PTC Creo Simulate gives design engineers early insight into product behavior to significantly improve product quality, decrease rework, and save money with fewer iterations in the design process.
Virnig Manufacturing needed to maintain a high level of quality in their skid steer loader attachments and was looking to increase operational efficiency and customer satisfaction. Darin Virnig and his team use PTC Creo Simulate to reduce costs, decrease weight, and eliminate reliance on physical prototypes – ultimately reducing design time by twenty-five percent.
Check out how Virnig Manufacturing uses PTC Creo Simulate to change the way they innovate in early design stages.
Business Initiatives
When it comes to skid steer attachments, it doesn’t get better than Virnig. Located in the heart of Central Minnesota, Virnig Manufacturing has been designing and producing skid steer loader attachments for over 27 years.
However massive they may seem now, Virnig wasn’t always the manufacturer we know today. When Dean and Lois Virnig got their start in 1989, the business operated out of a two-stall garage repairing farm and construction equipment. After five short years, the company discovered its niche – creating skid loader attachments.
Today, all steps of the manufacturing process are completed in-house. From engineering and cutting raw materials, to machining, welding, and painting the finished product, every attachment is designed and produced at Virnig’s facility.
Virnig now carries over 40,000 attachment parts and offers more than 80 unique skid loader attachments. Headquartered in Rice, MN, Virnig’s 67 employees have over 400 years of combined industry experience. The family owned and operated business has grown into a premium skid steer attachment manufacturer supplying North America and beyond.
Business Challenges
Virnig has been challenged more than ever to produce high quality, lightweight attachments in order to outperform the competition.
Darin Virnig, Manager of Production and Engineering explained, “We try as a company to get repeat business and to demonstrate to our customers that we have a solution for their problems. As our products continued to get more complex, they became heavy and overbuilt compared to our competitors. We knew we needed to lighten the machinery parts to reduce cost. As a company, we had to look to practices that gave us confidence in our processes before jumping into prototyping.”
Darin knew his team needed to maintain a high level of quality and also saw an opportunity to increase operational efficiency and customer satisfaction. To deliver on this goal, Virnig needed to provide employees across the organization with an in-depth view of how designs performed in real-world conditions.
This understanding would help Virnig reduce or eliminate product related issues in the field, lighten machinery parts, and reduce costly prototyping. By virtually testing real-world conditions, Virnig could maintain high-quality standards while optimizing and adjusting to their product lines.
Solutions – PTC Creo Simulate
Eager to reduce costs, decrease weight, and eliminate reliance on physical prototypes, Darin and his team turned to a PTC product called Creo Simulate. Because the engineers had used PTC Creo (formerly known as Pro/ENGINEER) as their primary CAD tool for several years, they felt it was only logical to turn to PTC’s Creo Simulate.
Creo Simulate is designed to provide users with accurate design simulation capabilities right within their CAD platform. By using the software’s simulation tools to create virtual prototypes, users are able to visualize and test a product’s structural performance before cutting any steel. This saves Virnig’s engineers time, energy, and money as they are designing new products.
Prior to implementing simulation software, Virnig tested product designs using trial and error or the build-and-break method. As products became more complex, the team realized the importance of accurate structural analysis. Virnig’s engineers found PTC’s integrated simulation tool easy to design, analyze and optimize the attachment lines.
Improving engineering design standards with early simulation
Virnig used Creo Simulate to innovate their most popular product, the Pick-up Broom. Traditionally the product consisted of a top with hydraulically driven bristles engineered to propel dirt into the bucket located on the bottom. With the Pick-up Broom, in particular, Virnig faced challenges as they attempted to lighten the machinery parts. To effectively analyze the deflection and strength of the product components, Virnig needed to test several design variations.
Using Creo Simulate, the team was able to virtually test multiple product designs in real-world conditions. At the touch of a finger, Virnig identified overbuilt areas on the Pick-up Broom. Their findings directly translated into lowered manufacturing costs, and lighter weight products that adhered to quality and manufacturing standards.
With the help of Creo Simulate, Virnig was able to reduce the Pick-up Broom cost by 5% without compromising quality. Creo Simulate also allowed Virnig to save 10% on labor and assembly time throughout the product development process by eliminating most of the expensive and time-consuming prototype manufacturing.
Darin explained, “We were able to resolve the problems we had with field issues as we got more comfortable with the software. We saw it replicate places that had problems showing us the high-stress areas and factors.”
The benefits didn’t just stop there. This PTC simulation software allowed Virnig to use analysis early and often to verify and optimize the attachment product’s design integrity, function, performance, and cost. On average the company saved 25% on design time.
Darin stated, “We were able to finish the product faster, especially the structural parts that we manufacture by cutting and molding. Simulate on average has provided us a time savings of at least 25% because we don’t have to do as much trial and error on testing and prototyping.” Today, Virnig saves an average of 5 hours on every product they manufacture.
Darin explains what he considers the real value of Creo Simulate, “We have saved material, labor, and product while being confident that our quality hasn’t been compromised. Creo Simulate is saving us money and putting us at a competitive advantage – there is no doubt about that.”
By integrating the latest product development technologies and using top-of-the-line materials, Virnig continues to be a leader in the skid steer attachment industry.
Learn more about PTC Creo Simulate, contact us, or download the case study.
EAC’s been in the engineering and design technology world for a long time. Over the years we’ve carefully cultivated our product portfolio to meet the ever-changing needs of people and companies that design, manufacture, and service products. Our partnerships with PTC and ANSYS allow us to offer a few different design simulation and analysis solutions to our customers.
Design simulation, Computer Aided Engineering (CAE), Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), and many other terms all fall into the “simulation and analysis” bucket. These tools help engineers and designers create virtual prototypes of their products. This helps groups rapidly prove, or disprove, design ideas in a digital space – reducing the time and money spent on physical prototypes, and increasing confidence in designs.
“If you’ve seen one, you’ve seen ‘em all” does not apply to simulation software. Different tools offer different benefits, accuracy, speed, and ease-of-use. Here’s a quick overview of some of the tools we offer. Contact our sales group to learn more about pricing, full capabilities, and packaging.
Option 1) PTC Creo Simulate
Simulate is a fantastic tool that’s fully integrated into PTC Creo Parametric CAD software. It offers fantastic meshing capabilities and accurate simulation results directly within a user’s familiar CAD software interface. All you need to do select the PTC Creo Simulate tab and you’re off and running. This is great for designers and engineers looking to test the stresses and loads under which a product will operate in ‘real world’ conditions. Based on your simulation and analysis results, you can either fix design flaws or forestall them. If you’re already using PTC Creo you should explore PTC Creo Simulate. Because, why would you ever manufacture a product without testing and analyzing it first? Creo Simulate comes in two flavors – Simulate and Advanced Simulate. They come with two different price points. One or the other might be the best option for your company. It really comes down to whether you need to simulate materials with linear or non-linear properties.
Option 2) ANSYS Discovery Live
ANSYS Discovery Live blows my mind. This tool was released in late 2017 and delivers functionality never seen before. Discovery Live uses ANSYS Discovery SpaceClaim to pull in IGES, STEP, and CAD models. Then the interface guides users through applying materials and some constraints – and Boom! It runs the simulation…in real-time…right in front of you. I’m talking about the ability to run wind-tunnel testing in real-time! Discovery Live is different from PTC Creo Simulate and most other simulation tools. It uses the Graphics Card (GPU) to run the simulation. This means it doesn’t occupy your core processor and RAM to while solving. You get better computer performance and instantaneous results for structural, thermal, fluid flow, wind tunnel, structural/fluid interaction, and more. Discovery Live is a great tool for engineers and designers that want to test a lot of design options quickly. The price is incredibly reasonable for a tool this powerful. You can see pricing and compare Discovery Live to AIM here.
Option 3) ANSYS Discovery AIM
Sometimes simulating real-world conditions requires more features and control than tools like PTC Creo Simulate, Solidworks Simulation, or Discovery Live might offer. ANSYS Discovery AIM is a great option when that’s the case. ANSYS Discovery AIM is a “multi-physics” simulation tool. What does that mean? Multi-Physics or Multiphysics refers to the ability to combine properties and solvers to simulate product usage. “Physics” in the simulation world refers to the kinds of simulation you are running – e.g. electromagnetic, thermal, structural, radio frequency, fluid flow, etc. AIM is a workflow driven multi-physics tool. It guides users through the steps necessary to complete a successful simulation. This is the perfect option when companies want a robust solution, but may not have experienced analysts on staff. Much like how PTC Creo Simulate maintains a familiar interface to make simulations easier; AIM uses guided workflows to make detailed upfront simulation accessible to engineers and designers.
Option 4) Dedicated ANSYS analysis software
When product simulation and analysis goes to the next level you need the ANSYS flagship products. These are sometimes known as the ANSYS Workbench products. Unlike PTC Creo Simulate or the Discovery software, each of these tools focus on one area of simulation…and deliver results you can take to the bank (or the regulatory agency). They are more complicated and come with a higher price point, but the results are unmatched. ANSYS’ comprehensive software suite spans the entire range of physics, providing access to virtually any field of engineering simulation that a design process requires. Organizations around the world trust ANSYS to deliver the best value for their engineering simulation software investment. If you need to test a specific physic – fluids, structures, electronics, semiconductors, or embedded software – this is the option for you. Contact us to learn more about a specific solution’s pricing and functionality. Also, if you’re a start-up make sure you ask us about special offers available through the start-up/entrepreneur program.
So there you have it. My layman’s take on a variety of simulation options. I hope you found this helpful. Please reach out to us if you have any questions or would like to see a demonstration of any of these tools.
Engineering simulation is the key that will unlock your future innovation. It is the quickest way to validate and optimize designs. These software tools are no longer obscure systems that require specialized skill sets.
Some engineers and designers still shy away from simulation software, but that is quickly changing for two reasons.
1) There have been many improvements to CAD embedded tools like Solidworks Simulation and PTC Creo Simulate.
2) Companies like ANSYS have created easy-to-use upfront simulation tools like AIM and Discovery Live.
This article was written for the people hanging on to outdated misconceptions about engineering simulation. It’s time that everyone realized a few things.
The tools have gotten easier to use and processing power has become more accessible. This has begun to make it easier for engineers to run simulations. It doesn’t take a doctorate or a dedicated super-computer-workstation.
Due to the advancements in technology, eventually every engineer in every industry is going to be able to use engineering simulation. In fact, it could get to the point very soon if you are not using engineering simulation as part of your workflow; you could get left behind. It’s really that much of a competitive advantage when it comes to solving problems quickly.
Engineering simulation no longer needs to be looked at as something scary or complex. It has transformed into something that can be fast, easy to use, and affordable.
Take a look at the ANSYS Discovery product lines for example.
These new engineering simulation tools offer all engineers and designers a fast, simple way to create better products.
The discovery product family is a suite of tools that are designed to put simulation in the hands of every product development engineer. The Discovery family includes; Space Claim, Discovery Live, and Discovery AIM.
Space Claim is a direct modeling tool that provides the ability to quickly edit designs and repair geometry within CAD files. It’s bundled with Discovery Live and AIM to provide an easy way to simply geometry and perform quick design experiments.
Discovery Live is truly an instantaneous simulation tool that is designed for rapid design iterations. You won’t believe until you see it! Real-time concept exploration. No waiting, just results. Make a chance to your design and see simulation results update before your eyes.
Check out our demo on Discovery Live. There’s no “demo magic” here. You’ll see our engineers adjust geometry on-the-fly and quickly run simulations on several changes in a matter of minutes (We often blow people’s minds with this.)
Discovery AIM Complete simulation, driven by an intuitive guided workflow. In-depth concept and design analysis without any coding or guess work. This a high-fidelity tool that provides an entry point into the full power of the ANSYS platform. This multi-physics tool provides a high level of control and the ability to create your own meshes. With AIM’s combined physics workflows your team could easily evaluate how fluids and structures interact. You could look at electric conduction, stress analysis, and even add in additional contacts for assemblies you may want to observe.
The ANSYS Discovery product line really makes simulation accessible. Even an industrial designer that may not have a lot of engineering specific knowledge could use these tools to quickly optimize designs and validate design A versus B (or C, D, E, F, etc. if they feel so inclined).
These basic easy-to-use, affordable tools provide engineers with an entry into using simulation as a part of their workflow.
Don’t believe me yet? Watch this short video to see it for yourself.
Engineers leverage simulation tools to develop innovative and high-performing products in a virtual design space using computer-aided design (CAD) technology.
Imagine what you could do as a designer or engineer if you could take your simulation a step further and study a digital working copy of a product under actual working conditions. It could help you rapidly optimize the design, life, and maintenance of a product.
What is a digital twin?
Companies are collecting real-time operating data from product-mounted sensors. They use the data to create an exact replica of a working product, process, or service. This exact replica, called a digital twin, is a simulated model in a virtual space that performs under real-world conditions to help companies find performance issues, schedule predictive maintenance, reduce downtime, and minimize warranty expenses.
Digital twins drive innovation and performance. They give product development technicians predictive analytics and they give companies the ability to improve customer experience. Digital twins allow for better understanding of customer needs, enhanced existing products, streamlined operations, and improved service-after-sales; all while creating headway for new products and services.
The Internet of Things (IoT) has made it possible for digital twins to exist. IoT platforms bridge the gap between the digital and physical world. How does it work? Smart connected products and smart connected operations are connected to a cloud-based system that receives and processes all the data monitored by sensors.
Using the data captured by sensors, the simulation model, or digital twin, is continuously updated and gives designers and engineers the insight they need to improve future product development efforts. (An example would be visibility into real-world bearing operating temperatures and the downstream effects on tolerances right within a CAD model.)
By studying the digital twin under actual working conditions, companies can see the product in action. Engineers can make more informed choices during the design process and use digital twins to make their simulations more accurate.
Bringing digital twins to life with the Internet of Things
For businesses already using engineering simulation to design products, connecting the simulation to the physical product in the field is necessary to deploy the digital twin solution.
For businesses that are new to simulation, the engineering team would first need to build the 3D product model, optimize its performance, and replicate the real world in which the product system would operate. Re-using this data in similar product simulation scenarios for future product development saves time and money.
In process of applying a digital twin to your design is explained in PTC’s blog as follows:
- Build a product using 3D CAD
- Build a physical prototype of the product
- Add sensors to the prototype
- Build the sensors in the 3D CAD model
- Collect the data (E.g., via ThingWorx)
- Associate the sensors’ data streams to the sensors in your 3D CAD model
- Voila! Now your model can talk.
Not only do digital twins improve future innovation and product development efforts for designers and engineers – they build a stronger relationship between engineering and operations teams.
The data collected from sensors is analyzed by the operations team to optimize performance, service, and maintenance over the lifetime of a product. The digital twin can help organizations avoid costly downtime, repairs, replacements, or stay ahead of other performance issues.
Designing a product without integrating simulation into your workflow is like giving a concert but never rehearsing. Why would you do that?
Top Performing organizations meet cost targets, remain on spending plans, and beat their due dates. One way they accomplish these objectives is by utilizing simulation tools to empower their organizations. Here’s 10 ways simulation will put you ahead.
1. Simulation software = better design decisions
Simulation tools enable engineers to have better insights throughout the design process.
For example, with the use of simulation engineers can conduct sensitivity studies, analyze trade-offs, remove excess materials and even evaluate motion envelopes.
By using simulation during concept design, engineers are able to explore and consider more options.
These options permit engineers to see the influences and effects of different design guidelines and limitations.
Testing many conditions, simulation software allows engineers to narrow down choices for the best concept.
This is how engineers are able to make better, highly informed design decisions.
2. Simulation helps avoid over engineering
By simulating your designs in a variety of environments, you can easily determine what is necessary within your design and what is not.
This helps engineers eliminate excess materials, and ultimately create better products.
3. With Simulation software, you find problems earlier (while they’re still cheap to fix)
Engineering simulation software helps organizations discover hidden interactions that can cause big problems.
How? It’s simple.
If the materials you’re using to build and design a product can’t perform under stress, you can find out early in the design process.
This helps your design team get it right the first time.
4. Simulation tools improve product quality
Simulation tools enable engineers to analyze and validate the performance of 3D virtual prototypes before the part itself is created.
With the ability to validate and test designs early in the design process, engineers are able to create and evaluate more concepts and ideas within allotted time frames.
This means more ideas, more designs, better quality and ultimately a better product.
5. Simulation software improves product reliability
With simulation software, results are accurate and reliable and can be easily calculated with very little input from engineers.
By using simulation-driven design to optimize product performance, quality and durability- you can be sure that your is more than reliable.
6. Simulation tools cut product development time
Organizations are able to reduce product development time with simulation tools because less time is needed for physical testing, fixing late problems, and rework.
When design engineers know how to run simulations, they understand the requirements for the analysis model. By taking these requirements into consideration as they design, model, and build products, the analysis becomes easier and takes less time to prepare.
7. Innovation is increased with simulation
With the help of simulation tools, engineers can also be more innovative.
Time-savings allotted from simulation and virtual prototypes enable design engineers to evaluate more design iterations.
8. Simulation helps you get to market faster
Simulation tools help streamline product development activities by enabling concurrent design and analysis.
How? It’s simple.
With simulation, the analysis process is faster. For instance, you can forget any reliance on 3rd parties for analysis because you are able to now do it in-house.
By identifying and eliminating errors early in the design process you will resolve errors early, eliminating late-stage changes and tedious rework. This will also greatly speed up your processes.
Simulation tools empower design engineers to make better design decisions.
Better design decisions ultimately produce more competitive products that cost less and get to market faster.
9. In the long run, simulation tools save costs
Simulation helps engineers make better design decisions at much less cost because they can subject virtual models to real-world forces.
By using fewer prototypes and focusing simulation on areas of high sensitivity and fatigue, an organization can save time and money.
For example, engineers can reduce product costs by optimizing designs to meet multiple objectives, such as maintaining a product’s strength while reducing its weight.
This is exactly how the use of analysis and early optimization to properly size geometry can reduce material costs.
Aside from material costs, how do product failures, warranty, and repair cost impact company profits? Tremendously.
Using simulation tools organizations can avoid costly recalls and reduce after-market service, warranty, and repair costs.
It’s easy to see how simulation tools will save you money simply by eliminating the need for project re-work, prototyping, and over-engineering
10. More competitive products
Simulation software provides engineers with additional insight, which leads to better design decisions and product optimization.
By using simulation, design engineers are able to develop higher quality products that are easily differentiated in the market.
If you are an OEM supplier to a major fortune 500 manufacturing company it probably took you a while to become their supplier. You had to prove to them that you could deliver a quality product on time, at a fair price.
Now that you have won their business it is probably equally as important to maintain that business as it was to win it in the first place. Your company probably has a nice cash flow and your employees are enjoying a nice secure job because of this win. However, the most important thing that will keep your customer coming back to you is quality.
Most major manufacturing companies realized years ago that the sooner that you can discover flaws or issues in the design phase, the easier and more cost-effective it is to fix the problem.
They found out that after completing the design process in CAD, they could move on to using simulation software, like ANSYS, to simulate prototypes. By simulating their prototypes they are able to run multiple simulations of their prototypes at one time and pick out the prototype that met their requirements to move forward and begin manufacturing.
Over the years these huge corporations have saved millions of dollars in time-savings and reduced the amount of times projects have to be constructed.
In the interest of time-savings and cost-savings, I suggest you consider looking into a simulation tool yourself. As your customer will appreciate knowing that their supplier realizes how important a quality product is. Who would you rather buy from? A company that has thoroughly tested their product or one that hadn’t?
If you’re interested in learning more about the benefits of simulating your products early and often, learn more about simulation here.
