CENOS Simulation Software

While most of Volkswagen's successful projects remain hidden to outside observers, there is one that is worth mentioning. By simulating with CENOS engineers in Volkswagen reduced the induction heating time for the assembly of the power steering rack by a factor of five - from 9 seconds to 2 seconds. As a result, the productivity of the production line for power steering components is now almost 5 times higher. 𝗟𝗲𝘁’𝘀 𝗯𝗲𝗴𝗶𝗻 𝘄𝗶𝘁𝗵 𝘁𝗵𝗲 𝗰𝗵𝗮𝗹𝗹𝗲𝗻𝗴𝗲 Normally, it took 9 seconds to heat up the power steering rack with a process of induction heating. This might seem fast, but in car making, every second that can be saved is crucial for staying ahead. In Braunschweig, Germany, Marcel Ruthmann, a dedicated engineer at Volkswagen Group Services, teamed up with Fabian Bauer from Volkswagen in Wolfsburg. They were set on making a big improvement in how car parts are made, focusing on the power steering rack, which is a key piece of the car. 𝗧𝗵𝗲 𝘀𝗼𝗹𝘂𝘁𝗶𝗼𝗻 Marcel and Fabian used CENOS Simulation Software. This tool lets engineers try out ideas on a computer before doing them in real life. This saves time, money, and materials because they can see what works best without any waste. By using the software to test and adjust their ideas, they managed to cut down the heating time dramatically. To be precise, from 9 seconds to just 2 seconds. This wasn’t just a small improvement. It multiplied the speed of their production line by nearly five times. In technical terms, Marcel and Fabian used the software to fine-tune parameters like the coil design and the power output of the induction heater. They ran simulations to see how changes in these areas could improve heat distribution and reduce heating time. Their success came from pinpointing the optimal settings that maximized efficiency while maintaining product quality. 𝗜𝗻 𝗰𝗼𝗻𝗰𝗹𝘂𝘀𝗶𝗼𝗻 This improvement is very important for Volkswagen and for any engineer or manufacturing manager who wants to speed up production without sacrificing quality. Marcel and Fabian’s work shows how integrating advanced simulation technology can lead to huge gains in manufacturing processes. #volkswagen #innovation #automotive #simulation #productivity

To maximize wireless charging efficiency and reduce device charging times, engineers are facing the tough challenge of making sure these systems work well even when not perfectly aligned. When devices aren't perfectly aligned, the inductive connection weakens, and the power transfer efficiency drops. Not just side-to-side misalignment, but even if devices are separated vertically (z-axis), also changing gap size between Tx and Rx assemblies. It affects how well they can transfer power. Using simulations, engineers can evaluate how changes in different system parameters affect the quality (Q) factor, which is widely used as a reference for the quality of the coil. Tuning the resonance frequency can help mitigate misalignment issues, and simulations help us understand how this affects the system's stability. 𝗛𝗲𝗮𝘁 𝗮𝗻𝗱 𝗺𝗮𝗴𝗻𝗲𝘁𝗶𝗰 𝗳𝗶𝗲𝗹𝗱𝘀 Misalignment doesn't just reduce efficiency, but it also creates more heat. When the alignment is off, the magnetic field induces electric currents in nearby materials, which causes energy loss in the form of heat. Managing this heat is crucial to keeping the system working properly. Engineers need to consider how nearby materials affect the magnetic field. Electrically conductive materials can distort the magnetic field, reducing the power transfer efficiency. By tweaking design variables such as coil shape, size, material, and the distance between coils, engineers can predict how these changes affect the overall performance of their system. This allows them to find an optimal balance between energy efficiency and charging speed, ensuring the device charges as intended without excessive energy loss. 𝗧𝗵𝗲 𝗤𝗶 𝗦𝘁𝗮𝗻𝗱𝗮𝗿𝗱 𝗮𝗻𝗱 𝗼𝗽𝘁𝗶𝗺𝗶𝘇𝗮𝘁𝗶𝗼𝗻 Unlike the earlier Qi 1 standard, where the phone needed to be positioned very accurately to start charging, the Qi 2 standard's built-in magnets in the charger attract corresponding magnets in the smartphone. This magnetic pull guides the phone into the perfect position for charging. This alignment ensures that the maximum possible power is transferred from the pad to the phone, minimizing charging time and improving efficiency. 𝗔𝗱𝗮𝗽𝘁𝗶𝗻𝗴 𝘁𝗼 𝗺𝗶𝘀𝗮𝗹𝗶𝗴𝗻𝗺𝗲𝗻𝘁 Future WPT systems will need to be adaptive, adjusting in real-time to maintain efficient power transfer even when devices are misaligned. This might involve changing coil parameters or using advanced algorithms. CENOS Simulation Software can model these adaptive systems, helping engineers see how effective they are before building physical prototypes. #cenos #wirelesscharging #simulation #simulationsoftware #innovation

Webinar reminder ⏰ 𝗝𝗼𝗶𝗻 𝘂𝘀 𝗼𝗻 𝗠𝗮𝘆 𝟮𝗻𝗱 𝗳𝗼𝗿 𝗮𝗻 𝗟𝗠𝗦 𝟭.𝟬 𝗿𝗲𝗹𝗲𝗮𝘀𝗲 𝘄𝗲𝗯𝗶𝗻𝗮𝗿 where we dive into the capabilities of the CENOS Liquid Metal Stirring tool.   ↳ Overview of CENOS Liquid Metal Stirring tool.   ↳ Step-by-step simulation walkthrough of the Induction Crucible Furnace.   ↳ Stay ahead with exclusive insights into our future roadmap.   ↳ A live Q&A session where your questions bring valuable discussions to the surface. 𝗗𝗼𝗻’𝘁 𝗺𝗶𝘀𝘀 𝘁𝗵𝗲 𝗰𝗵𝗮𝗻𝗰𝗲 𝗮𝗻𝗱 𝘀𝗲𝗰𝘂𝗿𝗲 𝘆𝗼𝘂𝗿 𝘀𝗽𝗼𝘁 𝘁𝗼𝗱𝗮𝘆! ↳ 𝗥𝗲𝗴𝗶𝘀𝘁𝗿𝗮𝘁𝗶𝗼𝗻 https://lnkd.in/dTrzxiF5 #CENOS #SimulationSoftware #LiquidMetalStirring #LMS #Webinar

Webinar reminder ⏰ 𝗝𝗼𝗶𝗻 𝘂𝘀 𝗼𝗻 𝗠𝗮𝘆 𝟮𝗻𝗱 𝗳𝗼𝗿 𝗮𝗻 𝗟𝗠𝗦 𝟭.𝟬 𝗿𝗲𝗹𝗲𝗮𝘀𝗲 𝘄𝗲𝗯𝗶𝗻𝗮𝗿 where we dive into the capabilities of the CENOS Liquid Metal Stirring tool.   ↳ Overview of CENOS Liquid Metal Stirring tool.   ↳ Step-by-step simulation walkthrough of the Induction Crucible Furnace.   ↳ Stay ahead with exclusive insights into our future roadmap.   ↳ A live Q&A session where your questions bring valuable discussions to the surface. 𝗗𝗼𝗻’𝘁 𝗺𝗶𝘀𝘀 𝘁𝗵𝗲 𝗰𝗵𝗮𝗻𝗰𝗲 𝗮𝗻𝗱 𝘀𝗲𝗰𝘂𝗿𝗲 𝘆𝗼𝘂𝗿 𝘀𝗽𝗼𝘁 𝘁𝗼𝗱𝗮𝘆! ↳ 𝗥𝗲𝗴𝗶𝘀𝘁𝗿𝗮𝘁𝗶𝗼𝗻 https://lnkd.in/dTrzxiF5 #CENOS #SimulationSoftware #LiquidMetalStirring #LMS #Webinar

𝗝𝗼𝗶𝗻 𝘂𝘀 𝗼𝗻 𝗠𝗮𝘆 𝟮𝗻𝗱 𝗳𝗼𝗿 𝗮𝗻 𝗟𝗠𝗦 𝟭.𝟬 𝗿𝗲𝗹𝗲𝗮𝘀𝗲 𝘄𝗲𝗯𝗶𝗻𝗮𝗿 where we dive into the capabilities of the CENOS Liquid Metal Stirring tool.   ↳ Overview of CENOS Liquid Metal Stirring tool.   ↳ Step-by-step simulation walkthrough of the Induction Crucible Furnace.   ↳ Stay ahead with exclusive insights into our future roadmap.   ↳ A live Q&A session where your questions bring valuable discussions to the surface. 𝗗𝗼𝗻’𝘁 𝗺𝗶𝘀𝘀 𝘁𝗵𝗲 𝗰𝗵𝗮𝗻𝗰𝗲 𝗮𝗻𝗱 𝘀𝗲𝗰𝘂𝗿𝗲 𝘆𝗼𝘂𝗿 𝘀𝗽𝗼𝘁 𝘁𝗼𝗱𝗮𝘆! ↳ 𝗥𝗲𝗴𝗶𝘀𝘁𝗿𝗮𝘁𝗶𝗼𝗻 https://lnkd.in/dTrzxiF5 #CENOS #SimulationSoftware #LiquidMetalStirring #LMS #Webinar

How NETZSCH Bombas & Sistemas Brasil improve their machines with CENOS software? Netzsch is a manufacturing company in Brazil that makes hydraulic pumps. The company ran into some trouble with an induction hardening machine they have purchased several years ago. Netzsch was constantly working to improve their products and manufacturing processes. Therefore, multiple things had changed during the time - the design of the parts, the steel used, etc. Klaus Heizinger, the head of their research team, was determined to fix this problem. When trying to adjust the hardening process, Klaus and his colleagues were struggling to get satisfactory results. They wanted to keep making their products better and needed their machines to keep up. 𝗧𝗵𝗲 𝗣𝗿𝗼𝗯𝗹𝗲𝗺 Netzsch was updating their products and using new types of steel, but their old hardening machine wasn't keeping up. The machine had very basic settings like "high frequency", "medium frequency" and "low frequency" without any information of what are the absolute values of those frequencies. This lack of clear settings made it really hard for the team to figure out the best way to use the machine. They ended up wasting a lot of materials and time trying to guess the right settings. 𝗖𝗼𝗻𝘁𝗶𝗻𝘂𝗲 𝗿𝗲𝗮𝗱𝗶𝗻𝗴 𝘁𝗵𝗲 𝗳𝘂𝗹𝗹 𝘀𝘁𝗼𝗿𝘆 ➜ https://lnkd.in/dr2nWxAA

The RFID Journal LIVE! in Las Vegas brought together industry leaders and innovators. It’s the world's biggest RFID event and we at CENOS are extremely proud to have participated in that expo. We are sure that you saw us in booth nr 111 with Emils Vjaters and Bricia Alvarado from CENOS. We were there to dive into the latest advancements in #RFID (Radio-Frequency Identification), #IoT (Internet of Things), and #AI (Artificial Intelligence) technologies. But also, we were there to introduce the capabilities of the CENOS Simulation Software, and how it can support the initiatives of RFID technology. A big part of the conference was about different RFID tools, different readers and antennas, and how they are used in various industries. Here are the main points we extracted from the event. 𝗪𝗲 𝗮𝗹𝘀𝗼 𝗽𝗼𝘀𝘁𝗲𝗱 𝗮 𝗹𝗼𝗻𝗴𝗲𝗿 𝘀𝘁𝗼𝗿𝘆 𝗼𝗻 𝗼𝘂𝗿 𝗯𝗹𝗼𝗴. 𝗟𝗶𝗻𝗸 𝗶𝗻 𝘁𝗵𝗲 𝗰𝗼𝗺𝗺𝗲𝗻𝘁𝘀.

Imagine a world where you don't have to plug in your devices to charge them. This isn't a dream. It's becoming real with wireless charging. This new way of charging is not just for our phones. It's changing bigger things, like how electric cars (EVs) get their power. 𝗪𝗶𝗿𝗲𝗹𝗲𝘀𝘀 𝗰𝗵𝗮𝗿𝗴𝗶𝗻𝗴 𝗶𝘀 𝘁𝗵𝗲 𝗳𝘂𝘁𝘂𝗿𝗲. It can help in many ways, from medical devices that save lives to making our daily drive in electric cars better. But, making this technology work well is not easy. There are challenges to solve, especially for important things like heart devices and car chargers. One big dream for the future is electric cars that don't need to be plugged in. People worry about how far these cars can go before needing a charge and how easy it is to find a place to charge them. Wireless charging is the future for EVs and there are some challenges: ⚙ 𝗦𝗮𝘃𝗶𝗻𝗴 𝗽𝗼𝘄𝗲𝗿 The biggest job for engineers is to stop energy from getting wasted. They're looking at how to make the coils—the parts that send and receive power—better. ⚙ 𝗢𝘃𝗲𝗿𝗵𝗲𝗮𝘁𝗶𝗻𝗴 If the coils or things around them get too hot, it's a problem. They have to find a balance between charging quickly and not letting things overheat. ⚙ 𝗖𝗵𝗮𝗿𝗴𝗶𝗻𝗴 𝘄𝗵𝗶𝗹𝗲 𝗱𝗿𝗶𝘃𝗶𝗻𝗴 Charging a car while it's parked is one thing, but charging while driving is a whole new game. Engineers have to think about all the different ways a car might move over the charging pad. ⚙ 𝗠𝗲𝘀𝘀 𝘄𝗶𝘁𝗵 𝗼𝘁𝗵𝗲𝗿 𝗲𝗹𝗲𝗰𝘁𝗿𝗼𝗻𝗶𝗰 Another big thing is making sure the wireless charging doesn't mess with other electronics nearby. The charging system can send out waves that might cause trouble, so it needs a good shield around it. So, companies are looking for ways to charge the battery using the maximum amount of energy without losing it and use as much power from the battery as they can to make the car go further. These are the challenges that CENOS Wireless Charging simulation software can help engineers with. 𝗛𝗲𝗿𝗲'𝘀 𝘄𝗵𝗲𝗿𝗲 𝗮 𝗯𝗶𝗴 𝗶𝗱𝗲𝗮 𝗰𝗼𝗺𝗲𝘀 𝗶𝗻. Using computer simulations. Instead of making a real model and seeing how it works, companies can use simulation software to test their ideas. This saves a lot of money and time. It helps them make better electric motors and other parts. Engineers use simulation software to model and predict where and how much energy will be lost in the wireless charging process. Simulations allow for the optimization of charging design by adjusting parameters like material properties, geometry, cooling system design, and control strategies to minimize energy losses and improve efficiency. For people who create things, engineers, and company managers, this is a big deal. Using computer simulations to design products, like wireless charging for cars, is smart. It means less waste of time and money. And it helps make electric cars better and more common. #CENOS #WirelessCharging #WirelessPowerTransfer #SimulationSoftware

How thyssenkrupp Presta AG saved 90 % on tooling and 30 % on energy. Marcus Hellriegel – an engineer at ThyssenKrupp Presta in Germany - tried to find a solution for the very short service life of the so-called hairpin coil used to harden the inner ball track. The goal was to improve the design of the coil in order to achieve a longer service life and lower production costs. ➜ The solution: Marcus decided to use simulation software to virtually test the design candidates and 3D print the final coil. He succeeded in designing a new induction coil for hardening the ball raceway in a ball nut (part of the steering system). He reduced tooling costs per part by 90% and energy consumption by 30%. This resulted in seven-figure savings for the company per year. The design was completed in a couple of months in a very cost-efficient way by using CENOS #InductionHeating #SimulationSoftware and 3D-printing technology. ➜ A traditional way: A traditional approach would be to order conventionally manufactured coils from a supplier. It would take ten design and prototyping iterations, which would take more than a half-year. It would cost around EUR 60,000 just to test different coil design versions. For such a sophisticated coil type, ordering 3D printed coil prototypes from a supplier could save time, but the process would still take 3-4 months and cost around EUR 10,000. ➜ Using simulation platform: Marcus decided to learn simulation software so that he could perform all design iterations using computer simulation and 3D-print the final design candidate for the real-world test. Marcus chose CENOS Simulation Software because it provides better learning speed thanks to its simple interface for induction tasks. ➜ The new coil design was completed in a few months. The use of simulation allowed him to test even the most crazy ideas at no additional cost. Everything was tested virtually on a PC before being fabricated using 3D printing. ➜ When the new coil was 3D printed, it was time for the lab tests. Test showed an energy saving of up to 30% for the newly designed coil compared to the old one. The reason for this dramatic increase in energy efficiency is the fact that the 3D printed coil has no solder joints. A conventionally manufactured coil of this type has up to 20 soldered joints. Each solder joint increases the overall resistance of the coil, which leads to higher energy consumption. A 3D-printed coil, on the other hand, has no solder joints and therefore a lower electrical resistance. ➜ The results: While the main goal of the project was to develop a new design for the coil that would not break as often, there were huge savings through lower production costs and higher energy efficiency of the coil. The efficiency of the coil was made possible by 3D printing technology, and the simulation software made the design process extremely efficient. All of this resulted in saving 90% on tooling and 30% on energy expences.

Here’s a short study of how CNPEM is using CENOS software for simulations. The Brazilian Center for Research in Energy and Materials (CNPEM) is continuously pushing the boundaries in materials engineering. Recently engineer Víctor Ferrinho Pereira was working on these two simulations: 🔬 𝗦𝗶𝗺𝘂𝗹𝗮𝘁𝗶𝗼𝗻 𝟭 𝗩𝗮𝗰𝘂𝘂𝗺 𝗶𝗻𝗱𝘂𝗰𝘁𝗶𝗼𝗻 𝗳𝘂𝗿𝗻𝗮𝗰𝗲 𝗳𝗼𝗿 𝗬𝗔𝗚 𝗰𝗲𝗿𝗮𝗺𝗶𝗰𝘀 ⤷ Matched the target temperature for sintering YAG ceramics, enhancing power input for precision. ⤷ Employed a graphite susceptor to gauge the heating range, fine-tuning for equipment compatibility. ⤷ Identified the need for detail refinement for enhanced test accuracy. 🔩 𝗦𝗶𝗺𝘂𝗹𝗮𝘁𝗶𝗼𝗻 𝟮 𝗛𝗲𝗮𝘁 𝘁𝗿𝗲𝗮𝘁𝗺𝗲𝗻𝘁 𝗳𝗼𝗿 𝗡𝗯𝗧𝗶 𝗮𝗹𝗹𝗼𝘆𝘀 ⤷ Investigated induction coupling and temperature gradients in compact NbTi alloys. ⤷ Calculated optimal frequency for various temperatures, optimizing the heat treatment process. ⤷ Evaluated magnetic coupling to ensure achievable temperatures with existing coils and power sources. 𝗞𝗲𝘆 𝘁𝗮𝗸𝗲𝗮𝘄𝗮𝘆𝘀: ⤷ CNPEM's custom-built vacuum induction furnace is a result of their innovation. Both simulations by CNPEM delivered valuable insights, setting a new standard for material processing. ⤷ CNPEM's work with CENOS is opening the way for smarter, more efficient engineering solutions. These simulations aren't just technical achievements but they're building ways towards more advanced technology manufacturing. For engineers and industry leaders, this is an example of how simulation software is used for enhanced precision and performance. #Engineering #Innovation #Science #CENOS #SimulationSoftware