FsTech List of Products and Services

We will introduce a case study on cooling analysis of motors for electric vehicles using the general-purpose intelligent thermal fluid analysis software AICFD. As the adoption of electric vehicles accelerates, there is a demand for the development of more efficient and high-performance drive motors. Improving motor performance involves factors such as optimizing energy conversion efficiency and reducing weight, among which thermal management is a key element. The heat generated inside the motor can not only lead to a decrease in output and efficiency but also significantly impact durability and long-term reliability. Therefore, it is essential to implement appropriate cooling design and achieve efficient thermal control. In this analysis, we examined the temperature distribution around the coils, which are the main heat sources within the electric vehicle motor, and evaluated the cooling performance. By visualizing the temperature distribution obtained through simulation, we can confirm the effectiveness of the cooling design. *For more details, please download the PDF or feel free to contact us.*

We will introduce a case study on eigenvalue analysis of engine blocks using the general-purpose finite element analysis software AIFEM. The eigenvalue characteristics of the engine block are crucial factors that influence the overall operational stability and durability of the engine. In particular, they relate to the operational lifespan and reliability of key components such as the piston, cylinder liner, and crankshaft, and they also significantly impact the engine's NVH (Noise, Vibration, and Harshness) performance. The effects of external excitation are particularly pronounced in the lower four mode frequencies, where resonance can lead to amplified vibrations. Therefore, it is essential to identify the main mode shapes and frequencies through eigenvalue analysis and implement appropriate design measures. Applications of this analysis: ■ To avoid the risk of resonance and prevent damage due to excessive vibrations ■ To enhance comfort by optimizing NVH performance ■ To find the optimal balance between lightweight design and rigidity *For more details, please download the PDF or feel free to contact us.

FRIENDSHIP SYSTEMS, the developer of CAESES, has collaborated with MTU and Darmstadt University of Technology to develop a robust and variable turbine wheel geometry for turbochargers. The research, called Project GAMMA ("Efficient Gas Engines for Maritime Applications of the Next Generation"), aims to develop and prepare new technologies and interactions within the system for LNG/natural gas, which serves as fuel for efficient ship propulsion systems. *For more detailed information, please refer to the related links. You can download the PDF for more details or feel free to contact us.*

This time, I will introduce parametric modeling, which is part of the gear pump optimization project. This project began with the customer's request to "optimize the design of the gear pump" and has progressed with a focus on gear modeling techniques, aiming to create a more functional and user-friendly model. *For detailed information, you can view it through the related links. For more details, please download the PDF or feel free to contact us.*

Ansys CFD tools such as Fluent and CFX receive strong support from engineers for evaluating fluid dynamic behavior in design, along with various options and tools used for mesh creation. These tools provide valuable information and insights regarding the performance to be evaluated. Moreover, they enable automated optimization and design exploration workflows that include CFD. In addition to improving design and shortening development time and design cycles, these tools significantly enhance the development process by increasing information about the impact of various design variables on performance (product behavior) during the initial design phase, where there is a high degree of freedom in decision-making. *For more details, you can view the related links. For more information, please download the PDF or feel free to contact us.*

In the shape optimization of water pumps with shrouded impellers, it is important to have an efficient parametric model with numerous design variables. This time, we will introduce the design/modeling of water pumps, which have many shape variations and a high degree of freedom for fine-tuning. With the optimization software CAESES, equipped with CAD functions, robust parametric models can be flexibly created while incorporating the designer's ideas, and it is utilized in various stages of the design process. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

CAESES has been conducting optimization calculations for various types of valves and has implemented projects in collaboration with various companies. In this context, we would like to introduce one of the newly conducted projects, "Shape Optimization of a Globe Valve." This project was carried out in cooperation with GEMÜ Gebr. Müller Apparatebau, a German valve manufacturer and a global company specializing in aseptic valves, and SimScale, a leading engineering simulation company. *For more detailed information, please refer to the related links. You can download the PDF for more details or feel free to contact us.*

In this analysis, we will build an automated simulation process for the battery pack and perform optimization with the goal of mass minimization. The software interface provided by AIPOD makes the process setup very simple. For the optimization, the thickness of 36 plates in the battery pack was given as design variables. The optimization goal is mass minimization, but the model's frequency, maximum plastic strain, and maximum RMS stress will be set as constraints. *For more detailed information, please refer to the related links. Feel free to contact us for more details.*

When designing high-performance engines in the field of motorsports, it is necessary to pay attention to complex duct shapes, intake manifolds, and other uniquely shaped components. To increase the engine's horsepower, it is essential to find the appropriate shapes for these configurations. For example, advanced designs like high-flow turbo ducts can significantly accelerate the entire process through flexible and variable CAD shapes. By using a series of design variables, shape deformation can be performed through automated optimization strategies, allowing for the minimization or achievement of objective functions (such as pressure loss and desired flow characteristics like uniformity). At the same time, it is important to ensure that these do not violate constraints related to the designated space. *For more detailed information, please refer to the related links. For further inquiries, feel free to download the PDF or contact us.*

This analysis focuses on a battery pack for electric vehicles that uses a water-cooled cooling plate, and it analyzes the temperature distribution of the battery pack. The mesh model employs an unstructured mesh, with a total of 2.17 million cells. *For detailed content of the article, please refer to the related link. For more information, you can download the PDF or feel free to contact us.*

This analysis conducts a cooling analysis of the motors used in electric vehicles and verifies the temperature around the coils, which are the heat sources within the motor. The following conditions are set for the analysis. *For detailed information, please refer to the related link. For more details, you can download the PDF or feel free to contact us.*

This article introduces the optimization of the electromagnetic and noise performance of motors using the general-purpose optimization software AIPOD. The main source of vibration and noise in motors is the electromagnetic force that changes over time and space with the stator. To reduce the motor's vibration noise, it is key to weaken the amplitude of the corresponding order of the electromagnetic force. Through the software interface standardly equipped with AIPOD, external software's input and output variables can be seamlessly connected, allowing for rapid optimization of motor noise design. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The base model of the oil pan, which is the subject of optimization, was considered to have a primary natural frequency lower than the initially assumed requirements, resulting in poor NVH performance. In this case, we aim to improve the primary natural frequency of the oil pan through structural optimization. Assuming that the contour boundary of the base model remains unchanged, a partial parametric model will be created using external CAD software and incorporated into the node-based optimization process constructed in AIPOD. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The resistance to twisting and bending of the vehicle body are important indicators for evaluating the comfort, handling, and safety of the car. This analysis was conducted using high-performance computing servers to perform a static analysis of the automobile body with millions of elements, investigating the torsional and bending resistance. *For more detailed information, you can view it through the related link. For further details, please download the PDF or feel free to contact us.*

Using the general-purpose optimization platform AIPOD, we will optimize the battery pack beam structure. By linking software that plays the roles of modeling, meshing, and simulation within AIPOD, we will optimize the battery pack structure used in automobiles and achieve weight reduction of the beam structure. External software is used for modeling, meshing, and simulation, and the optimization process will be built within AIPOD. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.

Designing engine components for automobiles often involves considering many constraints, making it a challenging task within development design work. One example is the duct located just before the catalytic converter. Due to space constraints, this component is often designed to be bent quite sharply, which makes it difficult to ensure that the flow distribution is sufficiently uniform. In other words, if the flow characteristics of the catalytic converter are poor, there is a possibility that performance will decrease and emissions will increase. In this case, optimization of the duct for the catalytic converter will be performed using CAESES. *For more details, please refer to the related links. For further information, feel free to download the PDF or contact us.*

Using the general-purpose optimization software AIPOD, we will optimize the performance of the water cooling plate for battery packs used in new energy vehicles. Under unsteady low-temperature heating conditions and steady flow resistance conditions, when the minimum temperature of the cross-section rises by 5°C, the temperature difference in the Z-direction of the battery cell's 1/2 cross-section decreases, but the pressure loss in the flow path must be less than 25 kPa. The water cooling plate model used here is created with the parametric modeling software CAESES, and only the flow path area inside the water cooling plate will be the target for optimization, while other components and conditions will remain unchanged. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.

The comfort inside the vehicle is influenced by many factors based on environmental conditions such as the temperature of the airflow and the flow of air from the air conditioning. To create a more comfortable space for the people present, starting with the vehicle's air conditioning, it is necessary to evaluate the repeated design of the air conditioning vents and the thermal comfort and energy efficiency of the interior under various conditions at the conceptual design stage. This requires understanding the indoor conditions through simulations and pre-validation through numerous parameter studies, making the prediction of flow fields under specific conditions using AI technology effective. In this analysis, we evaluated the flow field and maximum velocity under specific conditions using the AI prediction function incorporated in AICFD. We also compared the results with those from conventional analyses to verify the effectiveness of the AI prediction function. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

Using the general-purpose optimization platform AIPOD, we will optimize the performance of motors used in new energy vehicles. The performance of the motor is a crucial consideration that directly relates to the driving performance of electric vehicles and similar technologies, and improving output and efficiency is essential for the development of better automobiles. AIPOD is equipped with an interface that allows for easy connection to Motor-CAD, enabling users to easily construct processes within the software. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The rigidity and strength of the door directly affect its reliability and also impact the airtightness of the passenger compartment. Therefore, it is important to analyze the structure and strength of the door to evaluate whether the maximum values of deformation and stress in specific directions are below the allowable limits. At the same time, the analysis of door sagging is also used to consider cost and lightweight design planning. This analysis is performed on a car door model to evaluate the stress applied to the door. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The intake port is a crucial component of the intake system in automotive engines and has a significant impact on the mixing of air and fuel. In the early stages of design, the intake volume and pressure loss are evaluated in advance using CFD analysis to optimize the design. In this case study, the pressure loss of the intake port will be analyzed based on the conditions of inlet total pressure and outlet static pressure, and accuracy verification will be conducted by comparing the results with reference values. *For more detailed information, please refer to the related links. For further inquiries, feel free to download the PDF or contact us.

Using the general-purpose optimization platform AIPOD, we will implement the pin layout optimization for heat sinks used for IGBTs in electric systems of new energy vehicles. Heat sinks are components that receive heat from a heat source and release it to the outside air. For this purpose, it is ideal for them to have a shape that maximizes surface area in accordance with constraints. Therefore, optimizing heat sinks is an important factor for the stable performance of electronic components and their long-term operation. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

This analysis examines the drag and pressure distribution that occurs on the body of a large truck under specific conditions. Under the condition where air flows at a speed of 20 [m/s] from the inlet boundary, we will evaluate the impact on the truck's body. By using simulations to confirm the drag coefficient and the state of the flow field, we can obtain information that leads to improved fuel efficiency by understanding the airflow and resistance around the truck. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The rear floor of the vehicle is influenced by both the static load of the tires and the dynamic load from the road surface. Verifying the deformation and stress distribution of the floor plays an important role not only in improving the safety performance of the vehicle but also in leading to proposals for new structural designs. In this analysis, we will conduct structural strength and eigenvalue analysis of the vehicle floor to investigate its structural performance. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The pressure loss in the intake manifold and the uniformity of the flow rates in each pipe are important factors for the engine's output and performance. In this analysis, we will examine the flow inside the manifold of a 4-cylinder automotive engine, as well as the pressure loss and flow velocity distribution in the branch pipes. *For detailed content of the article, please refer to the related links. For more information, you can download the PDF or feel free to contact us.*

Fuel cells are devices that directly convert the chemical energy of fuel into electrical energy and are expected to be the fourth generation of power generation technology, following hydro, thermal, and nuclear power. This electrochemical energy can supply the direct current power needed for external loads, and fuel cells do not emit nitrogen oxides or sulfur oxides. They have high power generation efficiency, a wide range of fuel options, low environmental pollution, and high reliability. In this case study, we will introduce rapid temperature field prediction using data analysis based on issues in the development and design of fuel cells. *For more detailed information, please refer to the related links. For further inquiries, feel free to download the PDF or contact us.*

In the modern industrial sector, motors are utilized as essential power sources across various industries. To maintain the normal operation of motors, it is crucial to prevent overheating, and in the case of air-cooled motors, appropriate heat dissipation design is directly linked to reliability and performance. The thermal fluid analysis software AICFD addresses such challenges and provides a tool for achieving proper thermal design with easy operability and efficient data acquisition. In this article, we conducted a heat dissipation simulation for air-cooled motors using AICFD and validated the analysis results. *For detailed content of the article, please refer to the related links. For more information, feel free to download the PDF or contact us.*

Battery packs are currently widely used in electric vehicles, smartphones, and energy storage technologies, and in such systems, improving the performance of battery packs often becomes the key to product enhancement. In this analysis, we will evaluate the heat dissipation and air cooling effects of a battery module for electric vehicles using a porous medium model instead of a heat sink, and assess the temperature results. As analysis conditions, we set the inlet flow velocity to 5 [m/s] and the outlet static pressure to 0 [Pa], applying the porous medium model to the fins of the heat sink. *For more detailed information, you can view the related links. For further details, please download the PDF or feel free to contact us.*

Simulating the flow around a vehicle and analyzing its aerodynamic characteristics is an important task for evaluating the impact of a car's shape and design on airflow. This provides various qualitative and quantitative information directly related to fuel efficiency, driving stability, and driver safety. In this analysis, which uses models of various scales from simple shapes to detailed models, information is derived through analysis to investigate the wide-ranging effects from design to manufacturing and driving performance, while considering computational time and machine leasing costs. In this analysis, we simulated the flow around the vehicle body using the AI acceleration feature integrated into AICFD. Additionally, we verified the effectiveness of the AI acceleration feature by comparing computational time and accuracy between the standard analysis and serial core using the same model. *For detailed content of the article, you can view it through the related links. For more information, please download the PDF or feel free to contact us.*

At FRIENDSHIP SYSTEMS, the developer of the CAD and optimization software CAESES, automatic optimization calculations were performed based on the shape sensitivity calculated by Adjoint Flow Solvers. The open-source optimization toolkit Dakota, integrated into CAESES, provides optimization methods that can directly accept gradient information obtained by combining shape sensitivity with CAD model parameters as input data. Based on this information, the algorithm selects parameters for design candidates created by CAESES, and calculations are performed using Adjoint Flow Solvers. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

With the development of the automotive industry and the increasing speed of vehicles, there is growing attention on the aerodynamics of automobiles. Excellent aerodynamic design not only achieves high efficiency and energy savings but also reduces noise and provides better ride comfort, driving performance, stability, and stronger security guarantees. In recent years, it has become an essential element not only in the aerospace field but also in various modern industrial designs. In this case study, we analyzed the aerodynamics of automobiles using a passenger car model and evaluated the underlying pressure distribution and flow vectors. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

The developer of CAESES, FRIENDSHIP SYSTEMS, previously worked on optimizing F1 rear wings. Since the CFD analysis was based on the entire vehicle, it was necessary to import the entire vehicle geometry into CAESES and replace only the initial shape of the rear wing with a parametric model. This case study introduces the parametric model of the rear wing created using CAESES' special CAD features. *For more details, you can view the related links. For more information, please download the PDF or feel free to contact us.*

In 2015, VW introduced a device called an airflow transformer aimed at improving emissions, which was installed in a significant number of diesel engines on the market. FRIENDSHIP SYSTEMS, the developer of CAESES, found this device interesting as a subject for optimization and conducted modeling and simulation. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

One of the components targeted for optimization in diesel engines is the injector. This component is designed with careful consideration of its orientation and dimensions to ensure that fuel is injected appropriately into the combustion chamber, making it highly refined. In this case, we will introduce a method for rapidly deforming the existing nozzle shape of the fuel injection system. Based on the shape data imported into CAESES in STL format, we will use the morphing function to implement shape deformation on the injector nozzle. *For more detailed information, you can view the related links. For further details, please download the PDF or feel free to contact us.*

The intake port is the final part of the engine's air intake system, connecting the intake manifold to the combustion chamber, and is opened and closed by the intake valve. Intake ports exist in various types of engines, but they have a particularly significant impact on the formation of the air/fuel mixture in gasoline (SI) engines. In diesel engines, the piston bowl also plays a role in this. Furthermore, the shape of the port affects the charge motion, and a favorable vortex shape reduces energy dissipation, influences the amount of air entering the combustion chamber, and an increase in air quantity leads to improved engine performance. In this case, we will introduce the design of the intake port using CAESES and the automatic optimization in collaboration with CFD analysis tools. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

FRIENDSHIP SYSTEMS, the developer of CAESES, has actively supported student racing teams such as FaSTTUBe and the Ryerson Formula Racing Team. Among these, CAESES was utilized for the optimization of the rear wing shape of racing cars in the Formula Student Germany (FSG) contest, which gathers students from all over Germany. This case study will introduce the optimization of the rear wing and its results. *For more detailed information, please refer to the related links. For further inquiries, feel free to download the PDF or contact us.*

The development of advanced automotive systems such as electric vehicles, autonomous driving systems, and safety enhancement systems will significantly increase the number of electronic devices added to the vehicle body, including sensors, radars, and cameras. It is crucial for these devices to function reliably while minimizing exposure to water to prevent damage and corrosion. One effective approach to achieve this is to reduce water splashes on the vehicle's body and underbody. This case study introduces simulation-driven optimization to investigate the impact of tire tread patterns on water splashes. *For more detailed information, please refer to the related links. You can download the PDF for more details or feel free to contact us.*

The optimization calculation software CAESES and the thermal fluid analysis software CONVERGE work together as a collaborative optimization system aimed at shape optimization and investigating the effects of design variables, providing support to engineers in the design and development field. In this article, we will introduce the functions that can be effectively utilized in CAESES when collaborating with CONVERGE, using intake port models and piston models. *For detailed content of the article, please refer to the related links. For more information, feel free to download the PDF or contact us.

In this case study, we conducted optimization regarding the drag and downforce (negative lift generated by a moving vehicle) of a sports car's rear wing. For this optimization, a parametric model of the rear wing was created using CAESES, and the adjoint solutions obtained from a commercial CFD tool were mapped to the design variables. *For more details, you can view the related links. Please feel free to download the PDF or contact us for more information.*

A torque converter for automobiles is a type of fluid coupling used in vehicles equipped with automatic transmissions to transmit rotational force from the engine to the drive shaft. Designers of torque converters work to minimize cavitation within the device and ensure good flow behavior of the transmission oil, aiming to maximize efficiency and torque ratio at high speeds. CAESES enables the modeling of such complex shapes and can build an optimization system that incorporates shape data into analysis software. By connecting CFD analysis software and proprietary CFD codes to CAESES, it analyzes flow behavior for each designed shape during optimization calculations and provides users with the optimal shape based on constraints. *For more detailed information, please refer to the related links. For further details, feel free to download the PDF or contact us.*

Diesel engines need to focus on reducing fuel consumption while maintaining high performance standards. From this perspective, direct-injection turbo diesel engines are one attractive solution, and when developing these engines, reducing fuel consumption and maintaining high performance standards, along with reducing exhaust emissions, become important challenges. Both issues of fuel consumption and emissions can be addressed through mechanisms within the engine. In the development of the engine combustion process, 3D CFD analysis is an important tool that allows for the investigation of flow within the cylinder, the formation and combustion of the internal mixture, as well as the formation of exhaust products. *For more detailed information, please refer to the related links. For further details, you can download the PDF or feel free to contact us.*

With the improvement in electric vehicle performance, the high output of batteries has progressed, and the increase in power consumption has also led to an increase in heat generation. Therefore, to ensure stable operation of the battery and maximize its performance, the design of an efficient cooling structure is essential. In particular, temperature management of the battery pack is directly related to the lifespan and safety of the cells, necessitating the design of an optimal heat dissipation mechanism. In this case study, we focused on a finned heat sink structure and conducted optimization aimed at improving thermal exchange efficiency. *For more details, please refer to the related links. For further information, you can download the PDF or feel free to contact us.*

In electric vehicles, the motor is a crucial power component responsible for driving the vehicle, and appropriate thermal management is essential to maintain its performance and durability. In particular, the cooling system plays an important role in efficiently dissipating heat from inside the motor and ensuring stable operation. In optimizing the thermal design of the motor, it is necessary to study appropriate cooling effects through various design patterns to maximize cooling performance. During the optimization process, design parameters such as the number and diameter of flow paths, the inclination angle and arrangement of end windings become important factors. Furthermore, to enhance cooling efficiency, careful attention must also be paid to flow control and temperature management of the end windings. In this case study, optimization aimed at minimizing the maximum temperature was conducted based on a flexible parametric model. The motor, composed of a stator and rotor, defines design variables that allow for various shape changes, leading to the derivation of appropriate flow path patterns. *For more detailed information, please refer to the related link. For further details, you can download the PDF or feel free to contact us.*

The battery is one of the most important components in electric vehicles (EVs), and its performance and lifespan have a significant impact on the vehicle's driving range, safety, and even energy efficiency. In particular, the operating temperature of the battery is directly related to the charging and discharging efficiency and degradation rate, making proper temperature management essential. If the temperature is not adequately controlled, issues such as accelerated degradation due to overheating, reduced safety, or, conversely, decreased output and charging efficiency in low-temperature environments may arise. Therefore, the thermal design of the battery pack is a crucial factor in maximizing the performance of EVs and ensuring long-term durability. In this case study, we constructed a parametric battery model with flexible deformation and conducted optimization calculations aimed at minimizing the maximum temperature. *For more details, please refer to the related links. For further information, feel free to download the PDF or contact us.*

The exhaust pipe installed in a vehicle plays an important role in efficiently processing the engine's exhaust gases. The performance regarding the flow of exhaust gases is directly linked to the overall exhaust efficiency and environmental performance of the vehicle, and particularly, pressure loss and flow uniformity are essential factors in maintaining the optimal function of the exhaust system. By improving these characteristics, it is possible to contribute to enhanced engine performance, improved fuel efficiency, and reduced exhaust emissions. In this case, we improved performance by optimizing the shape of the exhaust pipe using the automatic optimization feature, one of the powerful design support functions of CAESES. *For more details, you can view the related links. For more information, please download the PDF or feel free to contact us.*