crossing the chasm between ecad and cae - dfr · pdf filecrossing the chasm between ecad and...

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Crossing the Chasm Between ECAD and CAE


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


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)


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


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


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


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


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


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


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


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


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


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


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


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


Questions?

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