8/13/2019 digital rp

1/242

COVER STORY

In this article, software company Autodesk describes the benefits of digital over physical prototyping and details

the benefits and three industry application of its Autodesk Inventor software.

Digital prototyping brings together designdata from all phases of the product devel-opment process to create a single digital model.

This model simulates the complete product and

gives engineers the ability to better visualise,

optimise and manage their design before pro-

ducing a physical prototype.

Digital prototyping gives industrial machin-

ery manufacturers the ability to virtually explore

a complete product before it is built. By using adigital prototype, manufacturers can visualise

and simulate real-world performance of the de-

sign with less reliance on costly physical proto-

types, reducing design and production costs.

Digital prototyping moves companies be-

yond 3D modelling. It enables manufacturing

workgroups to create a single digita l model that

can be used in every stage of production, bridg-

ing the gaps that usually exist between concep-

tual design, engineering, mechanical design,

electrical controls design, manufacturing, and

sales & marketing teams.

Industry challengesIndustrial machinery manufacturers operate in a complex and

demanding environment and face unprecedented challenges

today. They are simultaneously confronted with increasing glo-

bal competition for new project opportunities and customer

requirements becoming more multifaceted and chal lenging. To

meet these requirements, industrial machinery manufacturers

often engage in engineer-to-order, configure-to-order or assem-

ble-to-order processes and operations.

Industrial machinery manufacturers struggle with increas-

ingly complex product platforms, from which product variants

and configurations are driven and the potential costs and quality-

control issues associated with them. At the same time, the need

to incorporate innovative design is essential, while managingquality and costs closely is critical to the bottom line. Successful

manufacturers must effectively collaborate with both local and

global product development teams and supply chain partners in

order to develop and deliver more complex products in less time.

Strategies for successSucceeding in this market requires an intense focus on meet-

ing customer needs. Establishing a product development

methodology that effectively utilises a product platform to

create a multitude of configurations to adapt to the customers

needs is paramount.

Whether a new product platform or a derivative of an exist-

ing one, development teams need the ability to explore a designearly in the process and communicate that design with stake-

holders and customers.

The ability to design, visualise and simulate a product from

the earliest concept phase is a prerequisite to avoiding design

errors that may not appear until the physical prototyping stage.

Just as important is the ability for multiple disciplines to com-

municate and collaborate throughout the development process,

without recreating data to meet their needs.

Implementing the right solutionThe Autodesk Inventor product line provides a comprehensive

and flexible set of software for 3D mechanical design, simula-

tion, tooling creation and design communication that helps man-

ufacturers cost-effectively take advantage of the digital prototyp-

ing workflow to design and build better products in less time.

The Inventor model is an accurate 3D digital prototype that

enables designers to validate the form, fit and function of a de-

sign, minimising the need to test the design with physical proto-

types. By enabling designers to use a digital prototype to design,

visual ise and simulate products digitally, Inventor software helps

designers communicate more effectively, reduce errors and de-

liver more innovative product designs faster.

Award winning designs with AutodeskInventorideas*is a Melbourne-based engineering services firm which

used Autodesk Inventor to provide detailed design and engineer-

ing for a massive $20m, state-of-the-art construction recycling

facility. The size of four football fields, the plant was designed to

efficiently recycle one million tonnes of discarded construction

and demolition materials per year.

In order to offer a more interactive and consultative experi-

ence that enables everyone to explore what-ifs throughout the

design process, we needed to move beyond 3D to digital proto-

typing, said Michael Percy, managing director at *ideas.The company used Autodesk Inventor software to digitally

prototype the recycling plant. This provided the flexibility to

integrate all structural and mechanical components, effectively

communicate the design and help enable rapid modification dur-

ing the many design iterations.

Digital prototyping for industrialmachinery manufacturers

Australian Bulk Handling Review: September/October 2010

Images courtesy

of ideas* and

Pacer Engineers.

8/13/2019 digital rp

2/243Australian Bulk Handling Review: September/October 2010

COVER STORY

Also, Autodesk Inventor software provided a platform that

enabled ideas* to more seamlessly integrate design aspects that

leveraged its investment and commitment to AutoCAD software.

By expanding on its AutoCAD skills, while adopting the new

strategy, the company could reduce the cost of transition and

decrease disruption to its production schedules.The collaborative approach helped increase overall produc-

tivity by 20 per cent and helped enable the entire project to be

installed within 10 months of the fi rst designs.

Taking the leap from 2D to 3DBased in Western Australia, Pacer Engineers (Pacer) delivers bulk

material handling and mineral processing infrastructure projects

to a range of high-profile mining and resources clients. Before

bringing on board an in-house design team, Pacer worked prima-

rily with external drafting contractors utilising two-dimensional

design software.

2D modelling required components such as structure, di-

mension and design to be outlined on separate individual draw-

ings and relied on the expertise of draftsmen to notice clashesand errors, explained Cameron Jacotine, lead designer, Pacer En-

gineers. The 2D process meant fixing problems, such as incor-

rectly placed holes and clashing pipes, was very time-consuming

and customers werent able to see the whole product while it

was being developed.

Pacer implemented a digital prototyping solution comprising

of Autodesk Inventor Suite, AutoCAD and AutoCAD LT to remain

competitive, streamline the overall design process and improve

collaboration with stakeholders.

The major benefit of us being able to digitally prototype is

the interaction with our customers. We now produce a prelimi-

nary digital prototype for first review to communicate our pro-

posal. Once this is accepted by the client, we then start on thedetailed requirements of the project and present them with a 90

per cent complete digital prototype for a hazard and operability

study, said Jon Wright, engineering manager at Pacer Engineers.

Before we implemented digital prototyping this process took

us significantly longer. Our solution facilitates a greater level of

collaboration between our client and our design expertise. As a

result our clients feel more involved in the design process and itgives them greater clarity on the outcome of their projects.

Winning business with digital prototypingAs a global leader in motion and control technology, Parker Han-

nifin (Parker) currently reaches annual sales exceeding $12bn.

To increase revenues and margins, Parker transitioned from

simply supplying parts to offering customers complete motion

and control systems. Digital prototyping has helped Parker shift

its focus by supporting a streamlined, highly efficient product

development process.

The company combines surface models from Autodesk Alias

software, electrical schematics created in AutoCAD Electrical

and mechanical design data from Inventor to create a single dig-ital model. Parker shares digital models, which are accurate dig-

ital prototypes, with reviewers and customers using the visuali-

sation tools in Autodesk Showcase and the collaboration tools

in Autodesk Streamline.

Using Autodesk solutions, over a hundred design depart-

ments around the world are able to work within a single digital

model environment, speeding design times and reducing er-

rors. By relying more on digital prototypes to validate designs,

Parker has cut back on the expensive physical prototypes it

must produce.

We cant underscore enough the value of mak ing even one

fewer physical prototype, said David Bosworth, manager of En-

terprise Engineering Systems at Parker Hannifin. With digital

prototyping, the time-to-market and cost savings are very real.Thats why we require digital prototypes for al l our parts.

Creating accurate, realistic and compelling renderings of

digital prototypes is also yielding dividends for Parker. Weve

successfully eliminated photography in the catalogues for our in-

strumentation division, said Bosworth. And were doing it with-

out tying up our precious design and engineering resources.

About AutodeskAutodesk, Inc., is a leader in 3D design, engineer ing and enter-

tainment software. Customers across the manufacturing, archi-

tecture, building, construction and media and entertainment

industries including the last 15 Academy Award winners for

Best Visual Effects use Autodesk software to design, visual-ise and simulate their ideas. Since its introduction of AutoCAD

software in 1982, Autodesk continues to develop the broadest

portfolio of state-of-the-art software for global markets.

Contact: www.autodesk.com.au