In my job I need to exercise a fair bit of creativity. Sometimes my ideas are readily picked up. Some require a lot of massaging and some never see the light of day… I used to take criticism of my ideas personally but not since hanging out with engineers. If there’s one thing I’ve learned from you guys is that there’s no such thing as failure – only outcomes. As Thomas Edison famously said “I have not failed. I’ve just found 10,000 ways that won’t work.” If a design fails to meet specifications it isn’t a failure. It’s an iteration and provides you with useful information.
Keeping this statement in mind is particularly helpful when you’re setting up models for analysis. One of the most complicated tasks related to CFD is meshing. Some consider it a black art that takes years to master. A mesh needs to be fine enough to provide you with an accurate result but the finer the mesh the longer the solution might take. So experience definitely counts because you’ll need to play with the mesh until you’ve achieved the right balance … a mesh nirvana of sorts. I remember back in the early 00’s meeting an analyst who would spend a couple of months refining the mesh on jet engines he was testing. Iteration after iteration … refining the mesh. And the more time you spend on meshing the longer you spend on analyzing the design (something that would slow down the entire This is a cost you pay for using traditional CFD software. No wonder some design engineers shy away from using CFD but I’ve got news for you. The new generation of CFD solutions such as FloEFD, feature the latest in technology so you can reach mesh nirvana quickly
Let me introduce you to the Visual Instruments Operations Division at Seiko Epson Corporation in Toyoshina Japan. The group is involved in designing projectors. Projectors are a necessary bit of kit for every conference room. If you’re like me you don’t really notice them until you realize that you have to make a presentation and the projector is missing, it’s not working or the fan inside it whines so loudly that as a presenter you start yelling at the top of your lungs. Not a fun experience for either party in the room!
Their analyst team started using thermal simulation back in the 90s. And in 2009, the organization adopted FloEFD to help enable design engineers analyze their own designs (as opposed to wait for the analysts) and speed up productivity. I found it interesting to read about their adoption of CFD during the early stages of the design process and how they optimized the design of their projectors while accounting for factors such as heat sources, noise and even humidity. It was fascinating to read that among their requirements for selecting CFD software for use by design engineers was that all members of the team had to be able to use it with ease of meshing being a top criteria. So by using FloEFD, their design engineers can now modify designs as they are developed. Fantastic! To read about Seiko Epson and their experience with upfront CFD please follow this link.
Pretty cool, no?
And as projectors go, the one in our conference room drives me batty. If only someone could figure out how to make all of our laptops work with it without having to revert to black magic and incantations, our meetings would actually start on time Or maybe I’ll go have a chat with the IT group and see if we can get one of these beautiful Seiko Epson projectors… hmmm I feel a plan hatching!
Until next time,
PS. Thought I’d tell you guys about this brilliant initiative by Google and IEEE – The Little Box Challenge and its $1M prize! All you have to do is design a smaller power inverter (they’re looking for a reduction in size of 10x or greater). If anyone can do this, it’s you guys! And if you need a bit of help on the testing side get in touch with us. You’ve got until the end of Sept 2014 to register and it and runs through 2015. I look forward to reading about your efforts and drop me a line if you enter the contest!!! I’ll be cheering for you from the sidelines