iPhysics
Digital engineering, simulation and augmented reality for machines, production lines design and plant logistics
ilPhysics is a product of Machineering Gmbh.
ilPhysics is a product of Machineering Gmbh.
iPhysics is an innovative simulation platform for the digital design and virtual commissioning of complex production machines, lines and plants. By integrating the mechanical, electrical and software engineering it provides substantial benefits, such as the possibility to further optimize the machine sequence planning, immediately verify solutions and reduce costs.
iPhysics enables comprehensive engineering from the CAD level to the PLC and robots simulation. It provides the ability to realistically simulate lines and plants and obtain better Throughput and OEE estimates. It enhances communication between the mechanical and the automation design teams effectively reducing risk for complex plants and projects and simplifying commissioning. It provides the possibility to evaluate multiple design solutions and seamlessly explore new ideas and what-if scenarios. Furthermore, industrialPhysics integrates the Augmented Reality features that advance the production processes visualization allowing to effectively engage the design and sales teams with customers.
A collection of videos, which show some applications of this innovative platform for the design and simulation of machines, lines and production plants.
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CASE STUDY
This study was part of the Virtual Optimization PAsta production process (OPAV) research project,
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CASE STUDY
In this case study, EnginSoft engineers explain how they used modeFRONTIER to assist Comau, a Fiat Chrysler subsidiary, to optimize their approach to the preliminary design of production systems for automotive manufacturing system RFQs.
automotive optimization rail-transport modefrontier SIMUL8 iphysics industry4
Our competences in iPhysics
CASE STUDY
Performing flow simulations to investigate the complex loss mechanisms caused by the interaction of the rotating oil ring within a piston in the inside of the roll of a calender, which is an important device of a paper machine. Hereby, the trends of the churning losses are determined for design improvement conducted by Voith Paper R&D.
particleworks mechanics
CASE STUDY
Stranding and closing planetary machines are huge pieces of equipment designed to twist multiple heavy spools of strand at noticeable speed, to manufacture large section steel ropes.
recurdyn multibody mechanics
CASE STUDY
This article provides a non-exhaustive overview of some of the latest advances in the adoption of CAE technologies in the medical field by citing some ongoing EU research programs.
rbf-morph biomechanics
CASE STUDY
This study was part of the Virtual Optimization PAsta production process (OPAV) research project,
modefrontier ansys ls-dyna magma optimization food-beverage consumer-goods
CASE STUDY
This paper presents the preliminary simulation study of a typical centrifuge currently produced by Gamma Meccanica. The objective of this study is to evaluate the behaviour of the centrifuge using moving particle simulation and discrete element method (MPS-DEM) simulation techniques with Particleworks 7.2.1 to gain a better understanding of phenomena that are impossible to monitor experimentally.
mechanics particleworks
CASE STUDY
ECM Technologies has significantly streamlined the design, installation, and commissioning of its large-scale heat treatment systems for the automotive industry by using digital twin technology and Rockwell Automation’s Emulate3D software. Faced with tight timelines and software compatibility challenges during a major project in Mexico, ECM used virtual models to simulate and test their systems in parallel with production. This approach reduced commissioning time by 50%.
digital-manufacturing emulate3d industry4 rockwell
CASE STUDY
In the lime industry, the process engineers of Cimprogretti advise on process safety, analyse and interpret laboratory and plant data and provide specialised support to ensure the technical integrity of equipment and plants.
mechanics rocky
CASE STUDY
This article discusses a multi-objective optimization study to determine the optimal matrix for the routing of the actuating cable system in order to minimize the cable load on the robot and maximize the robot’s payload.
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CASE STUDY
This article describes how the company created and tested a process to construct a parametric CAD model capable of providing its designers with a starting point for any new machine to be designed.
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CASE STUDY
The aim of this study was to find the best quality glass-clamping system, through parametric model optimization, for a new pyrolytic self-cleaning oven by Indesit.
modefrontier optimization consumer-goods appliances
CASE STUDY
This paper presents the RENAULT F1 Team’s AM process for an aerodynamic insert in titanium Ti6Al4V. Production was optimized by identifying the best orientation for the parts and the best positioning for the support structures in the melting chamber, in addition to using the ANSYS Additive Print module, a simulation software useful for predicting the distortion of a part and for developing a new, 3D, compensated model that guarantees the best “as-built” quality.
automotive additive-manufacturing optimization
CASE STUDY
Transmission design is mainly based on the mechanical aspects of the transmission and lubrication is an aspect that is verified, and eventually corrected, based on bench testing, i.e. once the design phase has been completed and a physical prototype is available.
mechanics particleworks automotive
CASE STUDY
Stacker cranes handle pallet placement in the warehouse, moving longitudinally along the aisles between the warehouse shelves to deposit and retrieve loads. Stacker cranes are susceptible to earthquakes that can damage them and the racks around them.
mechanics civil-engineering
CASE STUDY
In this article, Uteco describes how it applied Computational Fluid Dynamics (CFD) to assist the design and improvement of its printing machines.
cfd ansys mechanics
CASE STUDY
In this technical article, the authors discuss the development of CAE models for simulating the behavior of shaped charges, devices used in various industrial sectors, against two types of target – a monolithic steel target and a multi-layer steel-ceramic target – in order to better understand the physics of penetration.
ansys ls-dyna civil-engineering mechanics oil-gas
CASE STUDY
In this case study, LION Corporation uses Particleworks to simulate fluid flow to improve the design of a new cap spout for its new HARETA brand of laundry detergent.
particleworks cfd consumer-goods mechanics
CASE STUDY
This technical case study explains the application of a two-step methodology using the MATLAB and Adam algorithms in the modeFRONTIER software platform.
optimization modefrontier automotive
CASE STUDY
This paper explores the transformative potential of Extended Reality (XR)—encompassing Virtual Reality (VR), Augmented Reality (AR), and Mixed Reality (MR)—when integrated with Artificial Intelligence (AI) in industrial and engineering applications. XR technologies enable businesses to visualize, interact, and optimize product designs, training processes, and customer support functions.
digital-manufacturing optimization artificial-intelligence
CASE STUDY
This technical article illustrates the advantages of using virtual simulation to evaluate the thermal processes of die casting to reduce the formation of residual stresses and deformations in the components produced.
metal-process-simulation mechanics magma
CASE STUDY
This article presents an example of a proposed design optimization approach with a case study.
biomechanics modefrontier
CASE STUDY
The purpose of the case study was to implement a design methodology that used multi-disciplinary simulation and an automated process to analyse thousands of product configurations and highlight vehicle performance distributions in terms of handling, comfort, and cost. This approach ensures that the best solution is always selected.
mechanics modefrontier automotive optimization
CASE STUDY
The avoidance or reduction of chainsaw kickback is a key safety feature for manufacturers. The challenges for engineers are to obtain more accurate analyses of the problem over the tool’s lifecycle.
maplesim maple mechanics ansys consumer-goods
CASE STUDY
This technical article details the application of the methodology developed using ANSYS WorkBench
ansys mechanics maplesim
CASE STUDY
Material models used in structural finite element analysis (FEA) are often one of the key aspects that engineers need to describe very accurately.
optimization modefrontier ls-dyna
CASE STUDY
Nederman’s Air Purification Tower is the perfect choice if source extraction is not a satisfying option.
ansys mechanics
CASE STUDY
Cimolai Technology explains the business benefits it has achieved since the installation in terms of time savings in planning, and design, and improvements in product quality and in delivery forecast ability.
ansys mechanics rail-transport marine
CASE STUDY
The Arvedi Group approached the University of Trieste to find a solution to the uneven distribution of material inside the hopper of their blast furnace in Trieste, Italy.
optimization modefrontier rocky mechanics
CASE STUDY
The premium software RecurDyn was used to simulate a Double Pole Single Throw Switch using three different modeling schemes. A comparison of the results provided useful information for the designers.
recurdyn mechanics multibody
CASE STUDY
In this technical case study, EnginSoft assists Casappa to further refine an already-optimized standard series pump for an electrical motor and generator
mechanics optimization modefrontier
CASE STUDY
This article discusses a realistic multi-objective parameter optimization study of a highly athletic one-legged robot, called Skippy, in which both the parameters of the mechanism and the parameters of its optimal behaviors were sought.
optimization modefrontier biomechanics
CASE STUDY
Vin Service, founded in 1976, is a world leader in dispenser technology and the first Italian manufacturer of draft-wine dispensers. Its core business is in the dispensing equipment industry and in cooling systems for beverages.
ansys mechanics food-beverage
CASE STUDY
Racing engines are continuously evolved and fine-tuned to allow them to achieve extraordinary levels of performance, albeit with great complexity. However, MotoGP regulations restrict engine development by constraining some of the main design parameters.
optimization modefrontier cfd ansys rail-transport
CASE STUDY
Oil or gas pipelines that cover long distances pose complex design challenges. Every environment the pipeline crosses is characterized by different potential geohazards. One of the most dangerous for a pipeline is a rockfall.
oil-gas mechanics ansys
CASE STUDY
Since this cannot be accurately measured in an implanted stent, manufacturers decided to use Multiphysics to simulate the process to better understand the method and to calculate the forces operating on the implant in order to improve the stent design and the surgical procedure, as described in this article.
cfd biomechanics ansys
CASE STUDY
In this interview, engineer Luca Cavalli, of Immergas’ advanced engineering team, discusses the technical and business benefits the company has realised since first introducing Computer-Aided Engineering (CAE) technologies into its R&D department in 1997.
ansys appliances cfd mechanics
CASE STUDY
Sailing and engineering teams have been dealing with a new set of challenges ranging from boat handling, tactics and, it goes without saying, the design of these new vessels and their subsystems.
marine optimization modefrontier
CASE STUDY
This brief article summarises how California-based electric car company, Lucid Motors, used the CAE application, ModeFRONTIER for performing Computational Fluid Dynamics (CFD)
automotive optimization modefrontier
CASE STUDY
This case study describes ISEO’s project to introduce a global dimensional management approach based on CETOL6σ that starts from the product concept phase and includes design development and prototyping and extends on to cover all other phases of production through to the finished product, with the guidance and support of EnginSoft.
tolerances cetol mechanics
CASE STUDY
A client wanted to evaluate the dynamic performance of a new-concept forklift, so a fully-functional multibody model of the forklift was built by assembling the client’s CAD geometries.
multibody automotive mechanics recurdyn
CASE STUDY
The aim of this study was to reduce the weight of the world’s tallest aluminum mast for a new series of single mast sailing yachts manufactured by Perini Navi under the brand name Salute.
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CASE STUDY
By taking advantage of EnginSoft experience in Simulation Based Engineering, by means of the FEM analysis, the Durability, Structural Integrity and Buckling behavior of a new group of toxic liquid and fuel storage tanks have been investigated.
energy mechanics ansys
CASE STUDY
Further reduction of the heat loss compared to the best design of the NSGA-II first phase design optimization: a further 4% gained
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CASE STUDY
Gamma Meccanica’s R&D department is constantly researching new solutions to improve the overall performance of equipment, production capacity and reliability while developing environmentally sustainable processes and applications to benefit its customers.
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CASE STUDY
In this case study, EnginSoft engineers explain how they used modeFRONTIER to assist Comau, a Fiat Chrysler subsidiary, to optimize their approach to the preliminary design of production systems for automotive manufacturing system RFQs.
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CASE STUDY
This technical article describes how engineers tackled a design optimization challenge to ensure the structural integrity of a section of the beam of a typical steel bridge whose web of main beams was subject to instability.
civil-engineering modefrontier optimization
CASE STUDY
The final portion of the paper path of a laser printer has been studied using the Media Transport Toolkit to evaluate the influence of the corrugating roller which is used to corrugate the sheet to keep it straight before falling into the tray.
recurdyn multibody mechanics consumer-goods
CASE STUDY
A fascinating article on the origin, history, and evolution of roller coasters from their earliest prototypes in Russia in the 16th century on the banks of the Neva River of St. Petersburg, and then dives into detail on how numerical simulation of roller coasters works to ensure their success both as entertainment and from a safety perspective for users and operators.
mechanics civil-engineering construction optimization
CASE STUDY
Elettronica SpA designs and produces systems for electronic warfare. Each system design is unique according to its platform and purpose. In this article, the company describes how it used CAE to approach the challenging design of a single sandwich radome.
ansys optimization electronics
CASE STUDY
The study described in this article was designed to obtain greater insight into the gas transfer mechanism at microscopic scale using computational fluid dynamics in order to accelerate design exploration to find the optimal solution.
biomechanics ansys
CASE STUDY
Mesh morphing has proven to be a valuable tool in parametrizing numerical models to perform shape optimization. It allows engineers to save time in generating new configurations for analysis because it does not require geometry modification and mesh re-generation.
ansys mechanics
CASE STUDY
The ultimate goal of the study was to optimize the Drift Chamber’s performance in terms of stiffness, strength and weight o be mounted on the Mu2e particle detector at FermiLAB in Chicago
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CASE STUDY
In a recent interview, Enrico Boesso (EnginSoft) and Daniel Campbell (Capvidia) discussed how Model-Based Definition (MBD) is transforming manufacturing by replacing traditional 2D drawings with data-rich 3D models as the "single source of truth".
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CASE STUDY
In this example, these features were tested by simulating the motion of a very thin plastic film (32µm) being dragged by two rollers.
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CASE STUDY
A developer of innovative equipment designed a system to simplify the towing and laying down of marine pipelines in shallow water fields.
energy modefrontier optimization oil-gas recurdyn
CASE STUDY
Special Springs commissioned EnginSoft’s engineers to calculate the production cost repercussions of a technical product modification requested by an important customer.
eztol mechanics cetol tolerances
CASE STUDY
This detailed technical case study describes how the students arrived at a supersonic aircraft drone prototype using MATLAB and modeFRONTIER in order to reduce the time and costs of numerical and wind-tunnel testing.
automotive modefrontier optimization
CASE STUDY
The main structure of the yacht is made of composite laminates with the presence of many composite reinforcements and bonded joints. We conducted a detailed structural analysis of the entire structure and verified the structural requirements.
marine optimization
CASE STUDY
Multibody simulation is integral to engineering, enabling precise analysis of structural loads and dynamic behaviours in complex systems. In the context of forklifts, where tyres play a critical role due to the absence of suspension systems, accurate tyre modelling is essential. This study develops and validates a hysteretic Bouc-Wen model for the radial dynamics of solid rubber tyres to enhance simulation reliability.
multibody recurdyn mechanics automotive
CASE STUDY
This technical article describes a project undertaken by OPEM to optimize and validate the laws of motion governing the moving operations of a machine that produces coffee capsules, namely the cut and weld unit, the film feeder, the conveyor and the support structure.
consumer-goods multibody recurdyn food-beverage mechanics
CASE STUDY
Modern propeller requirements involve many different characteristics, not limiting only to maximum efficiency, but considering also propeller cavitating behavior and, more and more, its side effects, in terms of radiated noise and pressure pulses.
marine modefrontier optimization
CASE STUDY
In this article, Del Negro explains how Ricardo is developing solutions to support its customers to predict the lifecycle of motorcycle components, using finite element analysis (FEA) and fatigue analysis.
femfat mechanics automotive
CASE STUDY
The following article explains how this new approach to the design of automated machines can enable industrial automation OEMs and system integrators to achieve these business imperatives with the assistance of industrialPhysics simulation software.
mechanics iphysics industry4
CASE STUDY
The text discusses the importance of digital simulation models in modern factory design and reconfiguration, particularly in response to shorter product lifecycles and increased customization demands. Traditional design methods often lead to inefficiencies and high costs, making digital simulation essential for creating flexible and adaptable production systems. The article highlights a case study involving a furniture assembly factory, where a manufacturer needed to efficiently handle a variety of custom kitchen cabinet orders. The system integrator was tasked with designing a robotic assembly line that could maintain production efficiency despite the high variety of products.
industry4 SIMUL8
CASE STUDY
This article proposes the use of computational fluid dynamics (CFD) to address these complexities.
ansys mechanics
CASE STUDY
Spiral bevel gear pairs (SBGs) play an important role in transferring power between non-parallel shafts in transmission systems. This paper presents the dynamic results of the case study investigated and illustrates nonlinear phenomena.
masta mechanics
CASE STUDY
A multibody model of an excavator was developed to calculate the loads acting on the structure and to perform static structural verifications of the different components.
automotive multibody recurdyn mechanics
CASE STUDY
This paper presents the main steps taken in the development phase of the IVECO cab suspension brackets to comply with the new ECE R29 crash regulation for Heavy Commercial Vehicles (HVC).
modefrontier optimization automotive
CASE STUDY
In this example, a tracked bulldozer was simulated to evaluate the dynamic behavior of the vehicle on different terrains and with different obstacles. The model can also be used to calculate the loads operating on the vehicle’s structure..
recurdyn automotive mechanics multibody
CASE STUDY
This technical article describes a human body model (HBM) wizard developed for RecurDyn and discusses what is already possible and what is in the development pipeline for the near future. Biomotion Solutions provides software to quickly build HBMs in industrial-grade simulation packages.
multibody recurdyn industry4 biomechanics
CASE STUDY
This technical article describes an acoustic emissions study conducted on an electric water circulation pump used for supplementary cooling or heating functions in vehicles, by the Modeling & Simulation Pumps Department of Pierburg Pump Technology
acoustic ansys mechanics
CASE STUDY
This technical article describes how high-end numerical Computational Fluid Dynamics (CFD) simulations were applied to mimic the realistic operating conditions of a Ventricular Assist Device (VADs) and analyze its hemodynamics in order to identify potential areas for optimization of the device’s performance, safety and efficacy.
ansys cfd biomechanics
CASE STUDY
This article presents an example of the analysis of a powder composed of spherical particles. Since powders have a very fine heterogeneous structure, a multi-scale approach based on homogenization analysis is proposed.
multiscale ansys mechanics
CASE STUDY
At this particular moment in time, this article wishes to reflect on the evolution of CAE and simulation in an effort to present a big-picture view when most of us are daily dealing with all the devil in the details in every aspect of our lives. We approached some long-standing business friends in engineering simulation from various regions around the world to help us in this task
ansys industry4 news
CASE STUDY
In this technical case study, EnginSoft was called in to assist in the application of Computational Fluid Dynamics (CFD) to model the flame size of a regeneration gas-fired heater for a project in Oman.
ansys mechanics energy oil-gas
CASE STUDY
The study allowed the engineers to estimate the shape profile geometry after each roll pass, the rolls wear and the total load and point at which the beam will bend in off-center setups.
construction metal-process-simulation forge mechanics
CASE STUDY
This study discusses the complex and challenging problem of controlling vortex-induced vibrations (VIV).
cfd mechanics ansys rbf-morph
CASE STUDY
In this technical case study, we illustrate how EnginSoft engineers helped ABB to optimize the design of the Emax2 project.
tolerances cetol electronics mechanics eztol
CASE STUDY
This paper demonstrates how the biological growth method, studied by Mattheck in the 1990s, can be easily implemented for structural shape optimization finite element method (FEM) analyses using advanced radial basis functions (RBF) mesh morphing.
ansys biomechanics rbf-morph
CASE STUDY
The article focuses on the difference in fatigue behaviour between rubber and metal materials. While metal fatigue is often described by a simple rule: increasing mean strain is detrimental to fatigue life, rubber fatigue is more complex and depends on the material's ability to strain crystallize. The text concludes that while tensile mean stresses are always detrimental in metals, in rubber they may be either beneficial or harmful depending on whether the rubber can strain crystallize.
mechanics endurica automotive
CASE STUDY
In this article, we show that the main turbine characteristics, such as efficiency and exit flow angle, can be sufficiently improved using parametric optimization.
modefrontier energy optimization
CASE STUDY
Optimization tools, and specifically response surface methods (RSM), can be adapted very well in the design process to provide information around the design of a compressor stage. This article will cover two of the possible optimization uses: the search of optimum performance and data generation.
modefrontier optimization mechanics
CASE STUDY
Have you ever grappled with the nonlinearity of materials? This article introduces Multiscale.Sim’s curve-fitting feature for predicting material constants for viscoelastic problems.
multiscale mechanics composites
CASE STUDY
The text provides an in-depth account of Stefano Odorizzi’s journey in founding and growing EnginSoft, our engineering company specializing in computer simulation and modelling. Established in 1984, EnginSoft overcame early challenges, such as the high cost of computing, to emerge as a leader in simulation services, particularly in the fields of mechanical engineering and computational fluid dynamics (CFD). The narrative highlights several key milestones in the company’s history.
cfd metal-process-simulation industry4 news mechanics optimization
CASE STUDY
In this technical article, Fiat Chrysler Automobiles explain how they created a multibody optimization project to identify the optimal values for the powertrain suspension stiffness for a three-cylinder engine in order to minimize the vibrations at idle condition and ensuring greater ride comfort to the passengers.
automotive optimization modefrontier
