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Farewell, Prototype Testing

Posted December 02, 2010 7:38 AM

The more sophisticated computer simulation programming gets, the more engineers depend on them, and less on physical verification. Should we worry about going too far, about the temptation to do away with physical, real-world testing of prototypes altogether?

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#1

Re: Farewell, Prototype Testing

12/02/2010 5:10 PM

Just take a look at how many common simple items are designed in a virtual environment and then cause massive safety recalls because they where never fully or properly tested in a real world usage environment.

How many billions of dollars a year get waisted because of that?

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#3
In reply to #1

Re: Farewell, Prototype Testing

12/02/2010 10:38 PM

I like yout bi-line... dead on!

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#2

Re: Farewell, Prototype Testing

12/02/2010 10:29 PM

No knowledgeable engineer is EVER going to rely solely on a computer simulation. Simulations are approximations. There is no guarantee that the simulation is giving you valid results- until you validate the results with real-world testing. Those who believe something is going to perform exactly as a simulation are not long for this world...

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#9
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Re: Farewell, Prototype Testing

12/20/2010 11:27 PM

Like the world Climate scam...I mean climate change industry?

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#10
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Re: Farewell, Prototype Testing

12/22/2010 7:07 PM
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#11
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Re: Farewell, Prototype Testing

12/22/2010 7:30 PM

Believe or disbelieve as you see fit. It is in the nature of the vast bulk of current humanity to either disbelieve, not care or not notice. Whatever the truth is it is highly unlikely that civilized humanity will muster any meaningful response that will slow the current conditions that cause ocean levels to rise and the resultant shift in climate patterns.

So if you disbelieve you will have plenty of company. But best to avoid long term commitments to ocean front property and desert farmland dependent on irrigated agriculture to support it.

Ed Weldon

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#12
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Re: Farewell, Prototype Testing

12/23/2010 8:55 PM

The wife has been after me for years to buy a beachfront property. I keep telling her, depending on who we choose to believe, our current residence will be ocean front within the next 25 to 75 years or so, although the beach will be obscured by all those abandoned buildings that now stand in the way. On the other hand, think of the wonderful fish habitat Manhattan will make...

The current increase in greenhouse gases, and subsequent global warming, are NOT unprecedented- man just hasn't been around long enough to record the data accurately. This was quite obvious in the original UN Climate report (in the section on paleoclimate). I don't know if this has been removed from subsequent versions of the report.

There have also been studies suggesting that human-induced climate change can be detected more than 5000 years ago, long before the adoption of fossil fuels- resulting from deforestation of large areas of Eurasia for agriculture. This information has been suppressed by the climate community.

Planting trees is a whole lot cheaper, and a whole lot more reliable than trying to pump excess carbon underground- and, with the money one could save (based on the projected cost of one project for which data is available, located in Illinois), one could probably build at least two nuclear power plants along the proven design scheme used in France or Japan, without having to re-invent anything.

I have no hope that the world governments will be able to come up with an appropriate response to the existing "climate crisis". I, for one, am a strong advocate of a warmer world. Look at the globe- look at how much valuable farming real estate becomes available in the Northern Hemisphere as the temperate regions move north. Think of all the hunger this will present.

Global warming is far preferable to the alternative, which is global cooling (i.e., a new ice age)...

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#4

Re: Farewell, Prototype Testing

12/02/2010 10:51 PM

OK, since i retired 10 years ago, i did not have access to the superb simulation packages available now. The top item on my wish-list was a package to predict arc-quenching behaviour of circuit breakers. At least one company now has this kind of software which they had to develop themselves. Excellent. All this does is to reduce the number of actual tests on physical prototypes. The actual testing is the final proof, at least in this field of electric power. The arc is still black magic.

Now...how good is actual testing ? For example Americans have tougher standards than Europe. NEMA/UL vs IEC. SO, someting OK as per IEC may not pass NEMA without some improvements.

When testing, there are certain worst-case scenarios considered. Real life may, once in a blue moon, throw up even worse situations, causing disastrous failures.

Anyway, the new simulation packages do make life simpler for designers and companies, and reduce time to market. They will remain so i feel for at least a couple more decades.

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#5
In reply to #4

Re: Farewell, Prototype Testing

12/02/2010 11:15 PM

GA, kvsridhar. See guys, Bangalore has a lot more going for it than good western English accents on the phone.

Ed Weldon

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#6
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Re: Farewell, Prototype Testing

12/02/2010 11:27 PM

Thank you kind sir....

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#7

Re: Farewell, Prototype Testing

12/03/2010 8:27 AM

As simulation packages improve so do the options and quality of rapid prototypes. I can get my hands on a usable part often within 24 hours. Combined with computer modeling and simulation I now can quickly converge on design alternatives.

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#8

Re: Farewell, Prototype Testing

12/04/2010 2:53 PM

I'm just going to merge the thoughts I've already seen posted here because they pretty well cover it on this one...

Provided simulations are used to save time and money getting a viable prototype and not to substitute for physical prototype testing then it is a great technological boon saving resources that would otherwise go to waste. Simulations are clearly no substitute for prototype testing but they are a great tool to reduce time spent fabricating and testing ineffectual solutions.

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