crossing the chasm between ecad and cae - dfr solutions€¦ · crossing the chasm between ecad and...
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1 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Crossing the Chasm Between ECAD and CAE
2 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
The Industry Leader in The Industry Leader in Quality-Reliability-Durability Quality-Reliability-Durability
of Electronics of Electronics
Best Design Verification Tool
- Printed Circuit Design
Who is DfR Solutions?Who is DfR Solutions?
50 Fastest Growing Companies in the Electronics Industry
- Inc Magazine
2012 Global Technology Award Winner
3 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
What is the Goal and what are the Problems?
Goal: Predict the reliability of circuit cards when subjected to various vibration and mechanical shock environments
● Real-World Testing● Too expensive● Too few data points● Time-consuming
● Finite Element Analysis● Convert CAD 2D model to CAE 3D model (time-consuming)● Assign material properties to elements (data management)● Define conditions and tests (tedious, FEA expertise)● Convert CAE results to reliability predictions (tedious, programming
expertise, reliability expertise)● Report Generation (time-consuming, tedious, error-prone)
4 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
How does Sherlock help? ● Convert ECAD 2D model to CAE 3D model
● Provides various tools to import data from ECAD files● Generates 3D model for external CAE tools
● Assign material properties to elements● Determines properties and assigns to 3D objects
● Define conditions and tests● Provides tools to define Life Cycle events (thermal, shock, vibe)● Generates FEA conditions for each event● Generates tests required for desired reliability results
● Convert CAE results to reliability predictions● Imports displacement and strain results from FEA tool● Generates reliability results for all parts using validated models
● Report Generation● Custom report generator (100+ pages per card if desired)● Export data sets or images for custom reporting
5 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Bridging The Gap
Mode 1: Manage FEA testing completely within SherlockMode 2: Export model from Sherlock for manual FEA testingMode 3: Import FEA results into Sherlock for reliability analysis
ElectronicDesign Files
Life CycleConditions
SherlockDesign
Analysis
3D Model /Analysis Steps
Pre-Processing
ReliabilityResults
SherlockFailure
Analysis
3D Model / Disp Results /Strain Results
Post-Processing
SherlockData Store
PartsPackagesMaterials
FEATool
FEA Analysis
Model Results
FEAScript
6 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
FEA Model Building● Supports standard ECAD file formats
● ODB++, ODB XML, GenCAD, Eagle, BOMs, NetList, Pick&Place, etc.● Resolves inconsistencies between design files
● All extracted values are saved, "best" choice is used● User can review all data and override as needed
7 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Reduced Data Entry● Automatically extracts data from EDA files
whenever possible● User need only confirm correctness
● Point-n-Click data editors● Part Editor● Package Chooser● Laminate Chooser
● Sherlock Data Stores augment EDA data● Packages● Materials● Laminates
● Part Database saves confirmed data● Update Parts List from Database● Update Database from Parts List
8 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Sherlock Part Wizard
● Extracts part data from millions of decodable manufacturer part numbers
● Electrical properties● Ratings● Package dimensions
● Part Number Patterns● 40+ patterns provided by DfR● User-defined patterns
● Part Wizard● Point-n-Click editor● No programming required● Built-in test support
9 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
PCB Stackup Made Simple● Stackup definition
● Extracted from EDA files● Defined or edited by user
● Laminate Chooser● 400+ materials
● Computed PCB properties● Copper layer percent● Average density, CTE, E
10 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Life Cycle Conditions● All environmental conditions to be seen
● Thermal, Vibration, Shock● Can be shared across organization
● Profile Editors● Discrete data points● Composite waveforms
● Automatically converted to FEA loading
11 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Simplified 3D Objects● Mount Points (holes, standoffs, pads, pins)
● Automatically defined by Sherlock from ECAD files● Graphical editor to add / remove / edit
● Test Points (static loads)● Automatically defined by Sherlock from ECAD files● Graphical editor to add / remove / edit
● Sub-Assemblies● Multiple PCBs in a single model● Mezzanine or edge-connected● Graphical orientation tools
12 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
FEA Support
● 3rd Party FEA Tools● Calculix (public-domain)● Abaqus (v3.1, 4Q13)● Ansys (in development)● Nastran (in development)
● Multiple Models● Merged
– part and PCB elements share common nodes in a single mesh– speeds up analysis, can be used to compare results across tools
● Bonded– part and PCB elements are meshed independently and bonded together– allows for more uniform meshes, requires additional constraints
● Geometric– high-level objects in CAE that can be easily refined and used for manual testing
● Analysis Types● Modal Response (natural freq)● Static Load (ICT)● Modal Dynamic (harmonic/random)● Transient Dynamic (mech shock)● Custom Analysis
13 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
FEA Post-Processing
● Import FEA results from FEA tool● 3D model used in the analysis● Nodal displacement and strain values
● Generate reliability predictions● Determine max displacement / strain seen by all solder joints● Predict reliability based on validated package-specific models● Assign score to all parts, PCBs and project based on safety-factor● Generate life-prediction curve
– combines all PCB and test results● Generate results
● Exportable tabular results● Exportable 2D results● Exportable 3D results
14 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
FEA Post-Processing (cont'd)
● Report Generator● Not over until the paperwork is done● Works with current or archived results
● Dozens of report elements● Test descriptions● Life Cycle definitions● Analysis inputs● Summary results● Detailed results● Top N problems
● PDF Output
15 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Sherlock FEA Demonstration
● Shock Analysis of Single PCB● Sherlock generates FEA model, conditions and test● Sherlock controls all FEA processing● Sherlock imports FEA results and generates reliability results
● Static Load Analysis performed by user using FEA tool● Sherlock exports FEA model and conditions● User defines test and performs analysis● Sherlock imports FEA results and generates reliability results
● Static Load Analysis of Multi-PCB Assembly● User defines sub-assemblies in Sherlock● Sherlock generates FEA model, conditions and test● Sherlock controls all FEA processing● Sherlock imports FEA results and generates reliability results
16 9000 Virginia Manor Road, Suite 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
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