Cybernet Systems is a company

that supports manufacturing with

Computer Aided Engineering

What is CAE?What is CAE?CAE Technology and Market NeedsCAE Technology and Market Needs

1Energy for your innovation

1.1. What on earth is CAE?What on earth is CAE?Dad, you work at a car company don’t you? When I visited you at workbefore, you were sitting in front of a computer… what were you doing?

I was running various simulations with the computer. Forexample, what would happen if two cars crashed intoone another. Actually crashing real cars into one anothercosts money and is difficult work, but with a computerwe can do it over and over again!

Eh! You crash cars together inside the computer? I didn’t know computerscould do things like that!

That’s right. Because we can do experiments on the computer beforeactually making things it also reduces the need for prototypes andwaste/garbage produced, so it’s kind to the environment, too! It also helpsreduce the amount of time from starting the design to when the car isactually completed. We call these computer-based experiments “CAE.”

CAE? What’s that?

CAE stands for “Computer Aided Engineering.” I suppose it’s a kind ofcomputer-based engineering support system. It’s used in the design anddevelopment of all kinds of things apart from cars, too, from familiarappliances and devices like refrigerators and smartphones to things likerockets and robots!

Dad, that’s amazing! Maybe I’ll write a report about CAE for my free-studyproject this year. Dad, please teach me all about it!

Ok, you got it! Now, first of all, let’s take a look at the history of CAE, shallwe? Let’s take a look at how and in what kind of situations it’s used, too!

[Contents]1. What on earth is CAE?2. The history of CAE: The birth of computer simulation3. The process up to completion of a car: In what ways is CAE used?4. Review: Manufacturing & CAE5. Benefits of introducing CAE6. Industries in which CAE is used7. CAE has many specialist fields!8. More accurate simulations that consider various specialist fields together, at the same time:

Multi-domain solutions9. Summary: Things that can be done with CAE & things that we can do because we are Cybernet

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2. The history of CAE:2. The history of CAE:The birth of computer simulationThe birth of computer simulation

ENIAC Computer

1940s

Bell Labs, USA, develops Ballistic Computerfor calculations of ballistic trajectoriesSpurred on by the breakout of World War II in 1939, the USAsucceeded in developing the world’s first computer capable of near-instantaneous calculations of the trajectory of shells and other ballisticprojectiles. The computer was named ENIAC.

Development of the Finite Element Method(FEM)*During the 1950s, a transition was underway for passenger aircraft,shifting from propeller aircraft (which had been the mainstream untilthat time) to jet aircraft. There was therefore a demand for high-precision oscillation analysis for jet planes which fly at high speeds.

1950s

The birth of general-purpose structuralanalysis (3D CAE) software using the FiniteElement Method (FEM)During the 1960s, structural analysis software utilizing the FiniteElement Method (FEM) came to be developed. The ANSYS®software sold by Cybernet was also created during this time, thanks tothe research efforts of Dr. John A. Swanson, who then worked atWestinghouse Electric Corporation.

1960sANSYS Developer,

Dr. John A. Swanson

1970s ~ 2000s

Period of growth and expansion for 3D CAE(application in a widening range of fields)With improvements in computer performance, the use of CAE becamemore typical and widespread. It became possible to model andanalyze fluids such as air and water, and other things such as heat,light, electromagnetic fields and sound. It also became possible tomodel and analyze collisions and falls of objects.

2000s ~present day

Expansion of the use of CAE during the initialstages of design and development (theappearance of 1D CAE)The number of scenes and situations in which CAE is used isbecoming increasingly wider, and is now not only limited to the use of3D CAE based on 3D design data, but also 1D CAE, whichmathematically simulates the feasibility of performance andfunctionality during the initial design and development stages.

*Finite Element Method (FEM) is a numerical technique that subdivides a large problem (i.e. the object being modelled) into smaller,simpler parts that are called finite elements. The characteristics of these finite elements are expressed using simple formulae andequations, which are then combined to analyze the entire problem. This technique forms the basis for present-day CAE.

The history of CAE is surprisingly long, and the range of fields in which it isused is becoming increasingly wider, too. Originally, CAE began with theidea of first thinking of the design and then simulating whether or not thatshape would work properly. Now, we’ve come to a stage where CAE isbeing used even before the design is actually drawn.

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3. The process up to completion of3. The process up to completion ofa car: In what ways is CAE used?a car: In what ways is CAE used?

Let’s ask Mr. Tanaka from ABC Automotive about the process leading up tothe completion of a car, and in what kind of ways CAE is used during thatprocess!

Hello! OK, first of all, let me explain about what kind of jobs are involved inmaking a car. There are actually a lot of different jobs involved between thebeginning of the process—when we are deciding what kind of car we are goingto make—and when the cars are actually lined up on sale at the dealership.

1. Thinking of a New Car [planning ~ concept finalization]Planning for a new car begins from between three and four years earlier. We think about changesin trends and lifestyles, etc., and decide on a general direction for what kind of car we are going tomake.

2. Determining SpecificationsFor example, let’s consider specifications for a car that is geared towards mothers with babies orsmall children, which places more emphasis on safety and fuel economy than on speed.

- If we place importance on engine power, the fuel economy will be bad. Forhousewives, fuel economy might be more important than engine power,mightn’t it? What kind of fuel economy and power will we give our engine?

- We want to reduce oscillations (shaking and vibrations) so as not to wakethe baby, too, don’t we? What level of performance should the suspensionhave? We also have to consider cost properly, too!

How do you run simulations when you don’t evenknow the shape of the car yet?

Because we don’t know the shape, we think about specifications using mathematical modelsof the way things move.It’s a bit difficult. For example, let’s think about the specifications for our engine. For this, wedecided that we should place more importance on fuel economy than power, didn’t we?We do various simulations by expressing the way the engine will work in terms ofmathematical formulae; for example, how much power we get and how much gasoline isconsumed when we inject this amount of gasoline into the engine with this much force.

These simulations used for designing specifications are called “System LevelSimulations” or “1D CAE.” It’s a bit of a specialist term, but in the ControlSimulation field we sometimes also call it MBD (Model Based Development).

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3. Detailed Design

4. Prototyping & Testing

5. Assembly & Production ⇒ Sale

Wah! There’s strings coming off the car!

Hahaha. Those aren’t strings. We’re simulatingthe flow of the air around the car when it’smoving. The wind whirls around in a whirlwindbehind the car after it passes.

This is a simulation of a touch panel fora car navigation system. We’re testingto see how the force of a personpressing the screen will affect the panel.

Repeating these kinds of virtual experiments (i.e. simulations) allows us to rectify (fix) theproblems that we identify before the prototyping stage. In this way, we can shorten the timebetween discovering the problem and finding a solution, and reduce the number of prototypeswe need to actually build.

After conducting many simulations and fixing various faultsand problems, we build a prototype (a test version of thecar) and test it under actual driving conditions. Finally, weactually drive the prototype around a test course.

What happens if you find a problem at this stage?

That’s a good question! If that happens, we have to goback to the drawing board to check what was wrong withthe design and then make another prototype. This takesmore time, effort and money. Simulations also play animportant part in avoiding that.

Once we make a prototype and test it, we can collect various kinds of data. We use thedata to check if our simulations were correct, or if there is a disparity (difference)between the simulations and the actual test results. If there is, we think about why, andcome up with ways of ensuring that we can run more accurate simulations for the nextproduct that we design.

We prepare for production by thinkingabout the order in which we will assemblethe various parts, and about the slightdifferences in sizes and positions of partsthat will inevitably occur.We even have software that calculates andtells us just how wide a margin of error isacceptable!

Data provided by: Advantage CFD

Once the specifications are decided, we use software called CAD (Computer Aided Design) todecide the shape of the vehicle body and various parts. We then run simulations from variousviewpoints to check whether the car will work properly in that shape, and to check the strength ofparts and the impact of heat, etc.

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4. Review: Manufacturing & CAE4. Review: Manufacturing & CAE

What is CAE?CAE is a technology that enables us to reduce the number of prototypes and testsrequired to predict and resolve various problems (from various different directions) inmanufacturing a product by running simulated (i.e. virtual) experiments and tests on acomputer and analyzing the results.

By using CAE we can…1. Check how a product will move/work before we build a prototype2. Eliminate problems at an early stage in the design process and improve quality

Enables new products to be launchedonto the market at an early-stage

Reduces prototyping and testing costs

Lets us handle simulations for productsfor which it is difficult to build a prototype

Performs where high-precision productdesign is demanded

Is essential where particular attention isbeing focused on safety

CAE is a “trump card”that has revolutionized processeslike R&D, design, manufacture and maintenance; and

caters to the diversifying and increasingly sophisticatedneeds of customers.

CAE is alsoenvironmentally friendly!

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CAE:

5. Benefits of introducing CAE5. Benefits of introducing CAE

Mazda succeeds in development of high economical enginemaking full use of CAE for SKYACTIV Technologydevelopment

Source: Nikkan Kogyo Shimbun, p26, 2014/10/17

Mitsubishi Heavy Industries shortens time taken for analysisin development of gas turbines, etc., (which took around 30days 5 years ago) to half a day

Source: Nikkan Kogyo Shimbun, p6, 2015/4/7

Asics shortens development times by utilizing CAE indevelopment of soles for running shoes

Source: Nikkan Kogyo Shimbun, p5, 2015/4/27

Konica Minolta shortens time taken for inspection / validationin the development of commercial printers (that originally took3 months) down to 1~2 days

Source: Nikkan Kogyo Shimbun, p5, 2015/6/29

Nissan and Osaka Prefecture University shorten time takenbetween analysis of welding conditions for steel sheets ofvehicle body and actual production line application to around1/6 of the original time taken

Source: Nikkan Kogyo Shimbun, p8, 2016/1/22

JAXA and partners reduce noise on airplanes by analyzingairflow and the shape of main wing and fuselage /undercarriage parts of aircraft

Source: Nikkan Kogyo Shimbun, p5, 2016/4/12

So CAE isn’t only used in making things like robots and cars… It’s even used inmaking shoes!

It can even be used to do things like analyzing the movement of air when a soccerball is flying through the air, and simulating how the ball will move when it is kicked.It’s also used in the development of things like the printers you use at school, inthinking of the shape of plastic PET bottles to make them easy to crush. Actually,CAE technology is used in making lots of familiar things around us.

Image provided by: Dyson Ltd.7

Pressure

distribution

Flow

lines

6. Industries in which CAE is used6. Industries in which CAE is usedLet’s take a more detailed look at what kind of industries CAE is used in. Iwonder what industries you’d like to know more about, Taro… If there are anythat interest you, why don’t you check them out on the Internet!http://www.cybernet.co.jp/english/products/cae/field/

It makes me really happy to hear that.OK, let’s take a look at a few more real-life examples.

CAE really is used in all kinds of different places, isn’t it?!I want to know even more about it now!

“Flute-playing Robot”Photo provided by: Takanishi Laboratory, Waseda University

■ RobotsThis is an example from Waseda University. Thisrobot is controlled using a simulation of themovements made by a human tongue whenplaying a flute, created using a piece of 1D CAEsoftware called Maple.This research laboratory also develops otherrobots, including a “jaw robot” that doctors canuse for practicing surgery on a human jaw.

This is a simulation of how drops of eyemedicine fall from the bottle when it issqueezed… because there would be problemsif it all came running out at once!

This example is for the designof a luxury cruise ship. Basedon the shape of the ship (CADdesign), CAE is used to checkhow the ship will deform(change shape) when the forceof the ocean waves are appliedto it, and what problems seemlikely to occur.

Example: German cruise ship builder Jos. L. Meyer GmbH & Co.

This example is a simulation for the built-inantenna inside a smartphone. It’s good ifwe can check that there is no negativeeffect on human users using a simulation,isn’t it!

■ Pharmaceuticals

■ Smartphones■ Luxury Cruise Ships

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Automotive

Industrial machinery

Shipping & maritime

Sports

Aerospace

Chemical & materials

Construction & civilengineering

CAE education &promotion

Electronics

Energy & environment

Healthcare & foods

Production technology

7. CAE7. CAE has many specialist fields!has many specialist fields!

It gets a bit difficult from here. In many cases, the CAE software used differsbetween different specialist fields. Let’s take a look at what kind of specialistareas there are.

1D CAE (MBD)1D CAE software allows us to perform mathematical calculations tocheck whether or not products will perform as expected, during the firststages of the design, before the shape of the product has even beendecided. I wonder if you remember… If we say it in terms of the softwareused at the company where I work, it corresponds to software such asMaple and the MapleSim software that we use together with it.Maple is a piece of STEM (Science, Technology, Engineering, andMathematics) software. MapleSim is used for the MBD (Model BasedDesign) processes used in the automotive industry, so it is alsosometimes called MBD software.

MCAEMCAE is short for Mechanical CAE. Mechanical means “relating to machines orphysical (dynamic) forces.”This group of software applications is used mainly after the shape of the producthas been decided to a certain degree, and the CAD design has been completed.The eye-dropper, luxury cruise ship and internal smartphone antenna examplesshown on the previous page are example applications of ANSYS Inc. software.

Optical DesignThese pieces of software are used to simulate the way in which lightprogresses (i.e. moves through different objects and media), and are used todesign things such as lenses (for products such as cameras and machines formanufacturing semiconductors), LED lights and other lighting fixtures, andbacklights such as those used in LCD displays (lights shone behind displays tomake the screen appear brighter).They are also used in designing things like radars, and lights used in cars.

EDA

Taro, I wonder if you’ve already studied about how electricity works?EDA stands for Electronic Design Automation. These softwareapplications are used in automating the design of electronic devicesand things like semiconductors.They allow us to design electronic circuits and printed circuit boardsso that they will work as designed, and to run simulations to checkthat they will actually work properly as intended. It might be a bitdifficult for you to understand yet Taro…

In reality, MCAE is subdivided further into fields such as heat analysis, fluid analysis and acoustic analysis. If youwould like to know more about these, look them up on the internet.http://www.cybernet.co.jp/ansys/case/

Software: mainly ANSYS (an ANSYS Inc. product)

Software: Mainly CODE V, LightTools and other Synopsys products

Software: Mainly HyperLynx and other Mentor Graphics products

Software: Maplesoft products (Cybernet group development)

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More accurate simulations that consider various specialist fieldsMore accurate simulations that consider various specialist fieldstogether, at the same timetogether, at the same time

8. Multi8. Multi--domain* Solutionsdomain* Solutions

Case study 1: Lens design (heat and light)

Case study 2: Oscillations and sound in cars

CAE software is very specialized, so software types are divided between different fields (domains),such as those used in light/optical, heat/thermal and sound/acoustic analysis. But in reality, multiplephenomena like these occur and interact with one another, so in order to carry out more realisticsimulations that are closer to actual real-world conditions we need to combine multiple pieces ofspecialist software. On the other hand, combining different pieces of specialist software that areused to analyze different physical phenomena—for which the various software developers whoproduce and sell them are different, and for which the units of measurement also differ—is said tobe very difficult.Using its strengths as a company that has been dealing in CAE software for various differentdomains for over 30 years, Cybernet has developed a method for achieving overall simulations byweaving together different pieces of specialist software. We call these “multi-domain solutions.”

Problem Lens design and structural design are developed through simulations, using optical tools and MCAEtools, respectively. Even though the design seems to perform as intended during simulations, theprototype didn’t work as it should…

Cause The cause of the problem was that the plastic lens warped due to the heat of the light source, distortingthe shape of the lens.

Proposal

Typically, optical, MCAE (structural) and MCAE(thermal) elements are analyzed separately,using separate tools. We proposed linking theseseparate tools together using the Cybernet-developed software Optimus and running anintegrated, overall simulation.

*”Multi-domain” means an analysis domain that bridges multiple domains, such as heat/thermal analysis and light/optical analysis.

We wanted to reduce the rattling noise produced while a car is moving, but first of all we wanted tobeginby investigating which part of the car we need to fix to reduce the noise…

We ran various simulations from various aspects to investigate the properties of sound sources(oscillations from the tires and suspension) and different materials used in the car body and tires, etc.,and combined acoustic and oscillation analysis tools to achieve an oscillation-to-sound simulation.

Techniques for analyzingmaterials with different material

properties simultaneously

Techniques foranalyzing soundand oscillationssimultaneously

Techniques foranalyzing thewhole system

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Problem

Proposal

99.. SummarySummary:: ThingsThings thatthat cancan bebe donedonewithwith CAECAE && thingsthings thatthat wewe cancan dodobecausebecause wewe areare CybernetCybernet

Issue/Problem Solutions using CAE

1. Cost reduction:Measures for improvingcompetitiveness of prices andincreasing profits

(1) Reduce number of prototypesIn the case of cars, prototyping costs for one vehicle model areover 1 billion yen.

(2) Reduce the number of tests/experimentsIn the case of cars, one collision test costs over 100 million yen.

2. Shortening time taken:Manufacturers that launch theirproducts onto the market at anearlier stage enjoy greaterprofits/revenues

(1) Shorten testing times• One example is rusting experiments (where actual real-life

testing) would take too long. CAE simulations cut 10 years downto one day

• Tests for fatigue due to long-term use can also be carried out inthe space of a few hours

(2) Shorten development times (see page 7)

3. Making environments that aredifficult to test in real lifetestable/verifiable by virtualsimulation

(1) Simulations under extreme environmental conditions, such asin space, ultra-fine/nanoscale environments, ultra-low andultra-high temperature, in high vacuums, etc.

(2) Analysis of dangerous phenomena, suchas collisions and falls

Issue/Problem Cybernet’s unique solutions using multi-domain solutions

4. Performance, quality and costimprovement:Measures for seeking to differentiatefrom competitors by adding additionalvalue to products

Simulation by multi-domain simulations that analyze accordingto the actual phenomena are indispensable.

(1) Solving noise problems inside cars and other vehicles• 1D CAE analysis, acoustic analysis, ANSYS

(2) Batteries for hybrid vehicles• Optimization analysis of engine and battery

performance by1D CAE• Chemical cell property analysis (numerical formula

processing), thermal analysis and vehicle fueleconomy(1D CAE) analysis for maximal optimizationof batteries

(3) Advanced drivingsupport systems• Optical analysis and control design technology for

designing headlights that shine in the direction ofmotion, even around curves

• Optical analysis for creating digital meters(speedometers, etc.), navigational displays and HUDs(heads up displays) that are easy to see andunaffected by ambient brightness

• Thermal, oscillation, electrical noise and materialsanalysis for designing ECUs and light harnesses thatcan perform even in cars undergoing heavy vibrationsand high temperature conditions

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Mar 11, 2019 version[Copying and unauthorized re-use are prohibited]

Try our AR technology (cybARnet)!The Company’s corporate introductionmovie is able to be easilyviewed on smartphones.

( i) Search “ARnex” throu g h AppStore or Goog le Play ( the m ark s as presented beloware earm ark s).

( ii) Lau nch applications and tap “スタート” bu tton.( iii) Reading the QR code below .

( iv) Hold you rsm art deviceoverthe m ark as presented below ,pu sh “動画再生” bu tton,and theintrodu ctionm ovie w illappearinthe virtu alspace.

CYBERNET SYSTEMS CO.,LTD.Corporate Planning and IR Department

Address: Fu jiSoft Bldg .,3,K anda Neribei-cho,Chiyoda-k u ,Tok yo 10 1-0 0 22,JapanTEL: +81-3-5297-30 66FAX: +81-3-5297-360 9E-m ail: irqu ery@ cybernet.co.jpURL: https:/ /w w w .cybernet.jp/eng lish/

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