Projects

Provide advanced HPC and Cloud Computin services, Communication breaktrouh between Slovenia and Italy, Stimulate awareness and demand for HPC and Cloud Computing services, Regional talent and skils development

Tourism 4.0

We don’t want to follow the changes, we want to co-create them. Since more than 25 years Arctur’s Research and Innovation department has been serving as crossroad of creativity, failing and learning from mistakes, to live the interdisciplinary spirit by merging the most different worlds of science, art and business into one innovative energy. With this energy we want to transform the perception of tourism and business around it.

 

 

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HPC based high-resolution modelling of magnets

Magneti produces its magnets through a process called compaction, which uses a hydraulic press to apply pressure to magnetic powders until they solidify. The hydraulic press is made up of several very expensive parts which regularly wear out and must be replaced. The pressing tool needed to be optimized, so it could be used for longer and with lower material costs, but doing this requires the ability to automatically detect yielding of the tool under a given pressure. This requires many iterations of computer simulation and post-processing, which exceeds in-house capabilities.

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HPC-Cloud-based simulation of light-aircraft aerodynamics

The challenge facing Pipistrel was to perform simulations of the flow over its aircraft which were sufficiently detailed to model real physical effects accurately. Such simulations require expensive computer resources which are normally beyond the means of an SME. However, the use of Cloud-based HPC offers the possibility of running such simulations on a pay-per-use basis which is financially viable for an SME. The challenge was therefore to demonstrate the feasibility of such an approach.

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HPC-Cloud-based microscopy

The challenge addressed in this experiment was to adapt VIRTUM to an HPC-Cloud-based infrastructure and to test if the enhanced VIRTUM could be applied beneficially in four test cases. The test cases comprised: the analysis of the images from remotely controlled fluorescence microscopy; the processing of the data from super-resolution microscopy; the management and visualization of spectroscopic data; and whole slide imaging and analysis in digital pathology and high-throughput screening. These test cases are numerically intensive each taking around a full day on a PC.

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HPC-based design of non-circular gears

Non-Circular Gears generate a prescribed motion with great precision, regardless of external factors. This is a highly desirable feature in advanced transmissions. Designing these gears is a complex process that requires a significant amount of expertise and expensive, computationally intensive iterations. In-house computing systems are not powerful enough to perform these calculations. A cloud-based engineering workflow would significantly shorten the time required to design and deliver an NCG. A key element of this is cost-effective access to the necessary computing power.

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HPC-Cloud-based design of copper-alloy moulds

In the past, IMR has tried to conduct simulations with commercial software, but never with HPC. However, it wanted to investigate how these could improve the time to market and productivity. There were no success stories reported for such simulations in this sector. Furthermore the costs of dedicated casting software and the necessary hardware and the training required for its use are excessive for a SME like IMR whose normal activities do not require such an investment. The challenge of this case study was therefore to demonstrate the benefits of HPC-based simulation to IMR.

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Cloud-based design of high-pressure vessels

The challenge was to develop a model for the simulation of composite materials and to implement it on an HPC system. The goal was to improve Mikrosam’s capability to satisfy the principal ISO 11439 standard and the ECE R 110 normative for Gas cylinders “High pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles” by developing a model for the design and simulation of composite laminates that could be implemented on an HPC system and obtain accurate results in an acceptable time.

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Cloud-based simulation of steel casting

In the field of continuous casting there is an increasing industrial demand for the development of new technologies for preventing slag transfer from the ladle to the tundish. Such an event may cause a breakout, that is the breaking of the solid skin of the solidifying cast products, which results in hazardous dispersion of liquid steel within the industrial plant. Ladle-slag monitoring is currently performed by operators on an empirical basis. Given the relevance of both safety and the economic implications of a breakout, there is a significant demand for an effective, automated system for ladle-slag monitoring. While passing through the ladle shroud, liquid slag induces characteristic vibrations which can be measured. In order to develop an effective detection system, it is necessary to correlate the vibrational signal with the fluid dynamics of the system. Such a correlation requires a complex, detailed simulation, which can only be carried out on an HPC system.

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Designing Turbine Blades for Hydropower Plants with CAD from the Cloud

Due to the complexity of the underlying free-form shape, the 3D design of a hydraulic turbine blade at Stellba is a long process. In the traditional CAD design approach it is necessary to use a lot of basic operations when modelling such a blade. These operations are mostly repetitive and similar for each design. The goal of this case study is to reduce the amount of time needed to design a popular blade type called Kaplan blade. In Stellba's case, such a design process happens typically bi-weekly. An additional goal is to save, manage and share data by using the Cloud and a Cloud-based PLM system.

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System simulation in the cloud

Complex systems consist of components from various domains, such as mechanics, fluidics and control engineering. The interplay of these components should be analysed already during the design phase – long before any prototypes are built – to ensure not only that they work individually as expected but especially that they work together as a system. Systems simulation allows engineers to find optimal solutions in order to ensure functionality and safety for complete multi-domain systems long before they can be tested in real life.

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Efficiency Optimization of a Water Turbine via CFD Simulation on the Cloud

 Checking and assessing the aerodynamic or hydrodynamic performance of newly designed geometric parts by using Computational Fluid Dynamics (CFD) is a common practice in large(r) industry. The end user Stellba of this case study is a Germany-based SME active in hydropower plant maintenance, repair and overhaul, engineering and manufacturing one-of-a-kind products for the green energy sector with the goal to optimize energy efficiency. Every turbine they engineer and manufacture is different and tailored to the needs of a given specific power plant, which results in an extremely high development effort making CFD simulations a major component of Stellba’s engineering tool set.

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Product Lifecycle and Engineering Data Management (PLM) on the Cloud

 Engineering analysis processes include activities such as product design and product analysis, including mesh generation, definition of boundary conditions, simulation, and post-processing. In any engineering company the highly iterative simulation process results in huge amounts of files and data with many different representations of the 3D product model. For an engineer it is a challenge to keep an overview of related data (configuration control) and extract the essential information for product optimization, demanding a user-friendly overview over configuration controlled data sets and an easy and fast visual inspection.

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Simulating Machining Processes in the Cloud (CAM in the Cloud)

 Simulating and optimizing the manufacturing process before the machines actually start making a new product is one of the key stages in manufacturing engineering. The aim is to minimize manufacturing time, to avoid wasting raw material (resources) and to safeguard the machines from being damaged. One has to compute many possible tool paths, assess them, select an optimum one and finally generate the Numerical Control (NC) code to actually run the machine. All these steps are very time-consuming and minimizing the time to find the best possible solution is crucial concerning the costs for the company.

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Comparing point clouds and CAD models in the cloud

Checking the quality and accuracy of a manufactured part against the ‘as-designed’ status of the corresponding ‘nominal’ CAD model is a common process in industry. For this purpose, the machined part is scanned with a 3D acquisition device, e.g. a laser scanner, which results in several point clouds typically consisting of millions of measured, discrete 3D points. To determine where deviations between the CAD model and the point cloud exist, the two data sets need to be aligned and matched in a process called registration and distances between the closest points of both models need to be calculated.

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Electronics Design Automation (EDA): Modelling of MEMS Sensors

 Integrated circuits (microchips), are designed, modeled and simulated in more than 20 discrete design steps. Near the final steps where the design evolves to a physical layout, it is important that the models of the chip used in simulations are realistic, accounting for the electromagnetic behavior of the actual materials and geometries, so as to avoid performance shortcomings due to unforeseen, so called “parasitic”, electrical and electromagnetic properties of the various                                                chip components.

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Optimizing energy Consumption And noise Emission Of The Cooling airflow for Compressors

 Noise emission and energy consumption are two decisive factors for worker safety as well as human-compliant workplaces and resource-efficient factories, respectively. This CloudFlow application experiment aims at minimizing energy consumption and noise emissions created by the fan and the cooling airflow for the reference case of compressors. This goal is achieved through introducing simulation, more specifically computational fluid dynamics (CFD), to the design and development process at BOGE and derive acoustics information from the flow simulation results to influence fan selection and noise-reducing enclosure design.

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More Efficient Drug Production Using Cloud-Based CFD Simulation of Bioreactors

 Aerated stirred reactors, the most common type of both small- and large-scale bioreactors, are used for performing microbial fermentation or mammalian cell culture unit operations for the production of biological therapeutics such as vaccines, hormones, proteins and antibodies. Usually, basic design criteria have been adapted in such a way as to meet the requirements of cells. In particular, the shear sensitivity requires consideration in impeller design, aspect ratio and aeration. Sufficient oxygen transfer and carbon dioxide removal are very important criteria in selecting a bioreactor system. Taking into account the process criteria, the scale-up process of bioreactors still presents a challenge and requires detailed knowledge about diverse fields such as the mixing processes, agitation, aeration, heat and mass transfer, etc.

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Optimised machining processes leveraging cyber-physical systems

 Machining industry in Europe is a large market that accounted for 16.6 billion € in turnover in 2013. Computer Aided Process Planning systems providing simulation for machining process optimisation have been increasingly adopted by European SMEs, still they do not leverage cyber-physical systems information to a large extend.

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Optimizing moulds and stamping processes for bipolar plates used in fuel cells

 Optimizing tools for stamping processes, finding the right process parameters and ramp-up forming production of sheet metals is a big topic in manufacturing industry, especially for those segments heavily handling sheet metals. This experiment is specifically looking into bipolar plates for fuel cells, an emerging market contributing to renewable greener energy supply, e.g. for Fuel Cell Electric Vehicles (FCEV). However, to gain market share, fuel cell production costs need to decrease.

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Cloud Based Optimisation Of Extrusion Die

 After the design and manufacturing of an extrusion die, a tool must be put into operation, which is a complex process in itself. During the commissioning, iterative tests with the tool are conducted to detect necessary changes of the flow channel design. This very time consuming and cost-intensive process has not changed for decades. The manufacturing and commissioning of a flat slit die can take more than three months. Depending on the die size, costs of more than € 400,000 can occur, e.g. for quality steel, hours of work, commissioning material, etc.

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Improving fire safety of buildings by simulation in the cloud

 Fire safety of buildings is of relevance for each European citizen. Who does not want to feel save when shopping in a mall or visiting a theatre? In case of an emergency event, people have to get out of the building in a fast, streamlined but not chaotic manner, sprinklers have to be placed in the planning and construction phase so to keep fire under control or even extinct it, fire fighters have to have sufficient access routes and water supply, etc. This all should be simulated and optimized before starting the building process.

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A 3D printed gearbox to take the space industry to the next

 The SME has been working since 1997 on offering the best solutions to their customers; this motivation led them to invent and patent an innovative gearbox called NUGEAR (NUtating GEARbox). This gearbox couples the mathematical concept of nutation with bevel gears, reducing the high speed ratios reached by the motors in planes, satellites, rockets and other space applications, while multiplying the power (torque) of the motor.
However, producing the internal components of such a gearbox became a challenge for the Italian SME. While traditional gears are produced through conventional technologies such as hobbing, shaping and milling, the innovative gearbox required new techniques.

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Improved cavity mould for highly efficient plastic injection moulding process

 The main goal of a mould is to produce plastic parts for several years with very high precision, a good aesthetic aspect and a fast throughput. To reach all these characteristics, traditional technologies are exploited, such as: milling, grinding, Electrical Discharge Machining (EDM), etc. This way of working originates strong limitations for the manufacture of shapes and cooling systems that cannot be overcome with conventional technologies. The alternative, already used by several players, is Additive Manufacturing (AM) - generally known as 3D printing - with metal powder; however, this process is still based on the company’s know-how rather than on a scientific approach.

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