Dassault Systèmes Software has Designs on Energy

Tuesday, Jun 23, 2009

Abstract: The energy industry is benefiting from Dassault Systèmes Product Lifecycle management (PLM) technology across many disciplines ranging from the development of small wind turbines to nuclear fusion. This article looks at the most advanced applications of PLM software to the benefit of traditional and sustainable energy generation.

Rays of Hope

Fusion power technology is mankind’s biggest engineering challenge. Leading scientists, engineers and planners are working towards the solution significantly aided by the availability of 3D model based data held within a single Dassault Systèmes software environment.

Set the Controls For the Heart of the Sun

JET (Joint European Torus), located at Culham, UK, is a an experimental fusion energy device in which, by creating temperatures greater than that of the sun (around 100 million degrees C) and applying magnetic confinement, fusion of atomic nuclei takes place. The next stage of fusion technology development has started with the building of ITER, which is eight times larger in volume than JET. ITER is one of the most challenging scientific experiments ever undertaken, leading initially to a trial generating station followed by full-scale generators, supplying fusion energy to the grid by the end of this century.

Business Reaction

The business benefits that Dassault Systèmes methodology delivers to the ITER supply chain derive from using 3D model technology to develop and communicate information.

Some of the most complex elements of JET are the remote handling systems. These emulate human movement controlled from remote stations several hundred meters away and are developed by JET operator UKAEA in conjunction with Oxford Technologies staff. Simon Mills, Oxford Technologies’ Engineering Director explained the system’s operation. “A force reflecting master manipulator transmits a human operator’s motions and forces to a remote slave manipulator inside the tokamak* chamber. The system performs maintenance tasks without the need for engineers to enter the hostile tokamak environment. Some 20,000 tasks have been performed at JET over the last 12 years. These include installing components, changing configurations and updating systems inside the tokamak. Maintenance and enhancement periods occur at intervals of 3-4 years and may last from a few months to more than a year. Between these ‘engineering breaks’, the remote handling systems are used to develop techniques for performing future maintenance tasks.”

Once ITER is operational, there will be no human access to the tokamak or other areas of the plant containing highly active systems. All maintenance and future upgrades will then be carried out remotely.

Animated Communication

All companies in the ITER and JET engineering supply chains use CATIA, DELMIA, 3DVIA Composer and other Dassault Systèmes PLM software and methodology. One company that is involved with both JET and ITER technology provision is Oxford based, Desktop Engineering (DTE). MD. Geoff Haines talked about the company’s role. “JET and ITER bring together many engineering and scientific specialists who need to communicate and operate in a concurrent and collaborative way. DTE provides design to manufacture PLM software and support services to companies involved with both the buildings and structures as well as the systems that they house.”

Simon Mills added. “DTE helps us to derive maximum engineering and commercial advantage from our Dassault Systèmes technology with ongoing training and support. They have introduced us to the newest methodologies which save time and money by increasing productivity and overall efficiency.”

“One example of this was the introduction, by Desktop Engineering, to Oxford Technologies, of 3DVIA Composer to animate CATIA generated 3D imagery. This not only allows them to refine their designs through the better cognition that kinetics enables, but also gives all stakeholders a clear understanding of the equipment in its context and detail.”

Communication in 3D is the norm since the deployment of 3DVIA Composer allows non-CATIA users visual access and interaction with 3D digital models of Oxford Technologies’ remote handling systems.

Geoff Haines commented, “The production efficiencies derived from specifying Dassault Systèmes technology throughout JET and ITER supply chains are augmented by the introduction of 3DVIA Composer.  It provides simple access to 3D data and lets people understand how complex systems operate and interact.”

ITERative process

Oxford Technologies’ contribution to JET and ITER relies on the ability to develop and integrate truly innovative engineering solutions. These must operate reliably in the harsh yet delicate environment of the tokamak. Simon Mills concluded, “Devising articulated boom type devices, and ancillary components, to operate within the tokamak at maximum efficiency, safety, precision and speed, requires an engineering design platform that allows our full creativity and ingenuity to flourish. It also needs a technology partner, in this case Desktop Engineering DTE, to work with us and introduce and support economical, scaleable and fully compatible software.”

Geoff Haines added, “Helping companies to operate successfully within the JET and ITER programme builds on our experience of providing mechanical and built environment PLM systems at the highest level. The results of today’s fusion engineering will secure the world’s energy future. Its PLM foundation is optimised to assure future-proof scientific, engineering and commercial success for the project and the enterprises that it comprises.”

* tokamak |ˈtōkəˌmak; ˈtäk-| noun Physics

a toroidal apparatus for producing controlled fusion reactions in hot plasma.

Origin: 1960s: Russian, from to(roidal’naya) kam(era s) ak(sial’nym magnitnym polem) ‘toroidal chamber with axial magnetic field.’

Up on the Roof

Waterloo, London, UK based Solar Century, designs and installs solar panels across the world and is the premier firm for this increasingly significant part of the building industry.

With all responsible property owners now considering their carbon footprint Solar Century is experiencing rapid business expansion with consequent increased demands on its own infrastructure. The company employs around 100 people - and counting. Mat Burgess, the company’s Development Manager, described how by partnering with UK Dassault Systèmes Value Added Reseller Design Rule, they have introduced a flexible ENOVIA SmarTeam based methodology that provides the tools to efficiently manage all future business expectations. “Like many growing companies Solar century was running a range of diverse business management software which was not effectively connected.  This led to inevitable operational inefficiencies which we recognised and sought to address using Design Rule’s expertise.”

Free The Power

Generating your own power and selling it into the grid will become more profitable in the UK as it grasps the realities of sustainability and this spells sunny times for Solar Century. Design Rule MD Bob Hiller commented. “Inevitably companies that grow fast from a small base have the same issues to deal with as larger companies and many outgrow their IT infrastructure even before it has delivered any real business benefits.  To deal with Solar Century’s plans, an ENOVIA SmarTeam solution that matches the business’ current and future requirements has been deployed which can grow with them and is indeed grown by them using their own resources.”

By also using a set of software tools, DRLTools, developed by Design Rule, to augment SmarTeam Mat Burgess is able to more easily configure and fully utilise SmarTeam objects and associated data, design his own forms and objects and link their content with the same powerful ENOVIA SmarTeam technology and reporting systems that are used by the worlds leading design to manufacture enterprises.

He said, “ Design Rule’s SmarTeam Productivity Tools (DRLTools) allow us to synchronise information within and beyond our enterprise more intelligently. Automatic actions are generated from object input. This saves time on every job because the data builds into a single complete system that delivers all the information that people need in the way that they need it.

Magnified Vision

All information in SmarTeam is validated “in process”. Solar Century data covering, workflows, documentation, CAD, Bills of Materials, version control, quotations, budgets, project progression, materials specification, suppliers, purchasing and quotations are managed using SmarTeam Engineering Express, Workflow, BOM and Community Workspace. DRLTools is an enabler for delivering greater user acceptance and consequent productivity efficiency benefits.

“Measuring and reporting project progress in relation to business expectations is now a simple process that offers the benefits of being concurrent, consistent and in real time. This delivery of current business intelligence allows decisions to be made that are based on more reliable information.”

Bob Hillier added. “The technology used by the worlds leading manufacturers to unlock the value of company data was deployed at Solar Century in just two months. By utilising Dassault Systèmes ENOVIA SmarTeam methodology in a company the size of Solar Century its ability to improve efficiency is magnified. Profitability and working efficiencies become instantly visible while a complete workflow methodology becomes available.”

Many of Solar Century’s customers benefit from a service that includes technical consultancy, system design, panel manufacture and final installation. The company also devises and delivers other systems including wind turbines. The company has a strong network of partners who are now able to collaborate with Solar Century generating concurrent working practise. This allows for great productivity gains since there is less reliance on completion of one part of project before another can start.

Lofty Ambitions

Mat Burgess commented, “Among the advantages of SmarTeam is control over change orders and the communication of engineering concerns in a targeted way so that the correct expertise can be efficiently brought to a project. These factors allow people access to pertinent information and, as the company grows these software tools enable us to create new elements to our workflow to accommodate varying circumstances within our extended supply chain. As the system grows, the further automation that DRLTools helps develop will create more intelligent objects while the data that they contain or relate to becomes an increasingly valuable business asset. Also, because the system integrates with the MS Office suite of software, applications such as MS-Excel can be used to great effect and its data bi-directionally integrated with ENOVIA SmarTeam to create further efficiencies.

If every building in London was equipped with solar panels the scheme would pay back in 3 years and provide more than enough energy for the city’s needs for generations; the same is true for the whole planet. Solar Century is positioned to take advantage of market growth equipped as it is with an IT infrastructure that is not only future proof enough to take the company safely in to its destiny but is increasing becoming an AEC industry standard technology toolset.

The Answer is Blowing in the Wind

UK-based wind energy company quietrevolution has deployed Dassault Systèmes PLM solutions to enhance design and manufacturing of its wind energy generators.

Having calculated a mathematically correct shape for its aerodynamically optimized vertical axis rotor blades, quietrevolution uses Dassault Systèmes’ CATIA to design, engineer and manufacture its wind energy turbines. CATIA helps quietrevolution to capitalize on the growing demand for wind energy systems by providing an efficient design, development and production technology platform that allows the company to make the most of its resources.

quietrevolution Design Manager Richard Kingsley said, “Product development is at the heart of our work. In the short time that we have been using Dassault Systèmes’ CATIA virtual design solution, it has significantly improved our ability to efficiently complete the design-to-manufacture processes of advanced structures.” Mr. Kingsley, who has experienced PLM at Lotus Cars, Proton, Ascari and Aston Martin, added, “Dassault Systèmes PLM allows us to digitally design, sign off, investigate tooling feasibility, build products, and communicate 3D designs. CATIA is the industry standard among our supply chain and it allows us to exchange native files with partner companies leading to more efficient production processes.”

Mike Crow, director, Dassault Systèmes said, “We are glad that quietrevolution is utilizing CATIA leading-edge virtual design solutions to be at the forefront of the wind energy industry. Using best practices developed in conjunction with leading manufacturers from other industries, wind turbine manufacturers can avoid costly trial and error in the real world and significantly reduce development cycle time while manufacturing stronger products with higher energy outputs by integrating design, testing, and manufacturability analysis in a single environment.”

Darren Cairns of Intrinsys, the Dassault Systèmes value added reseller that implemented and supports the solution said, “quietrevolution is an example of a cutting-edge company using advanced 3D PLM technology to lead the world in this sector of the wind energy industry. We are proud to make our CATIA expertise available to help quietrevolution develop new energy solutions by providing advanced production software and the services that optimize its rewards.”

Realistic Simulation Accelerates Safety Evaluation of Mine Designs

A global mining company has achieved significant productivity gains with digital 3-D mine models developed with Abaqus finite element analysis software.

In a step change beyond traditional processes, Abaqus finite element analysis (FEA) software from SIMULIA (the Dassault Systèmes’ brand for realistic simulation) is being used to enhance mine design and engineering simulation at a number of major mines around the world. In North and South America, Africa and Australia some of the world’s biggest mining companies are applying FEA technology to evaluate safety and improve design planning, implementation, and operations.

Beck Arndt Engineering (BAE), a Sydney-based international consultancy, is a pioneer in the commercial development of engineering solutions for the mining industry. The consultancy has worked closely with engineers at SIMULIA Australia to expand the use of Abaqus FEA simulation software for mining applications.

Deep Down Safety

Among the early adoptors of mine-ready FEA technology is the world’s largest miner, BHP Billiton. With BAE’s help, BHP has already applied this technology to evaluate mines in Canada and Australia. At the BHP Billiton Nickel West Perserverance Deeps Project in Western Australia, Abaqus FEA software is now being used to help engineer the safety and productivity of planned deep-mining operations.

To achieve this goal in the deep-mining environment requires significant technological innovation. Using measurements of site deformation and seismicity, Abaqus FEA models have been calibrated and, in a single day, used to simulate a full, three dimensional, inelastic analysis of a mine’s life cycle.

In recent years, similar applications at Debswana’s Jwaneng Mine in Botswana, the Newcrest Mining Ridgeway Deeps Project in New South Wales, Australia, and Rio Tinto’s Argyle Diamond mine in Western Australia have also established Abaqus FEA analysis as the leading technology for multi scale, simulation-aided mining engineering.

Dr. Joop Nagtegaal, a pioneer of FEA and a Dassault Systèmes Corporate Fellow, says that Abaqus FEA software is unique in its capabilities to enable mining engineers to investigate design innovations from the drawing board to full production. “In the design stage, Abaqus models, which include rockmass volumes spanning several kilometers around the ore body and down to excavations just a few meters across, are used to compare and optimize engineering options,” he said. “Then, as the mine goes into production, large volumes of data from the field are incorporated with the analysis models to allow them to be calibrated to a precision not previously available to the mining industry.” 

Important Event

Seismic event forecasting has become increasingly important at several sites where mining-induced seismicity is a concern. Dr. Stephan Arndt, principal engineer at the BAE Perth office, said the vast amount of analysis required to create solutions in today’s competitive mining markets requires new technologies and methods. 

One innovation has been the development of the Dissipated Plastic Energy (DPE) analysis method. DPE analysis has been used to develop controls for potential problems, as well as to better understand how rock masses are damaged.

As the size and complexity of mining problems being studied increase, engineers are facing the need to leverage high-performance computing solutions. 

“The size of the models we now use in mining is unprecedented,” said Arndt. “Distributed Memory Parallel (DMP) processing, using 32 CPUs with Abaqus FEA software, gives us the capacity to compare a number of different scenarios for mine-scale model simulations in a very short time. The level of detail achieved in these models allows us to calibrate deformation and rockmass damage, seismogenic potential and ground support performance. Abaqus has an important role to play in mining and our analysis methods are setting new standards in this industry”

Another application of nonlinear modeling is the design of ground support. Similar to applications in tunnelling and civil engineering, mine excavations are subject to high deformation. Not so typical are the strains and loads involved. In some mining cases, tunnels must survive in very weak rock a very short distance from massive underground excavations at great depth.

Sounds Logical

“To ensure the safety of people and to achieve productivity objectives on these challenging sites with unique geological characteristics, mining engineers need to think outside the box,” said Arndt. “This technology enables quick, cost-efficient analyses, which in turn facilitate the logical decision-making process necessary for the future development of mines in safe, environmentally-sound and more economical ways.”

“Acceptance of FEA technology in mining is similar to the automotive industry experience, in which Abaqus has been accepted as a part of the vehicle body design process,” said Dr. Nagtegaal. “Auto makers have learned that performing crash simulations of their designs with FEA software is much less costly than real life barrier smashes, and provides a better platform for developing ‘what if’ scenarios.

“Today, we are integrating Abaqus as a tool for simulation-aided mining engineering in much the same way, with similar achievements in cost saving and improved safety.”

For Further Information

Desktop Engineering – http://www.dte.co.uk

Dassault Systèmes – http://www.3ds.com

SIMULIA http://www.simulia.com

Quietrevolution -  http://www.quietrevolution.co.uk

Solar Century -  http://www.solarcentury.com

Design Rule  http://www.designrule.co.uk