COSMOS helps slash design time of electronic components

Company Delphi Packard Electric Systems Industry Electrical/Electronics Location U.S.A. Product Used COSMOSWorks Type of Analysis Linear Static More Details

The Challenge
Delphi Packard, one of the worlds leading manufacturers of automotive electronic components, needed to design and test a module consisting of two cast aluminum plates with elastomer-bonded surfaces, two circuit boards containing some 200 electrical connections, and three springs providing the force to maintain the connections. In the past, the development of an assembly, from concept to prototyping to testing, took months.

The Solution
Engineer John DeNuto used COSMOSWorks Advanced configuration, employing GEOSTAR to extrude a surface mesh on the elastomer-bonded faces of the top and bottom plates of the module and model the elastomer, and then analyzed the module with COSMOS FFE.

DeNuto found that the analysis allowed him to optimize spring placement, control plate deflections, minimize wall thickness on the outside of the springs, and keep the stresses well below yield strength. "Being able to optimize the design with analysis leads to a better product in performance and cost, while minimizing waste," he said.

Summary and Metrics

• Delivered a lower mass part with higher reliability in less time
• Moved from the concept to the first structural analysis in just two days
• Improved response time to the customer
• Time savings directly relates to money saved