Modelling goes far beyond crash testing

Sophisticated modelling and simulation systems are increasingly being used to improve performance across a wider range of mainstream manufacturing. Leading CAE company NuTech Solutions, for example, reports that its technologies are now working across the automotive, CPG (consumer packaged goods) and oil and gas sectors – and providing paybacks that outstrip costs 10 or 20 times. Thomas Baech, managing director of the German operation, says the firm is being asked to help with everything from streamlining production, supply chain and logistics, to demand planning and optimisation – as well as more conventional crash testing simulation. In the process sector, for example, it’s working with Chevron to optimise oil field operations, and Air Liquide to concurrently streamline production and distribution. And in automotive, it’s not only being used to cut cost and time of crash testing, but to reduce material content of vehicles using a range of modelling algorithms. Baech says the increasingly diverse use of computer modelling is partly due to spreading acceptance of its role, but partly also new techniques. His company is using what he terms ‘expert heuristics’ on top of self adaptive, learning optimisers based on a range of algorithms to provide robust simulations for different applications much faster than has been possible. He believes that as applications are proven, so more systems will be developed, in particular for aerospace and general mechanical and chemical engineering. The tipping point will be the cost/benefits equation.