Virtual Engineering Centre - Examples of Virtual Prototyping and Multidisciplinary Design Optimization

The requirement for the use of Virtual Engineering, encompassing the construction of Virtual Prototypes using Multidisciplinary Design Optimisation, for the development of future aerospace platforms and systems is discussed. Some of the activities at the Virtual Engineering Centre, a University of Liverpool initiative, are described and a number of case studies involving a range of applications of Virtual Engineering illustrated.

FPGA Prototyping of Emerging Manycore Architectures for Parallel Programming Research using Formic Boards

Performance evaluation of parallel software and architectural exploration of innovative hardware support face a common challenge with emerging manycore platforms: they are limited by the slow running time and the low accuracy of software simulators. Manycore FPGA prototypes are difficult to build, but they offer great rewards. Software running on such prototypes runs orders of magnitude faster than current simulators. Moreover, researchers gain significant architectural insight during the modeling process. We use the Formic FPGA prototyping board [1], which specifically targets scalable and cost-efficient multi-board prototyping, to build and test a 64-board model of a 512-core, MicroBlaze-based, non-coherent hardware prototype with a full network-on-chip in a 3D-mesh topology. We expand the hardware architecture to include the ARM Versatile Express platforms and build a 520-core heterogeneous prototype of 8 Cortex-A9 cores and 512 MicroBlaze cores. We then develop an MPI library for the prototype and evaluate it extensively using several bare-metal and MPI benchmarks. We find that our processor prototype is highly scalable, models faithfully single-chip multicore architectures, and is a very efficient platform for parallel programming research, being 50,000 times faster than software simulation.

Rapid prototyping applied to a new development in moulds for rotational moulding

The aim of this work has been to adapt and apply the advantages of rapid prototyping and electroforming technologies to try to achieve an innovative mould design for rotational moulding. The new innovative design integrates an electroformed shell, manufactured starting from a rapid prototyping mandrel, with different designed standard aluminium tools. The shell holder enables mould assembly with high precision manufacture of a shell in a few minutes. The overall mould cost is significantly decreased because it is only necessary to manufacture one or two shells each time; however, the rest of the elements of the mould are standard and usable for an infinite number of shells, depending on size.

A Framework for Prototyping and Reasoning about Distributed Systems

A framework supporting fast prototyping as well as tuning of distributed applications is presented. The approach is based on the adoption of a formal model that is used to describe the orchestration of distributed applications. The formal model (Orc by Misra and Cook) can be used to support semi-formal reasoning about the applications at hand. The paper describes how the framework can be used to derive and evaluate alternative orchestrations of a well know parallel/distributed computation pattern; and shows how the same formal model can be used to support generation of prototypes of distributed applications skeletons directly from the application description.

Rapid prototyping applied to a new development in moulds for rotational moulding

Rotational moulding is a unique manufacturing technique for the production of hollow plastic parts manufacturing. Moulds for rotational moulding are generally not standardized, such as for injection moulding, so each new mould must be completely manufactured except for a few ancillary parts like screws or clamps. The aim of this work has been to adapt and apply the advantages of rapid prototyping and electroforming technologies to try to achieve an innovative mould design for rotational moulding. The new innovative design integrates an electroformed shell, manufactured starting from a rapid prototyping mandrel, with different designed standard aluminium tools. The shell holder enables mould assembly with high precision a shell in a few minutes with the advantage of changing different geometries of the electroformed shells in the same tool. The overall mould cost is significantly decreased because it is only necessary to manufacture one or two shells each time, however the rest of the elements of the mould are standard and usable for an infinite number of shells, depending on size. The rapid prototyping of the mandrel enables a significant decrease the global cost of mould manufacturing as well. © 2008 Taylor & Francis Group.

Efficient FPGA Hardware Development: A Multi-Language Approach

This paper presents a multi-language framework to FPGA hardware development which aims to satisfy the dual requirement of high-level hardware design and efficient hardware implementation. The central idea of this framework is the integration of different hardware languages in a way that harnesses the best features of each language. This is illustrated in this paper by the integration of two hardware languages in the form of HIDE: a structured hardware language which provides more abstract and elegant hardware descriptions and compositions than are possible in traditional hardware description languages such as VHDL or Verilog, and Handel-C: an ANSI C-like hardware language which allows software and hardware engineers alike to target FPGAs from high-level algorithmic descriptions. On the one hand, HIDE has proven to be very successful in the description and generation of highly optimised parameterisable FPGA circuits from geometric descriptions. On the other hand, Handel-C has also proven to be very successful in the rapid design and prototyping of FPGA circuits from algorithmic application descriptions. The proposed integrated framework hence harnesses HIDE for the generation of highly optimised circuits for regular parts of algorithms, while Handel-C is used as a top-level design language from which HIDE functionality is dynamically invoked. The overall message of this paper posits that there need not be an exclusive choice between different hardware design flows. Rather, an integrated framework where different design flows can seamlessly interoperate should be adopted. Although the idea might seem simple prima facie, it could have serious implications on the design of future generations of hardware languages.

Rapid design of discrete orthonormal wavelet transforms

A methodology which allows a non-specialist to rapidly design silicon wavelet transform cores has been developed. This methodology is based on a generic architecture utilizing time-interleaved coefficients for the wavelet transform filters. The architecture is scaleable and it has been parameterized in terms of wavelet family, wavelet type, data word length and coefficient word length. The control circuit is designed in such a way that the cores can also be cascaded without any interface glue logic for any desired level of decomposition. This parameterization allows the use of any orthonormal wavelet family thereby extending the design space for improved transformation from algorithm to silicon. Case studies for stand alone and cascaded silicon cores for single and multi-stage analysis respectively are reported. The typical design time to produce silicon layout of a wavelet based system has been reduced by an order of magnitude. The cores are comparable in area and performance to hand-crafted designs. The designs have been captured in VHDL so they are portable across a range of foundries and are also applicable to FPGA and PLD implementations.

Adding metadata to Orc to support reasoning about grid programs

Following earlier work demonstrating the utility of Orc as a means of specifying and reasoning about grid applications we propose the enhancement of such specifications with metadata that provide a means to extend an Orc specification with implementation oriented information. We argue that such specifications provide a useful refinement step in allowing reasoning about implementation related issues ahead of actual implementation or even prototyping. As examples, we demonstrate how such extended specifications can be used for investigating security related issues and for evaluating the cost of handling grid resource faults. The approach emphasises a semi-formal style of reasoning that makes maximum use of programmer domain knowledge and experience.

Creating New Design-Build-Test Experiences as Outputs of Undergraduate Design-Build-Test Projects

This paper describes a methodology of using individual engineering undergraduate student projects as a means of effectively and efficiently developing new Design-Build-Test (DBT) learning experiences and challenges.
A key aspect of the rationale for this approach is that it benefits all parties. The student undertaking the individual project gets an authentic experience of producing a functional artefact, which has been the result of a design process that addresses conception, design, implementation and operation. The supervising faculty member benefits from live prototyping of new curriculum content and resources with a student who is at a similar level of knowledge and experience as the intended end users of the DBT outputs. The multiple students who ultimately undertake the DBT experiences / challenges benefit from the enhanced nature of a learning experience which has been “road tested” and optimised.
To demonstrate the methodology the paper will describe a case study example of an individual project completed in 2015. This resulted in a DBT design challenge with a theme of designing a catapult for throwing table tennis balls, the device being made from components laser cut from medium density fibreboard (MDF). Further three different modes of operation will be described which use the same resource materials but operate over different timescales and with different learning outcomes, from an icebreaker exercise focused on developing team dynamics through to full DBT where students get an opportunity to experience the full impact of their design decisions by competing against other students with a catapult they have designed and built themselves.

An innovative electroforming process for oil heated rotational moulding tools

Rotational moulding is a method to produce hollow plastic articles. Heating is normally carried out by placing the mould into a hot air oven where the plastic material in the mould is heated. The most common cooling media are water and forced air. Due to the inefficient nature of conventional hot air ovens most of the energy supplied by the oven does not go to heat the plastic and as a consequence the procedure has very long cycle times. Direct oil heating is an effective alternative in order to achieve better energy efficiency and cycle times. This research work has combined this technology with new innovative design of mould, applying the advantages of electroforming and rapid prototyping. Complex cavity geometries are manufactured by electroforming from a rapid prototyping mandrel. The approach involves conformal heating and cooling channels , where the oil flows into a parallel channel to the electroformed cavity (nickel or copper). Because of this the mould enables high temperature uniformity with direct heating and cooling of the electroformed shell, Uniform heating and cooling is important not only for good quality parts but also for good uniform wall thickness distribution in the rotationally moulded part. The experimental work with the manufactured prototype mould has enabled analysis of the thermal uniformity in the cavity, under different temperatures. Copyright © 2008 by ASME.