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Why Design Validation is Important for New Product Development
- 3. Introduce Validation Earlier in Design Process Product Development Process Effort Time Production Conventional Process Early Design Validation
- 5. Design Validation Products SolidWorks Simulation Let’s Go Design SolidWorks Flow Simulation Computational fluid dynamics SolidWorks Motion Motion simulation SolidWorks Simulation Mechanical Design Validation
- 6. SolidWorks Simulation Capabilities SolidWorks Simulation Let’s Go Design Drop Test Static Frequency Thermal Non Linear Fatigue Optimization Post Dynamics
Notas do Editor
- The goal of this slide is to highlight the broad business advantages of using design validation to help increase companies’ competitiveness, market share, and profitability. Accelerate new product development Bring new products to market faster before the competition does. This is an important factor in volatile industries like electronics/medical where R&D costs are huge and time is of the essence. Design validation helps eliminate/detect design issues early in the product development cycle to meet project delivery timelines and also avoid late delivery penalties. Switch to alternate or cheaper material Raw material costs are increasing worldwide. One of the ways to remain cost competitive is to switch to a cheaper material. Manufacturers also face material specific related issues like manufacturability and regulations (corrosiveness/toxicity). With design validation, it’s very easy and quick to switch to an alternative material and test the product for any changes in performance or quality. Reduce prototype costs Prototyping is expensive and time consuming. By using design validation, users can detect problems early in the design process, saving a significant amount of time and money. Instead of spending time ironing out product problems downstream, with design validation companies can reduce the number of prototype tests to be performed followed by engineering changes. Improve product quality and performance Design validation is a preventive tool that improves overall product quality. Better quality products mean a decrease in warranty costs and an increase in customer satisfaction for repeat business. Product performance can also be enhanced by conducting design optimization for value add.
- At the product level, design and engineering departments have their own challenges to overcome in order to design better products. These include: Improve complex product designs One of the challenges in designing a better product is the complexity of design requirements. Trends can be analyzed using design validation tools to understand the influence of different design variables like fillet size, thickness, and the number of holes or bolts. Based on the results, adjustments can be made to optimize product performance. Reduce re-design Traditionally, products may be over designed and far less than optimal. Upfront design validation usually leads to passing the prototype test the first time, eliminating costly and time consuming iterations to fix last minute problems. Early problem detection and correction Design validation allows to quickly iterate back and forth in performing conceptual ‘what-if’ studies to evaluate the merit of different ideas, compare alternatives, and filter out design weaknesses. It saves from performing another redesign cycle to arrive at a better design. Greater product quality Have greater confidence in the warranties offered with your products. This can be achieved by improving overall product quality. Design validation can help subject the product through cyclic loading (fatigue) for its life expectancy and avoid unexpected field failures.
- The Conventional Design Process – Design-related problems are found and fixed late in the design stage, often resulting in weight, cost, manufacturing, and time penalties. Releasing products to market late can have a direct correlation with lost market share. 80% of the performance, cost, and quality of a product are established in the very early stages of the product design process. To shorten the product development cycle, companies need to evaluate and re-orient the process itself so that analysis is performed much earlier in the product development cycle. Design changes are much easier and more economical to make earlier in the design process, ensuring product development is headed in the right direction. Also, rapid feedback of several design possibilities early in the development stage leads to greater freedom to explore innovative ideas. For example, the Mars Rover robotic arm (refer to image) Benefits: Achieved NASA space requirements of strength and weight (light/compact), eliminated time, and cost of building prototypes by using upfront design validation.
- The COSMOS solutions are focused on helping SolidWorks users introduce design validation early in the product development process. Design validation for all SolidWorks users COSMOS offers an intuitive and easy to use interface for novice users. The learning curve is shorter, as there is no need to learn another GUI. It works in the same manner as SolidWorks software. COSMOS speaks the language of a designer with innovative features like the analysis advisor, smart connectors (bolts, springs etc), and the analysis library. COSMOS provides simplified analysis. Fully integrated within SolidWorks COSMOS leverages the advantage of being fully integrated within SolidWorks. (Example: Owning a printer/fax/copier/scanner separately vs. an all-in-one machine). There is no rework, such as exporting/importing CAD data, applying material properties, or setting up a new analysis every time. All this makes it easy and fast to perform ‘what-if’ design studies earlier in the design process and it helps provides interactive feedback. This is a best in class solution for all analysis needs – COSMOSWorks, COSMOSFloWorks, COSMOSMotion (all discussed in detail in the next slide). Single source solution Local SolidWorks VARs are trained and certified in COSMOS products – they provide a high level of service quality. Pre- and post-sales (professional training and support) are handled locally by the reseller for customer convenience. No hassle in dealing with multiple vendors.
- SolidWorks offers a full range of design validation tools to address all kinds of analysis needs, including: COSMOSWorks : FEA-based design validation tool helps in studying failures due to stress, excessive deformation, and factor of safety checks. COSMOSMotion : Physics-based motion simulation of moving components. Facilitates design of motors, actuators, gears, and cams. Motion can also help reverse engineer and perform interference checks. COSMOSFloWorks : Studies the flow of any kind of fluid inside or outside the product. Examples: pumps, valves, electronic enclosures, and medical and drug delivery equipment. All three products are fully integrated within SolidWorks. Results from COSMOSMotion and COSMOSFloWorks can be seamlessly used with COSMOSWorks.
- COSMOSWorks is easy to use AND a power tool with an extensive set of capabilities. Following are the types of analysis that can be performed: Static – Stress analysis Frequency/Buckling – Natural frequency/resonance and mode shapes Thermal – Effect of change in temperature and heat transfer Drop Test – Easy to use drop testing Optimization – Real time shape optimization Fatigue – Cyclic loading to calculate product life Non Linear – Analysis of plastics and rubber products Post Dynamics – Virtual shaker test, vibration analysis
- Here is a a small list of successful companies using COSMOS Analysis tools in their design processes.
- Machine Design Industry Challenges Decrease design cycle time Reduce recall and warranty costs Reduce re-design (ECO) Improve product quality and performance Reduce material costs COSMOS Benefits Design a product right the first time Virtual testing early in the design process Reduce time consuming and costly prototyping Check for weight, performance, and failure Design optimization and alternatives to offset material cost
- Medical Industry Challenges Accelerate new product development Adapt to demanding consumers Ensure consistent quality and performance Compliance to regulations like the FDA Reduce product liability exposure COSMOS Benefits Quickly study performance of multiple designs Reduce operating time and patient trauma Range of motion, interlock strength Material strength and conductivity Results and data management
- Consumer Industry Challenges Automation and better value for the money Deliver more features and functionality Better looking products Increase the size of your product range Provide innovations and incorporate new technology COSMOS Benefits Study different alternatives Performance improvement of complex mechanisms Drop testing of handheld devices Check for compliance to safety regulations Optimize design for size, weight
- Electronics Industry Challenges Accelerate new product development Regulatory compliance, recycling Improve performance and embed more functions Product packaging, reduction in size Develop innovations and incorporate new technology COSMOS Benefits Predict mechanical reliability Drop testing of handheld and portable devices Maintain safe component operating temperature Alternative materials (eco-friendly/non-hazardous) Optimize for size, weight, and efficiency