabins and bodies for commercial vehicles such as trucks and vans, agricultural machinery, and specialty vehicles. Precision design of future truck technology cabins will be the success of a vehicle. The night balance beweeen aerodynamic styling, an ergonomically driver's working place, user-friendly HMI, as well as innovative mobile home living area ideas will define new “Comfort Drive” layout for diverse applications and markets. We offer desig, simulation, styling, prototype and testing activities for body in white, exteriors, interiors as well as electrical/electronic integration and chassis interfaces development. *For more details, please refer to the PDF materials or feel free to contact us.

• Contract Analysis
• Prototype Services
• Mechanical Design

To enhance the reliability of power electronics products mounted on medical devices, strength analysis of printed circuit boards (PCBs) is essential. However, accurately evaluating the strength of PCBs with complex structures is not easy. Therefore, 'FEMFAT MELCOM,' developed by Magna Powertrain ECS, is software that predicts the strength of PCBs through simulation, enabling the identification of issues during the design phase. 【Application Scenarios】 - Design and development of power electronics products for medical devices - Strength evaluation of printed circuit boards - Prediction of PCB degradation due to vibration and heat - Identification of issues and countermeasures during the design phase 【Benefits of Implementation】 By implementing 'FEMFAT MELCOM,' the following benefits can be expected: - Improved product reliability through issue identification and countermeasures during the design phase - Reduced number of physical tests and shortened development time - Cost reduction - Increased efficiency in product development

• Structural Analysis

We introduce the software 'FEMFAT MELCOM' for efficiently conducting strength analysis of printed circuit boards (PCBs) used in power electronics products. In products operating in vibration environments, such as industrial machinery, defects on the printed circuit board can pose serious issues. FEMFAT MELCOM predicts these defects in advance through simulation, contributing to the improvement of product reliability. 【Usage Scenarios】 - Industrial Machinery: Prevent failures and performance degradation due to insufficient strength of printed circuit boards in industrial machinery operating in vibration environments. - Power Electronics Devices: Enhance the reliability of power electronics devices, such as inverters and converters, which are sensitive to vibrations. - Automobiles: Ensure the reliability of electronic control systems in vehicles, such as electric and hybrid vehicles, which operate in harsh vibration environments. 【Benefits of Implementation】 By implementing FEMFAT MELCOM, the following benefits can be expected: - Predict strength issues of printed circuit boards at an early stage of product development, allowing for countermeasures during the design phase. - Reduce the number of physical tests, achieving shorter development periods and cost savings. - Improve product quality and reliability, thereby increasing customer satisfaction.

• Structural Analysis

The printed circuit boards (PCBs) for power electronics products mounted on railway vehicles are exposed to vibrations and thermal loads, which can lead to issues such as cracks in solder joints and damage to components. To prevent these problems and enhance product reliability, strength analysis during the design phase is essential. 'FEMFAT MELCOM' is a strength analysis software developed to address these challenges for printed circuit boards. 【Usage Scenarios】 - Development of power electronics products mounted on railway vehicles - Strength design of printed circuit boards - Durability evaluation against vibrations and thermal loads - Identification of issues and countermeasures during the design phase 【Benefits of Implementation】 - Improved product reliability through strength analysis during the design phase - Reduction of cracks in solder joints and damage to components, extending product lifespan - Shortened development time due to reduced analysis time - Enables efficient design changes, reducing development costs

• Structural Analysis

In the development of power electronics products in the power sector, ensuring the strength of printed circuit boards (PCBs) is a critical issue. Damage to PCBs due to vibration and heat can lead to decreased product reliability and development delays. 'FEMFAT MELCOM' is a strength analysis software for printed circuit boards developed to address these challenges. 【Usage Scenarios】 - Development of power electronics products at power companies - Design of power conversion devices, inverters, converters, etc. - Evaluation of the risk of PCB damage due to vibration and heat - Improvement of reliability in product development 【Effects of Implementation】 By implementing 'FEMFAT MELCOM', the following effects can be expected: - Streamlining the strength analysis of printed circuit boards, shortening development time - Early detection of defects during the product design phase, reducing development costs - Improvement of reliability for power electronics products - Strengthening competitiveness

• Structural Analysis

The printed circuit boards of power electronics products mounted in communication equipment are exposed to vibrations and thermal loads, which pose a risk of defects such as cracks in solder joints and damage to components. These defects can lead to reduced product reliability and development delays, making it necessary to predict and implement countermeasures in advance. 'FEMFAT MELCOM' is a strength analysis software for printed circuit boards developed to address these challenges. 【Usage Scenarios】 - Development of power electronics products in communication equipment manufacturers - Strength analysis and durability evaluation of printed circuit boards - Prediction of defects caused by vibrations and thermal loads - Countermeasures during the design phase of product development 【Benefits of Implementation】 By implementing 'FEMFAT MELCOM', the following benefits can be expected: - Streamlining strength analysis of printed circuit boards, leading to a reduction in development time - Reducing the risk of defects and contributing to improved product reliability - Enabling countermeasures during the design phase, resulting in reduced development costs

• Structural Analysis

The printed circuit boards for power electronics products installed in home appliances are susceptible to loads from vibration and heat, making durability a challenge. 'FEMFAT MELCOM' is a strength analysis software for printed circuit boards developed to address these issues. Through simulation, it allows for the early detection of potential problems during the product development stage and facilitates design optimization. 【Usage Scenarios】 - Development of power electronics products for home appliances - Strength design of printed circuit boards - Durability evaluation against vibration and heat - Identification of issues and countermeasures during the design phase 【Benefits of Implementation】 - Increased efficiency in product development and reduced lead time - Cost reduction in development due to early detection of issues in the design phase - Improvement in product quality and reliability - Differentiation from competing products

• Structural Analysis

The printed circuit boards of power electronics products mounted on information and communication devices are exposed to vibrations and thermal loads, which can lead to issues such as cracks in solder joints and component failures. To predict these problems in advance and improve product reliability, advanced strength analysis is essential. 'FEMFAT MELCOM' is a strength analysis software developed to address these challenges for printed circuit boards. 【Usage Scenarios】 - Development and design of power electronics products - Strength evaluation of printed circuit boards - Improvement of reliability in product development - Prevention of failures due to vibrations and heat - Detection of issues and countermeasures during the design phase 【Benefits of Implementation】 By implementing 'FEMFAT MELCOM', the following benefits can be expected: - Increased efficiency in product development: Automated model creation and analysis can shorten development time. - Improved reliability: Strength analysis enhances product durability and reduces the risk of failures. - Cost reduction: Early detection of issues during the design phase leads to fewer corrections and rework in later stages, resulting in cost savings.

• Structural Analysis

Power electronics products mounted on semiconductor manufacturing equipment are becoming more high-performance and compact, while the risk of damage to printed circuit boards due to vibration and heat is increasing. Traditional design methods have made it difficult to adequately assess these risks, leading to longer development times and increased costs. 'FEMFAT MELCOM' is a strength analysis software for printed circuit boards developed to address these challenges. 【Usage Scenarios】 - Development of power electronics products mounted on semiconductor manufacturing equipment - Strength analysis of printed circuit boards - Evaluation of damage risks due to vibration and heat - Reduction of development time - Cost reduction 【Benefits of Implementation】 By implementing 'FEMFAT MELCOM', the strength analysis of printed circuit boards for power electronics products can be streamlined, achieving shorter development times and cost reductions. Additionally, pre-evaluation through simulation contributes to improved product reliability.

• Structural Analysis

The printed circuit boards (PCBs) used in power electronics products mounted on display products are exposed to vibrations and thermal loads, which can lead to issues such as cracks in solder joints and damage to components. To predict these problems in advance and improve product reliability, advanced analytical techniques are required. 'FEMFAT MELCOM' is a strength analysis software for printed circuit boards developed to address these challenges. 【Usage Scenarios】 - Development of power electronics products for display products - Strength evaluation of printed circuit boards - Durability assessment of solder joints - Prediction of component damage risks - Identification of issues during the design phase of product development 【Benefits of Implementation】 By implementing 'FEMFAT MELCOM', the following benefits can be expected: - Identification of potential problems early in the product development process, leading to cost reductions through design changes - Increased customer satisfaction due to improved product reliability - Shortened development periods - Reduction of human errors by automating complex analyses

• Structural Analysis

In the automotive industry, the introduction of new development methods such as Model-Based Development (MBD) is progressing from the perspective of shortening periods and improving efficiency. Engineering companies that undertake development work are required to have the experience and know-how to cover a wide range of technical items. Magna has provided a wide range of engineering services, including automotive development, EV/FCV drive system adaptation, CAE, prototyping, and testing, primarily to customers in Europe, accumulating achievements and experience. Leveraging this experience, we will propose solutions to our customers' problems. *We are currently offering a free collection of case studies on engineering services! Take this opportunity to download the PDF and take a look.*

• Contract measurement
• Other contract services
• Contract Analysis

As the first step in innovative system development, we propose a system architecture based on the collaboration of experts from various technical fields to meet our customers' diverse needs. This initial proposal of the system solution will serve as a foundation for important communication between customers and departments, leading to more refined and detailed developments in the subsequent development process. The system architecture is at the core of the development project, and development in each department will commence based on this. The system architecture is used as the foundation for development in projects involving passenger cars, commercial vehicles, and special vehicles, and will also be utilized for the next developments of innovative mechatronics technology, regardless of vehicle class. [Example of System Architecture] - Drive system - Chassis system - Driver assistance system [Further Steps Based on System Architecture] Some excerpts of activities conducted after the creation of the system architecture or in parallel with it: - Component research, supplier coordination - Development of EE architecture (HV and LV) - Formulation of CAN communication concepts - Development of thermal concepts - Considerations regarding function development and functional safety

• Other contract services
• Prototype Services
• Machinery and equipment installation/dismantling/relocation

Not limited to passenger cars, we support a wide range of vehicle development, including commercial vehicles, construction machinery, agricultural machinery, and special vehicles such as fire trucks. Leveraging our experience in commercial vehicle development, we provide world-class engineering solutions that excite customers around the globe. Our comprehensive portfolio covers all types of engineering services, from pre-development concepts to the development of finished vehicles. You can trust us with everything from concept creation to prototype development and hardware testing. Our deep understanding of the commercial vehicle market makes us the preferred provider to meet our customers' needs. Our development potential spans various areas, including setting up initial line-ups that include our customers' market profiles, concept studies through modularity and scalability approaches, series development stages, and supplier management. We are committed to delivering the functionalities that our customers and their products require. Furthermore, we focus on providing comprehensive solutions based on our expertise in vehicle systems and electrified vehicle development, with an emphasis on developing future technologies.

• Other contract services
• Prototype Services
• Machinery and equipment installation/dismantling/relocation

"FEMFAT MELCOM" is a software package developed by Magna Powertrain Engineering Center Steyr (ECS) to predict defects on printed circuit boards (PCBs) incorporated in power electronics products such as inverters through simulation. 【Features】 ■ Predicts cracks in solder joints on printed circuit board assemblies (PCBAs) due to vibrations in power electronics products. ■ Predicts flex cracks in multilayer ceramic capacitors (MLCCs) during the process of attaching PCBAs to power modules. ■ Predicts cracks due to thermal fatigue in response to temperature loads on PCBAs. *For more details, please download the PDF or contact us.

• Structural Analysis

We would like to introduce our "EV/FCV Vehicle Prototyping/Development." We are engaged in specification discussions for system specifications and vehicle system development, as well as concept development, integration considerations, and vehicle assembly. In vehicle assembly, we not only manufacture demo vehicles and prototype vehicles but also conduct software development and HIL testing. The tests we conduct include functional tests, misuse tests, vehicle tuning, and various durability tests. Our core competencies in vehicle development lie in vehicle design, vehicle integration, and system architecture design, with a particular focus on commercial vehicles, special vehicles, and vehicles equipped with electric powertrains. We offer flexible services tailored to customer needs, covering the full development process from concept design development to all verification processes and mass production preparation, or parts of the development. *For more details, please refer to the PDF document or feel free to contact us.*

• Prototype Services

Acoustic requirements of automotive components have increased in importance over the recent years due to legal regulations, lightweight design, higher customer demands and especially due to the introduction of electrical vehicles with lower masking noises and high tonal noise content. MNOISE supports the simulation engineer at the acoustic evaluation of components based on Finite Element (FE) simulations. In combination with common FE tools, it enables an acoustic evaluation even in an early concept design phase. Especially global dynamic characteristics of components are responsible for the acoustic performance. Those only can be influenced significantly in an early concept phase. Using MNOISE critical areas and acoustic hotspots can be detected on the virtual component by evaluating acoustic near field measures. Based on these results, design improvements can be done before a physical prototype is available. Development time and prototyping costs can be reduced. *For more details, please download the PDF or contact us.*

• Structural Analysis
• Acoustic Analysis
• Magnetic field analysis/electromagnetic wave analysis

"FEMFAT" is a leading software for fatigue life prediction that performs fatigue analysis in combination with general finite element programs. With interfaces for multi-body simulation, optimization, and measurement systems, it allows for complete and convenient integration into the CAE process, providing optimal solutions for all customers through flexible licensing options. With over 30 years of continuous development, FEMFAT has refined fatigue analysis methods and gained a reputation for excellent fatigue evaluation, earning the trust of engineers worldwide. It contributes to improving the reliability of various industrial products, not only in the automotive industry but also in industrial machinery and plant equipment. Developed by engineers for engineers, FEMFAT offers advanced features and analysis options for predicting the fatigue life of metallic and non-metallic products, including seam welds and spot welds. It enables various analyses, such as those involving base materials with welds, spot welds, multi-axial analysis using road load data, and probabilistic loads based on PSD. *For more details, please download the PDF or contact us.*

• Structural Analysis

When evaluating the fatigue strength of a set of stress amplitudes, mean stress, and constant stress, FEMFAT basic is an ideal tool. With FEMFAT basic, you can calculate the fatigue life or fatigue limit safety factor of components subjected to repeated or alternating loads. It simultaneously considers various influencing factors on fatigue and analyzes joining structures such as seam welding and spot welding along with the base material, allowing for appropriate fatigue life predictions to be obtained concurrently. It comes standard with a database of over 400 materials. Additionally, when creating new material data, you can use the "Material Generator" to create the necessary material data set for FEMFAT even from limited material strength data. *For more details, please download the PDF or contact us.*

• Structural Analysis

EMFAT plast calculates the elastic-plastic stress around the notch area based on the results of linear elastic analysis using the Neuber correction. The Neuber rule is a method that demonstrates the relationship between linear and nonlinear stress and strain, allowing the representation of the Neuber hyperbola using Young's modulus E and nonlinear strain εplast. To represent the hysteresis loop of the cyclic stress-strain diagram (using the cyclic hardening coefficient K' and cyclic hardening exponent n'), the Ramberg-Osgood rule is used to calculate the nonlinear stress as the intersection point with the Neuber hyperbola. This eliminates the need for FE analysis considering material nonlinearity for local plasticity, allowing the elastic-plastic stress to be corrected with FEMFAT plast. Additionally, FEMFAT plast enables a reduction in computational effort for FE analysis. FEMFAT plast is compatible with FEMFAT basic, FEMFAT max, and FEMFAT spectral. *For more details, please download the PDF or contact us.*

• Structural Analysis

Predicting fatigue life under multi-axial loading is one of the significant challenges. The approach applied in FEMFAT max is based on research results conducted in collaboration with international research institutions, as well as the latest development achievements and academic papers within the company. All methods, theories, and hypotheses have been utilized in various projects and have been successfully validated. FEMFAT max includes ChannelMAX and TransMAX based on loading conditions, evaluating damage or fatigue life, fatigue limit safety factors, static fracture safety factors, and multi-axiality at each FE node. 【Module Introduction】 - Accurate fatigue strength assessment under actual loading conditions - Interface for time history data compatible with general-purpose mechanism analysis software and measurement software (e.g., ADAMS, RPC, DIAdem) - Input of loads corresponding to superposition (Channel) and transient response (Transient) - Filtering function for quick calculations only at necessary locations - Safety factors and damage calculations for fatigue limits under multi-axial stress states *For more details, please download the PDF or contact us.

• Structural Analysis

To ensure the structural strength of passenger car and truck cabins, numerous spot welds and punch rivets are required. Each of these joints implies the potential for initial cracks, necessitating particularly reliable methods for fatigue strength analysis. FEMFAT spot provides an evaluation method for accurately simulating the stiffness and durability strength of thin sheet metal components composed of spot welds. FEMFAT spot offers two different approaches: ◆ A method using element stresses from shell elements ◆ A method using element forces from connection elements (JSAE method) *For more details, please download the PDF or contact us.

• Structural Analysis

In the development of components that include welded structures, accurately predicting the fatigue life of weld joints has become essential. By utilizing FEMFAT weld, precise fatigue life predictions for weld joints can be achieved. FEMFAT weld offers various functions, including sensitivity analysis to identify critical welding shape parameters and evaluation options compliant with standards such as BS7608 and Eurocode 3. When calculating the fatigue life and safety factors of welded structures, the highly flexible analytical methods implemented in FEMFAT weld allow for simultaneous analysis of shell element models and solid element models. For the evaluation of weld root areas and weld termination points, detailed modeling of the fillet shape of the evaluation area can be performed, eliminating the need for extensive manual work. *For more details, please download the PDF or contact us.*

• Structural Analysis

Thermal-mechanical fatigue (TMF) analysis refers to the fatigue life prediction analysis targeting the combination of thermal and mechanical loads. TMF analysis is one of the most challenging tasks in the field of fatigue analysis. By introducing FEMFAT heat, this challenge can be addressed. The purpose of TMF analysis is to calculate the damage to components subjected to mechanical loads. It applies to parts exposed to high-temperature thermal fluctuations, such as turbochargers, cylinder heads, and exhaust manifolds. FEMFAT heat is based on an evaluation method demonstrated by Dr. Sehitoglu (University of Illinois, USA) and utilizes not only time-series temperature distribution data from finite element analysis (FEA) but also employs elastic-plastic stress and strain in fatigue life predictions. The characteristics of this evaluation method consider three mechanisms related to TMF damage: - Thermomechanical damage - Damage due to oxidation - Damage due to creep The FEMFAT material database used in FEMFAT heat is expanded compared to the commonly used material database for evaluating (high-cycle) fatigue life.

• Structural Analysis

The FEMFAT visualizer is a lightweight 3D post-processor with an independent interface from other modules, capable of displaying the analysis results of FEMFAT and stress values from FE analysis. Furthermore, by using the FEMFAT visualizer, it is easy to define seam welds necessary for FEMFAT weld calculations in shell element models. The FEMFAT visualizer allows for the display of FEMFAT calculation results such as damage, fatigue life, and fatigue limit safety factors, as well as the creation of report materials. Additionally, by adding output options, it provides information that helps in gaining a deeper understanding of the analysis results. This information includes all parameters related to FEMFAT analysis (currently over 50 types). For example, it is possible to check the effects of equivalent stress amplitude, equivalent mean stress, or the influence factors related to fatigue used in the analysis on the local S-N curve. *For more details, please download the PDF or contact us.*

• Structural Analysis

In highly random excitation mechanisms (such as vibrations caused by bench tests or road surface inputs), analyzing vast amounts of time series data requires significant computational costs. FEMFAT spectral provides the optimal solution to this challenge. By directly performing damage calculations from multi-axis time series inputs in the frequency domain (random response fatigue), it can significantly reduce the computation time for fatigue life analysis. To achieve this, FEMFAT spectral transforms data into the frequency domain known as PSD (Power Spectral Density). This allows for damage calculations under multi-axis loading conditions to be executed directly in the frequency domain. In many application cases, the excitation loads are not completely independent. Therefore, FEMFAT spectral offers the option to consider the correlation between individual excitation loads by defining the cross power spectral density (cross PSD). Utilizing cross PSD provides an additional advantage by allowing the equivalent stress PSD to be statistically formed correctly. *For more details, please download the PDF or contact us.*

• Structural Analysis

FEMFAT break is the only module within FEMFAT that is not used for analyzing fatigue strength. It is an extended module that calculates the safety factor against "fracture or yielding" of structural components that undergo local plastic deformation and fracture or yield. FEMFAT break can be integrated with FEMFAT basic or FEMFAT max. *For more details, please download the PDF or contact us.*

• Structural Analysis

By using this module, you can calculate the fatigue limit safety factor and damage based on measured strain data, and you can also compare the measured strain data with simulated strain data. FEMFAT strain links the results of bench tests and simulations. Using this module allows for fatigue life predictions for specific areas based on measured strain data. Therefore, it is not necessary to perform FE analysis (STRAIN calc). The second option can be used for calibrating the FE model. It is possible to compare the stress values measured on actual components with the values from the simulation results (STRAIN comp). FEMFAT strain is available as an additional result output (STRAIN comp) for FEMFAT basic and FEMFAT max. Additionally, STRAIN calc is a separate independent module. *For more details, please download the PDF or contact us.

• Structural Analysis

FEMFAT laminate is a module for fatigue analysis of continuous fiber reinforced resins (available in ChannelMAX). Within the MAX module, fatigue strength evaluation can be conducted individually for each laminate. The front and back sides of each laminate in the composite material are subject to damage calculation. The analysis method is adapted to the laminate material using the stress types of "Critical Component in Critical Plane," evaluating fiber breakage and interlayer breakage within the fibers. Furthermore, when using a solid element model (typically 8-node hexahedral elements), delamination can also be assessed. For damage calculation, static strength characteristics (tensile strength and compressive strength) and fatigue strength characteristics (S-N curves) are required for loads in the parallel and perpendicular directions to the fibers, as well as for shear loads in the laminate plane. It supports shell and solid elements defined with COMPOSITE properties using Abaqus inp files and odb files. *For more details, please download the PDF or contact us.*

• Structural Analysis

This is a token-based extension module that enables the use of multiple CPUs installed in a workstation to accelerate the analysis time of FEMFAT. By using this module, FEMFAT analysis jobs can be automatically divided into multiple jobs, which can be executed simultaneously. In this parallel computation, the job's analysis group is divided into a specified number of subgroups of approximately equal size, and FEMFAT is launched for each of these subgroups. The computation results from all analysis jobs (.fps files) are ultimately consolidated into one. For parallel computation of fatigue analysis, either parallel tokens or standard licenses are used. *For more details, please download the PDF or contact us.*

• Structural Analysis

Magna International Japan Co., Ltd. provides proposals and support for data measurement and simulation model creation methods for MBD development. In addition to the preparation of standard measurement sensors, we support measurements from the development of special sensors and mounting methods under difficult conditions where sensor installation is challenging. We handle the formulation of driving conditions, preparation/integration of special sensors, and data collection on appropriate test courses or market roads. For more details and case studies, please refer to the downloadable materials. 【Features】 ■ Structural analysis models for fatigue evaluation ■ Models for vehicle motion characteristics/NVH evaluation ■ Proposals for simulation modeling methods and calculation methods suitable for each purpose ■ Extensive support experience *For more information, please refer to the PDF materials or feel free to contact us.

• Contract measurement
• Contract Analysis