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As Einstein said, “Everything should be made as simple as possible, but not simpler.” Foster-Miller knows that different types of modeling are needed at various stages in the design process, and we have the expertise to do the right analyses and simulations that always trade off complexity and accuracy versus simplicity and insight. In developing high-performance electromechanical and thermal systems, our experience has shown that modeling and simulation early in the design cycle can play a crucial role in enabling the project team to develop the intuitive technical insight into a problem that is a prerequisite for arriving and innovative and practical solutions. We use our analyses and simulations to distill complicated design problems into relatively simple representations that capture the essence of the problem while limiting model complexity. Later in the cycle after designs have been formulated, simulation is invaluable for design verification. We can then create more detailed and complex models to test our original assumptions and the designs that resulted from them. This type of modeling provides details needed to fully optimize a design and investigate the robustness of the concepts. Foster-Miller has all the tools and analysts in-house that are needed to perform more elaborate analyses and simulations like finite element or boundary element analyses for magnetic, structural, and thermal systems, and time transient simulations of mechanical and electrical systems. Increasingly, mechanical systems are being closely coupled to the dynamic electrical systems that power and control them. To design and build these hybrid systems at a world-class level, Foster-Miller has perfected techniques for the modeling and simulation of these “mechatronic” systems – modeling the combination of dynamical mechanical systems to the algorithms and electronics that control them. We employ specialists with a wide range of backgrounds in areas such as robotics, rolling element bearings, rotor dynamics, cable dynamics, and electric machines. These specialists draw upon a wealth of experience in analytical techniques in their areas to create both simplified models and analyses for the purposes of machine design, controller design, and system optimization, as well as more elaborate models for design verification. The latter models can be end-to-end simulations of a dynamic system and its controller, implemented either as a custom simulation program, or using standard modeling tools such as Matlab/Simulink. Focusing on the analysis and design of low-frequency electromagnetics, Foster-Miller is ready to analyze and simulate the electric machines of the 21st century. We fuse classical electric machine analysis techniques with cutting edge numerical analysis tools to obtain precise yet insightful analysis results. Rather than merely employing numerical analysis tools such as finite element modeling, Foster-Miller’s engineers and scientists create custom modeling tools that give us the flexibility we need to analyze novel electric machines and machines that are difficult to analyze using standard techniques. The ultimate results are superior electric machine designs for novel applications. Foster-Miller has over 40 years of experience in the art of analyzing thermal/fluid systems and has developed heat pumps, wearable refrigeration systems and novel, small-scale engines during the course of working in this area. We begin by creating analytical models for thermal systems that expose the interdependencies of the system’s design. These models allow us to quickly understand and address a customer’s thermal problems, as well as provide insight into the effects of various parameters on a new design. For design verification, Foster-Miller has access to sophisticated numerical tools such as finite difference heat transfer codes and finite element flow codes. These tools, combined with our analytical modeling acumen, result in accurate analyses and optimal designs for thermal systems. Foster-Miller’s structural mechanics capabilities extend from advanced nonlinear finite element analysis (FEA) of railroad collisions to analytical predictions of fatigue crack growth in aging aircraft. We have designed and built structures ranging from portable bridges for Army tanks to gossamer booms for NASA. Our structural mechanics tools include a full working knowledge of virtually every FEA system on the market and many internally developed codes specifically built to meet our customer’s needs.
Foster-Miller is often called upon to solve problems that no one has ever examined before. In solving these problems, our personnel have become internationally renowned experts in fields as diverse as tensioned cable dynamics, high energy impact analysis, and nanometer level friction mechanics. We routinely tackle challenges that are out of the ordinary and are accustomed to having to start from the structural mechanics fundamentals. Foster-Miller does simulation, design, testing and development of biomechanical systems that can be used to analyze, reduce and/or prevent injuries. Our technical staff is experienced in computerized modeling of the human body, including the skeleton, interconnecting muscles and tissue, and the internal organs. This makes it possible to see the internal stresses, loads and movements in accident or collision scenarios and to better understand the injury mechanisms involved. We are also developing software that will monitor and help diagnose, prevent and treat foot ulcers in diabetic patients. Recent advances in both video camera technology and computer science provide the foundation for automating the process of reviewing video imagery. Digitizing of videotape has become inexpensive and feasible with the power of present-day computers. The introduction of digital video cameras has improved the quality of the raw video data to be analyzed. Foster-Miller personnel are developing software to analyze such video data. Our software reduces the time required for this type of analysis and provides summary information on the content of the video sequence. Foster-Miller has the expertise necessary to execute end to end optical system design. In addition to experience with commercial optical design tools such as ZEMAX® and MODTRAN, we have developed custom optical design software to meet unique challenges, such as non-sequential ray tracing, use of complex indices for calculating fresnel refraction, and polarization tracking. The custom software performs Monte Carlo ray tracing to optimize grating blaze angle and grating efficiency as a function of polarization, incidence, immersion medium index and groove profile, and an optimization routine for both imaging and non-imaging systems. We can use this software to model optical components such as waveguide spectrometers, evanescent fiber optic probes, hollow waveguides, and infrared fiber optics. We apply this to the modeling of the emission and scattering of radiation off complex surfaces as well.
Foster-Miller uses these capabilities to make highly realistic optical models of complex multilayer surfaces, including the approximation-free treatment of all orders of interference effects. Applications also include the ability to predict the polarization-dependent thermal emission signatures of tanks, planes, and structures with layered paint surfaces. Our optical software routines are also a highly useful laboratory tool for the analysis of optical constants of thin film systems using a Kramers-Kronig approach.
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