Who we are: Technology

Technology-fueled company

• Applied research to engineering

• State-of-the-art technical and scientific advances

Tools: Computational Mechanics

• Multibody Dynamics for machines and vehicles

• FEM for mechanical and thermal analysis

• CFD for fluid dynamics/thermal

Technical areas

• Simulation driven design/product development

• Multiphysics simulation

• Total design (analysis, optimization and evaluation)

Total design

In product design cycle, we provide:

1. Modelling, Simulation, Analysis:• Material modeling

• Structural trustworthiness. Failure, fracture

• Dynamics: transient effects and motion, fatigue cycles

• Heat transfer and coupled thermo-mechanics: creep,

relaxation, thermal shock, thermal cycles

• Thermal-fluid-dynamics

2. Optimization of designs based on technicalor economical criteria

3. Evaluate and validate:• Analysis tools validation: FEM Model Updating,

Identification of Dynamical Systems

• Lab and prototype testing

How we work: MethodologyUsing off-the-shelf software packages and state-of-the-art methods

for design problems of the industry

• FEM commercial or R&D package (FEAP, Code Aster, self-developed)

• MSD commercial or R&D package (self-developed)

• CFD commercial or R&D (Code Saturne, Syrthes, openFOAM, self-developed)

Generating ad-hoc tools for design/analysis of machines, mechanisms

and structures based on state-of-the-art in Mechanical Eng.

• Redistributable software packages

• Self-proprietary code

• Advanced C++/Python programming

• GUI programming (Qt)

• Advanced postprocessing tools (VR, GTK, Paraview, Salome)

• Detailed documented software and projects

Design: Analysis Tools1. Finite Element (FEM):

• Static and dynamic structural trustworthiness: creep, fatigue, maximum

service loads

• Thermal stress

• Elastic and inelastic stability: critical loads, postcritical behavior

• Modal analysis

• Design optimization and parametric modeling

• Non-linear material models (temperature-dependent, plastic, granular)

• Heat transfer: conduction, radiation, convection (Solar energy systems)

2. Thermal-CFD (Conjugate Heat Transfer)

• Coupled thermal-fluid analysis (solar receivers, heat exchangers)

• Simulation of variety of HTF’s for Solar industry

• Convective/radiation losses in semi-closed cavities (Solar Receiver)

3. Multiphysics: coupled field fluid-thermal-mechanical

4. Multibody Dynamics: machines and vehicles simulation

Design: Optimization ToolsOptimal Mechanical Design:

• Design problem is mathematically formulated as a non-linear optimization scheme

with constraints

• Objective function: total volume and weight, costs, global strength

• Constrains are given by: Ultimate and Serviceability limit states, geometry and

weight

Design: Testing tools

Data acquisition and sensoring,mechanical testing:

1. Validate computational models:• Material characterization, constitutive modeling

• Mechanical elements characterization

• Parameter identification of dynamical systems, unknown mechanical

properties: damping, friction coefficients, unbalances

2. Data acquisition and testing• Professional commercial systems

• Low-cost ad-hoc systems designed by Virtualmech (we deliver case-specific

hardware depending on customer needs: single/continuous use)

• Self-developed data acquisition software and postprocessing tools

• Micro-controllers/processors programming

What can we do for your company?Virtualmech can help you in:

1. Design, validation and certification of:• Singular structures

• Multiphysics systems: Solar energy, petrochemistry

• Mechanical systems, machines and vehicles

2. Automation of repetitive simulation oralgebraic calculations by means of ad-hocsoftware

3. Personalized design software for case-specificproblems• More flexible and easier to use and learn

• Cost-competitive and profitable

4. Optimization, improvement and cost-cutting ofexisting systems

Business Scope

CSP-CST Railroad Vehicle-Machine

Sector: CSP

Technology

• State-of-the-art Computational Mechanics applied to your CSP needs

• Coupled field Multiphysics fluid-thermal-mechanical simulations

• Computational Fluid Dynamics (CFD) techniques for fluid dynamics/thermal

problems: solar radiation to thermal energy conversion

• Finite Element Method (FEM) for simulation of thermo-mechanical problems:

thermal stress

• Total design: analysis, optimization, evaluation; based on simulation tools

• Simulation of transient phenomena: start-ups, shut-downs, clouds

Sector: CSP

CSP Services:

• Technology forecasting

• Technical consultancy

• Conceptual design of CSP components

• Basic and detailed engineering of CSP components and systems. Certification

• Independent Engineering

• O&M improvements and cost-cutting based on simulation, analysis and redesign

or replacement of components and systems. Plant modernization.

• Root Cause Analysis (RCA)

• Curves of parametric behavior for CSP components for integration in performance

and marketing/bankability analysis tools for plants

Application to CSP

Central tower (CT) receiver design:

• Thermal layout

• Thermal-hydraulic basic design

• Thermo-mechanic basic design

• Detailed engineering and certification

CT cavity design:

• Radiation and convection losses minimization

• Raytracing-based optimization to reduce optical losses

• Insulation design

CT receiver distributor and collector design:

• Pressure vessel code-based design (ASME BPVC)

• Inner insulation design for high temperature HTF’s (> 900 C)

Application to CSP

Inlet and outlet piping design for high temperature and pressureHTF’s:

• Insulation for controlled thermal losses

• Thermal-hydraulic and mechanical design (clamps, bellows, insulation shell)

• Ad-hoc flanged joints for high temperature and different piping materials

Linear solar collectors (Fresnel, Parabolic Trough): tube-receiver ormulti-pipe bundle designRCA and predictive analysis for O&M cost-cutting

• Ball-joints and flexible hose replacement analysis and strategy

• Solar Steam Generator and TES heat exchangers malfunctions due to transients or

decreased efficiency issues at design conditions

Application to CSP

TES tanks:

• Tank checkings under API codes

• Foundation thermal design

• Foundation mechanical design and geotechnical analysis

Low-medium temperature process heat and solar coolingapplications

Sector: Renewable Energy-Solar1. Fluid-thermal layout, mechanical design of CSP tower receivers:

• HTF’s (air, steam, SCO2, molten salts), high pressure and Temperature (> 1000◦C)

• Topologies: closed, open, volumetric, tubular

• Stationary structural trustworthiness: Ultimate and Serviceability limit states

• Transient-based design (plants start-ups, shut-downs, clouds):

• thermal shock

• creep and relaxation

• thermal fatigue and TMF

• viscoelasticity

2. Fluid-thermal design of semi-closed cavities for receivers

• Minimize loss: radiation and convection to ambient

• Insulation design: minimize conduction loss

3. Mechanical design of high-temperature components (up to 1600◦C)

• Special materials: ceramics, metallic alloys (Inconel, Incoloy), etc.

• Flanged connection (Patent): extreme operating conditions (not-normalized in design

codes), gasket detailed FEM modeling, different nature/materials pipes

CSP: Cavity coupled thermal-fluid design

CSP: Cavity fluid convection loss

CSP: Irradiated Pipes thermal behavior

Thermal-Mechanical

Thermal-Fluid

CSP: Molten Salts storage tanks: thermal analysis

FEM mesh Thermal behavior

CSP: Molten Salts tanks: mechanical analysis

CSP: Finite Differences Software package forthermal analysis of Molten Salts storage tanks

−2 −1.5 −1 −0.5 0 0.5 1 1.5 2

x 104

−14000

−12000

−10000

−8000

−6000

−4000

−2000

0

2000

r−coordinate (mm)

z−co

ordi

nate

(m

m)

X: −3500Y: −1.8e+04Z: 30.77

X: 1.22e+04Y: −3400Z: 33.07

X: 1900Y: −7400Z: 40.05

X: −2.14e+04Y: −2.8e+04Z: 27.09

X: 500Y: −2400Z: 361.2

X: 600Y: 0Z: 535

X: −6400Y: 800Z: 435.8

X: −6700Y: 600Z: 46.78

X: −9000Y: −250Z: 32.78

50

100

150

200

250

300

350

400

450

500

5400 5600 5800 6000 6200 6400 6600 6800 7000 7200

−600

−400

−200

0

200

400

600

800

1000

1200

X= 6000Y= −400Level= 430.7034

X= 6500Y= 0Level= 396.0315

X= 6000Y= 0Level= 535

X= 6500Y= 400Level= 334.7172

0

50

100

150

200

250

300

350

400

450

500

CSP: Solar Shield, tower support structure

Euro and Israel Code checksFinal Client: Alstom, Client:

Promat HPI

Sector: Vertical Transport

1. Dynamics and vibration simulation. vmElevator 2.4:

• First dedicated commercial code package for elevator dynamics

• Optimization: energy, eco-designs

• Flexible: Client-specific adaptations

• Provides: cabin dynamics, vibration, variety of loading, energy

requirements, inverter simulation, etc.

2. Ad-hoc analysis/measurement hardware

• Measurement of elevator comfort (ISO18738): vmRideAnalyzer 1.0

• Distributed acquisition network for elevator global dynamics

measurement. Used for computational models Validation and

Identification

3. Simulation/measurements-based analysis and consultancy

• Modelization of virtual prototypes. Simulation-based design.

• Vibration and noise analysis

• Forensic engineering (RCA)

Sector: Railway TransportDynamic simulation of vehicles

1. Methodology:

• Mathematical representation of vehicle and

track

• Virtual model of vehicle/track coupled

dynamics

• Computational simulation

2. Applications:

• Vehicle design

• Stability, critical velocity

• Curved track dynamics

• Wheel profile wear

• Derailment/security

• Passengers comfort

• Active control systems tuning

• Control over vibrations to environment

• Forensic engineering/accidents

Vehicle and track maintenance

1. Methodology:

• Real-time simulation

• Ins: Sensors data

• Outs: non-measurable quantities

(track-wheel contact), state of vehicle

2. Applications:

• Evaluate comfort and security

• Measurement of geometric quality of track

• Vehicle maintenance: wheel wear,

suspension, wheel-rail adhesion

• Active control systems

• On-line simulation-based information for

driver/company

Railway: Mechatronic applications

Real time simulation ofrailroad-vehicle dynamics

Simplified test case (track monitoring)

1. Inputs:

• Sensors: IMU

• Mathematical model

2. Outputs:

• Track geometry monitoring

• Wheel-rail contact forces (security)

• Accelerations on Passengers (comfort)

Clients

• Hidral

• MacPuarsa-MP

• Construcciones Sando

• ThyssenKrupp

• Albatros

• Wittur

• AICIA

• Kone Cranes

• Orona

Clients Solar

• Albatros

• AICIA

• Promat HPI

• AtriaPower/Ferrostaal

• Beroa-Dominion

• Schott Solar

• Rioglass

Virtualmech in ConsortiumCERSOL (High temperature and pressure Ceramic receiver for

Solar-hybrid gas turbine and combined-cycle systems)

Innterconnecta-CDTI-FP7

• Abengoa Solar NT

• Promat

• Teams

• CSIC/US

• 200 hours operation Summer 2015, target air temperature 1100C

SIMUVIA (Simulacion embarcada para auscultacion de vıas mediante

la observacion de estado de vehıculos ferroviarios) CTA-IDEA

• Construcciones SANDO

• Nadir

• Conacon

Virtualmech: Research projectsDesarrollo de un software embarcado para la evaluacion en tiempo real de la seguridad

de la marcha de vehıculos ferroviarios. (07/2015–12/2017)

• Programa: Accion Estrategica de Economıa y Sociedad Digital- Impulso

Tecnologico-2015

• Ministerio de Industria, Energıa y Turismo. Secretarıa de Estado de

Telecomunicaciones y para la Sociedad de la Informacion

Applied research activities:

• PhD. Thesis: Herramientas de simulacion computacional para procesos

termo-fluido-dinamicos aplicados a la Industria Solar de Concentracion.

Generacion Directa de Vapor

• Awarded Industrial PhD. by Spanish Government, 2016 Spanish Science Program.

• Fund raising for project: Reduccion de costes en tecnologıa Solar de

Concentracion. Receptores de torre y lineales. Aplicacion a sistemas de media

temperatura y generacion de Energıa Termica

• SolarPaces2016: Paper on convection/radiation losses on closed cavities for solar

tower receivers

Virtualmech: CSP recent activityAgreements, conversations and detailed quotations:

• Cobra: ball-joints

• Magtel/OHL: Fresnel receiver thermal performance and controllability simulations

• ACWA: SSG, molten salts piping transport

• CENER/TSK Flagsol: central receiver research project

• CSPValue: commercial agreement

• Schott Solar: receiver tubes coupled fluid-thermal-mechanical analysis

• TSK: TES tanks foundations analysis and design

• TSK Flagsol: High temperature outlet piping for R&D tower project (CAPTure-EU)

• SENER: TES tanks and foundations analysis and design: steady-state and transient operation

International Forums:

• CSPToday 2014-2015-2016

• CSP Focus China 2016

• SolarPaces 2016