What exactly is Upfront CFD & CFdesign?

I am constantly asked, “What do you do?”. It then spirals into…

“I work for a really cool software company.”

Wow, who?” (said w. enthusiasm)

“Well, a relatively small company that develops design software for engineers” (said w. enthusiasm)

“Oh, sounds interesting.” (said politely)

Yea, it’s awesome, we help engineers create really innovative designs, by reducing the number of physical prototypes, we turn their computers into a virtual prototyping environments. It allows engineers to turn their computers into a virtual flow bench, wind tunnel or thermal test rig!! Allows them to really understand how to improve their product performance by seeing how they work in 3D.”

“yea, wow, hmmm…I am going to grab another beer, you want anything!”

I am fortunate enough to work with a bunch of guys that are super excited about what we do. We all spin it a bit different, but in the end, we are all saying the same thing. Here’s a classic…

Check out the video above, really solid explanation of what Upfront CFD truly is.

Making Upfront CFD Part of the Critical Path

Often, after a demo, people say that they love what they have seen. Yes, they could “probably” use Upfront CFD to optimize flow paths, increase performance, even prevent failure. BUT!, they are getting by without it. Therefore, “we will have some selling to do to convince their management”. We immediately get placed in the “nice to have” category.

Fair enough. However, time and time again we hear stories of how expensive it can be to find out that a product actually failed in the field. Check out this little gem of a story of LED’s overheating in Boston. It is super critical to be able to manage the temperatures of the LEDs or you can cut their life-expectancy in half. Do a quick search on this blog for more info on LEDs. Below is a shot of a model, we recently worked on showing the air recirculating in the head of a lamp assembly.

Check out this article, which highlights how Daktronics avoided some of the issues of the folks in Boston. I don’t want this to be solely viewed as a sales pitch. As technology evolves and we as engineers are pushing the limits, we should begin designing smarter and more efficient.

There was a time, in the not so distant past, where 2D AutoCAD was considered revolutionary. We have to evolve and make Upfront CAE part of the critical path. Once this is the standard, what’s next?

When Everyday Life & CFD Converge

My wife convinced me to put a pool in our backyard. Probably not what you are thinking. You immediately thought in-ground, diving board with a slide and grotto, right? Not even close. We purchased an Easy Set Pool. You know the kind with the blow up ring at the top and you just fill it with water. Well, 3 pool fills later on uneven ground, the pool is up and running. “Easy” is all relative.

It comes with its own pumping filtration system. Enter the CFD part of the story. I turned it on initially and was amazed how quiet it was and the pumping power was amazing. Over the course of a couple weeks, I noticed that the pump was not cleaning the pool. I then noticed that there were large pockets of air at the discharge of the pump. I vented the pump numerous times and it seemed to be ok, but eventually would lose suction. Really cool to see cavitation in action and the effect it has on the performance of the pump.

Not one to read directions, I figured it was time. Sure enough, it recommended changing the filter on the pump every few weeks. I quickly changed out the filter and was having a great time checking out the internals of the pump, impeller, filter etc.. The filter was packed with all kinds of stuff, clearly impeding the performance of the pump. I have seen literally 100s of pump CAD models and run countless CFD analyses on pumps but haven’t seen the inside of too many in person. I quickly re-assembled and the pump worked like a charm. It made me appreciate even more the challenges that manufactures have to go through everyday to ensure their products perform as expected. Competition is tough everywhere and you have to get it right the first time.

Above is a model we did for Davey Water Pumps awhile back. Click on the image for more details as well. They were able to improve efficiency by 15% by redesigning the pump in CAD and leveraging the CFD results to drive the design changes. As consumers, we just expect that the pump will work all the time. Pump manufactures surely have a difficult challenge to package the pump in a small area, make it as efficient as possible, quiet as possible and sell for less than $100. There has to be a streamlined way for designers to gain insight to their designs.

Upfront CAE & Linux: Does a Future Exist?

The Linux OS has been around for about 17 years. It has grown in popularity and functionality, but really still has a “cult” following. Check out the above Wikipedia link for the details on its origin etc. Pretty sure most people reading this have a general feel for what it is about.

I am the first to admit that in the early/mid 90s I was really hooked on the entire idea. I had a standard windows machine and also had a “second” machine to tinker with Linux. I was introduced to it by some computer geek friends. It was intriguing to think that we were all very into the “alternative” way of doing things. Once out of school, I was working with some pretty high end CAE software packages and we were running UNIX/Linux etc, so I continued to tinker. I was always partial to SUSE/Linux (before big, bad Novell bought them) I still have it installed on an old laptop and when I really want to geek it out, I fire that bad boy up.

The fact is Linux is becoming mainstream, but not in the conventional way that you may think. It is being used in mobile phones, kiosks, game systems and a whole slew of other industries. The fact is most people are using Linux everyday and probably are not aware of it. But will it become mainstream and be leveraged by the multi-tasking engineer that is running Upfront CAE tools? The same question can be posed to the engineers that are driving MCAD today? The quick and simple answer is– probably not anytime soon.

You will certainly have the renegades out there, those that just can’t bring themselves to using Windows. Bold move, but power to them. My gut is that Windows is here to stay for awhile. It’s known, it’s legacy is overwhelming and let’s face it – we all know it pretty well. As a user that is, not in an IT kind of way. I am sure you can pitch it from a security standpoint. I am suggesting from strictly a user’s perspective and whether or not large organizations would take the plunge.

I think Linux is being adopted by the analysis community and will continue on that trend. But I think the Upfront community is more mainstream, tends to go with the flow (no pun intended) and these guys are typically windows users.
I think it is a toss up which direction the Upfront community will go; Linux or Mac?

LED’s are more than just another type of lightbulb..!

I have been talking to a fair number of engineers in lighting companies that are currently working on implementing “LEDs” into their product designs. Definitely the new thing right now. Let’s look at why…

  1. They are more energy efficient (more lumens/Watt).
  2. The lighting is directional, so there is no wasted light.
  3. Very long lifetime- 50-100k hours.
  4. Environmentally sound – no Hg, Pb etc.
  5. Infinitely dimmable
  6. Work great in cold environments

Above is a video of a model we did for a customer recently. The user wanted to optimize the performance by ensuring that the junction temperature stayed below a critical value. We tried a variety of options, such as, different heat sink designs, different LED arrangements and different housing configurations. Classic application for Upfront CFD. Allows us to provide an answer to the classic question, “what if?”.

There are a variety of challenges for engineers that are new to the LED world. Here is a list of the challenges engineers are facing.

  1. The desire to get the maximum output, so engineers are constantly pushing the limit of the LED devices.
  2. There is not enough data available so the “rules of thumb” are currently being developed.
  3. The data provided to engineers is not accurate from the manufacturers.
  4. The testing that is being done does not replicate the actual environments in which the LEDs are being used.
  5. A wide variance in the lifespan of the LEDs based on the junction temperatures.
  6. Finding creative ways to manage the heat.

The overwhelming concern for engineers is to maintain the junction temperature. Check out the graph above. It shows how increasing the junction temperautre drastically reduces the lifescycle of the LED.

There is a ton of info out there on the web that goes into more specifics. Go check it out. Always fun to be able to help engineers solve some of their fundamental issues. To me, LEDs are not much different than any other product out there from a simulation perspective. But it has been interesting learning more and more about how they are being used in the world.

On-demand "remote" Upfront Simulation?!?

There has always been buzz in the CAE industry for users to take advantage of remote cluster computing. Essentially, you would set up your models locally on a machine and run it on a server hosted by a vendor. Some of the old timers, like Fluent, have been in this business for a number of years. I tried their version about 5 years ago. Cool in concept, but the interface and process took some getting used to. I found it difficult to track the model’s progress.
The main problem or limitation on this capability will be the bandwidth. As internet access becomes more readily available and connections speeds improve, I think there is a future in “cloud computing” for Upfront CAE.

I currently do a mocked up version of cloud computing myself. I have a laptop and 64-bit desktop. In CFdesign, I am able to choose which machine I want to solve on directly from within the interface. So, this allows me to very efficiently setup and review models on my laptop and solve and store them on my desktop. I can even do this similar process remote. Takes a bit more copying and pasting and uploading/downloading but it works for now. Still trying to get Remote Desktop to work reliably. In the meantime, I will stick with GOTOMYPC. I used this all week while in Amserdam. Even on a fairly slow connection, I was able to access my dekstop and review a model’s progress.
Ideally, I would love to improve this process. Here’s my wish list. For starters, I would like to build models on my laptop, set them up etc and hit “GO” and have the option of what computer to solve on, even when I am traveling. I would like to have a “favorites” list of computers to choose. Some of us have one or two machines to use, others have a bit more. The file exchange would have to be super fast and lightweight. I then want a “link” to be created that I can access from any browser where I can monitor performance – convergence, mesh quality, mass balance, max temps, max pressures… I want the interface to have the look and feel of a modern web page that I can access from any computer or my phone!. To make life easier, I would like to have the option to have a text message or email sent with the link so I can have immediate access to it. I also want the option to text/email me when the model is finished, encountered an error or simply update me on the progress.
Version 2.0 should have a lightweight preview of the model (similar to JT or Adobe 3d) that allows me to pan, zoom, rotate and view my results. If I could have acces to all of the results, that would be great. But a lightweight model seems to make the most sense for web browsing.
This whole process would be great if I could do this on my “other” machine. But what if I had the option to do this to a remote farm of computers hosted by the software vendor? This way, I could have access to unlimited computing power, unlimited storage capacity (with a fee of course) and unlimited access to technical support in the event that something went wrong. A premium support model would exist so that I can “collaborate” with a support engineer using a variety of medias (texting, iming, email, forum type posts).
Think of the info that could be provided to the vendor on performance, mesh times and sizes, solver times, solver performance, application statistics etc.. The pluses are endless for all.
If I could add version 3.0 to my wish list – it would include driving optimization via this web interface. Cloud computing will only be appropriate for a select group of engineers. But I think the concept can give us endless possibilities. I am looking forward to seeing where the on-demand market takes the CAE industry.

Everyday is Earth Day

Today is Earth Day. It has been an annual event to promote awareness and appreciation of the Earth’s environment. I remember attending a festival ~15 years ago and it mainly consisted of hippy environmentalists. Today it is becoming a part of everyone’s responsibility to do their part.

We as consumers are encouraged to be conscious of the energy we consume, the trash we create and the products we buy. It is amazing how easy it can be if we just take a minute to think about it. We can all adjust the thermostat, recycle what we can and turn out lights that are not being used. This is just the tip of the iceberg.

We as engineers have a responsbility to do what we can to help expand the technology to make the world a bit greener. We in the simulation world are seeing a surge in optimizing products to help the cause.

I am looking forward to doing my part. I am also looking forward to seeing the technology that evolves in an effort to help improve the environment.

CFdesign is the Preferred Industry Partner for Autodesk

This post is more than just a marketing plug. I’ve been running Inventor since it came onto the market. It sure started off slow. It lagged substantially behind SolidWorks and Solid Edge. But over the last few releases it has advanced quite a bit.

I was fortunate enough to participate in an Autodesk event a few weeks ago. I saw first hand the vision of Autodesk the company and the plans for Inventor. It was awesome to see how Alias, Autocad, ProductStream etc all worked seamlessly together. I am really looking forward to the world of Simulation for Autodesk, I think they have a bright future in an untapped market for their customers.

Offshore Technology Conference (OTC) is around the corner

We have had quite a bit of success helping folks in the Oil & Gas Industry design better products. It is interesting that 95% of what they do involves fluid flow and some thermal, yet doing CFD early in the design phase is relatively new to them. Quite similar story in many industries, actually. But this all changing for the better. Check out the video below (has audio too…).

We will be at OTC this year. For some this may be near and dear to you, others – probably not. OTC is the world’s foremost event for the development of offshore resources in the fields of drilling, exploration, production and environmental protection. With more than 2,500 exhibiting companies, divisions, and subsidiaries, the Offshore Technology Conference (OTC) is the largest conference and exhibition in the offshore industry. It is being held at the Reliant Center in Houston, TX on May 5-8th, 2008. We are sharing booth #5763 with our friends at Autodesk.

Marin Bikes are designed using Autodesk Products

I wrote in a previous post, that I have been bicycle shopping. I chose to stick with REI as my bike shop. Quite a few reasons why I chose REI, partly because it is local to my house and I figured I’d support the co-op. The two main bike brands that REI sells are Novara and Marin. It was tough to decide between the two, but I noticed the Marin had a sticker “designed using Autodesk”. Being a big fan and user of Autodesk Inventor, I easily picked the Marin.

I decided to go with the Marin Muirwoods 29er. It is a hybrid bike that I can ride mostly on the streets of Philly but allows me to hit some of the gravel paths in the neighborhood parks.

Here is another shot of a model our team worked on for one of the other bike manufacturers.


I am looking forward to the warmer season and one of my goals this summer is to drastically reduce the need to drive a car. Not only is it great exercise, but it is one of the many things I think we all should be doing to help improve the environment.