ENGINEERING

Altair Engineering Inc., a leading global product design consulting and technology company, is using SolidWorks 3D mechanical design software to develop advanced technology buses that could revitalize the country's public transportation system. Under a new $550,000 federal transportation grant, Altair Engineering is designing next-generation buses that promise an estimated 40-percent reduction in cost of ownership over traditional buses. The vehicles will feature improved maintenance, fuel, emissions, and passenger comfort technologies, and be more than 33 percent lighter. The grant aids Altair in designing and building two prototype buses that will be initially deployed in metro Detroit as early as 2006 for regular transit use and evaluation. "We can give you a long list of features we like about SolidWorks software, but the number one reason we selected it was ease of use," said Jos Timmermans, Altair's technical director. "It does everything we need it to do, and it is very easy to learn. We have passionate career public transportation professionals joining us on this project, and they ramped up very quickly on SolidWorks. SolidWorks was easily integrated within our radically new engineering process, which has produced spectacular results so far." Altair engineers designed the bus around the passengers instead of making room for passengers in the bus design, a philosophy with tangible differences. Engineers first used SolidWorks to design and position the bus's major functional components - seats, windows, lights, storage, engine, and fuel systems. Engineers then invoked a special tool, Altair Optistruct topology optimization software, to determine the bus's optimal frame lines in and around the components with an eye toward carefully balancing loads. Traditionally, engineers would sketch the frame first, taking educated guesses about the proper design. Altair engineers then used SolidWorks to flesh out the frame design, selecting materials and setting heights, widths, and thicknesses. Engineers again used Optistruct to optimize component sizes and shapes to ensure the structure was as strong as it needs to be, but in no way overdesigned - a key to efficiency. Altair engineers have also been using the eDrawings(tm) e-mail-enabled communications tool throughout the process to share drawings with suppliers and potential customers. "Our success on this design project stems from an elegant combination of process, tools, and sound engineering," said Wes Blanchard, an Altair design engineer. "We rely on technology in cases where the optimal design is non-intuitive or too complex for traditional engineering approaches." Lowering cost of ownership The new demonstration buses will feature a modular assembly format allowing for quicker, simpler, and less costly replacement of critical systems when problems arise. Additionally, embedded sensors and telematics services will alert operators to required maintenance before expensive repairs are necessary. The lighter, shorter demonstration buses designed by Altair will help decrease overall operating costs by lowering fuel consumption. These increases are particularly important given the Department of Energy's plan to increase fuel economy for buses from three to nine miles per gallon by 2010. Altair will also explore alternative power train options for the prototype buses, with the potential for hybrid electric, fuel cell, and natural gas capabilities. These advanced power train technologies reduce air pollution and lower noise levels to provide a more desirable experience for passengers. Altair Engineering is collaborating on the grant with Automation Alley Technology Center, a business incubator located in Southeast Michigan's global technology cluster. The grant was secured by U.S. Rep. Joe Knollenberg (R-Bloomfield Township), supported by Sens. Carl Levin (D-Mich.) and Debbie Stabenow (D-Mich.). "Altair is making a positive impact on the public transportation system, and SolidWorks software is supporting Altair in every critical design decision," said Bertrand Sicot, SolidWorks Corporation's vice president of North American sales. "SolidWorks' ease of use and powerful capabilities let engineers focus more on the components and systems they're designing than on the software." Altair Engineering works with authorized SolidWorks reseller DASI Solutions for ongoing software training, implementation, and support.