Innovative Engineering Practices Transforming Modern Industries

Engineers spearhead new developments that are shaping our society. From advanced robotics to sustainable energy systems, mechanical engineers develop cutting-edge engineering methods to solve complex problems in design, production and sustainability.

This article will explore advances in engineering innovation that organizations use to facilitate progress.

AI and Machine Learning in Engineering Design

Artificial intelligence (AI) and machine learning technologies underpin many modern engineering techniques. They can accelerate mechanical engineering workflows for faster product development. For example, generative AI can create rapid prototypes based on specifications and data inputs. Mechanical engineers can then refine the designs based on AI models and performance information.¹

AI algorithms can improve product performance and functionality based on real-time and historical data. Incorporating real-time error detection can allow equipment to adapt and maintain itself. AI programs can also monitor equipment to determine when it needs preventative maintenance. This allows operators to optimize performance by servicing equipment before it breaks down, reducing downtime and lost revenue.¹

Mechanical engineers use AI to improve decision-making in product development. By analyzing virtual models or data from existing products, AI programs can suggest refinements to improve product design and decrease costs.¹

Smart Manufacturing and Industry 4.0

Modern history has seen four industrial revolutions, and mechanical engineers have been at the forefront of each one. The first was powered by water and steam. The second introduced assembly lines and oil, gas and electric energy. The third incorporated computers and telecommunications into the manufacturing process. The fourth, known as Industry 4.0 or smart manufacturing, is building on the progress of the first three by incorporating connected sensors that collect data to optimize all aspects of manufacturing.²

Internet of Things (IoT)

Manufacturers are integrating Internet of Things (IoT) technology, cloud computing and robotics into the manufacturing process. IoT sensors in equipment can collect data that can be analyzed and utilized for improved decision-making and real-time monitoring of equipment performance.

Business leaders can use sensor data to determine when machines need proactive maintenance. This allows them to service equipment before it malfunctions and causes unanticipated downtime. By creating a network of interconnected equipment and products, manufacturers can optimize production processes, minimize waste and reduce costs.²

Automation and Robotics

Automation and robotics are also major elements of smart manufacturing. Producing quality products in high-volume manufacturing relies on precision. Robots are capable of more precise and repetitive movements than humans, making them a valuable addition to manufacturing facilities. They can also work in hazardous conditions, reducing the danger to human workers. As robotic and automation capabilities continue to grow, workplaces of the future will feature a seamless integration of human and robotic workers.³

Digital Twins

Digital twins are virtual models of equipment that mechanical engineers can use to simulate and optimize production. Sensors on the physical model collect data that's automatically transferred to the digital model. The model lasts throughout the product’s lifecycle and is updated in real time to accurately reflect the condition of the equipment. Engineers can use the digital copy to run tests and analyze performance. They can make changes to the digital twin and test it virtually to see if they can optimize its performance. Modeling these changes virtually before implementing them on the physical equipment is cheaper and easier. Engineers don't have to interrupt operations to run tests and make changes that may not be effective.⁴

Edge Computing

 
Smart manufacturing is characterized by the massive amounts of data it produces. Although this is what underlies many capabilities, it also puts a strain on processing power. Cloud computing allows manufacturers to offload data storage and processing to remote data centers. While this saves time and money compared to handling these functions on-premises, it can slow down performance. Edge computing moves storage and processing applications closer to where the data is collected in a distributed network. If a manufacturer has several locations, it can use servers that are physically closer to each location. This reduces the time it takes for data to travel to servers, so engineers can achieve faster insights into the production process.²

Sustainable Engineering Practices

Mechanical engineers are leading the effort to design energy-efficient systems and renewable energy technology. Sustainable engineering practices work to optimize efficiency while reducing environmental impact. Engineers are developing solar, wind and thermal energy projects to reduce carbon emissions and help reverse climate change. For example, Flexi-wings increase the efficiency of wind turbines by optimizing the pitch angle, which is the angle of the turbine blade in relation to the wind. Previously, wind turbines were only efficient if the wind was blowing at the perfect angle. Flexi-wings improve wind turbine efficiency by 35%.⁵

Engineers contribute to a circular economy–a system designed to minimize waste by keeping resources in use as long as possible. Concrete is a good example of this in action. Bioconcrete and green concrete are designed to use biological materials in manufacturing. Bioconcrete incorporates bacteria that produce limestone. This allows it to self-heal by repairing its own cracks. Green concrete is manufactured using waste materials. It’s less expensive to produce while maintaining durability.⁵

Advanced Simulation and Modeling Techniques

Simulation and modeling techniques allow engineers to design and optimize products virtually. Finite element analysis (FEA) and computational fluid dynamics (CFD) are both examples of computer-aided engineering. FEA simplifies complex models by breaking them down into smaller parts to mathematically model behavior. This allows engineers to conduct structural, thermal and vibrational analysis on products as well as predict future failure. CFD is used to solve fluid dynamics problems in aerodynamics, HVAC systems, combustion, chemical processing and biomedical applications.⁶

These and other modeling and simulation programs can be used for virtual prototyping, testing, and validation. Producing physical prototypes is an expensive and cumbersome process. Virtual prototyping can cut down on the time and expense associated with creating viable products. Although virtual prototyping doesn’t completely eliminate physical models, it does move the process of creating physical prototypes to the later stages of the design cycle. By virtually prototyping earlier in the process, you can improve performance and reduce the cost of your design.⁷

Advanced simulations aren’t just effective for design and prototyping. They’re also an effective method of analyzing equipment health and performance. Digital simulations, such as digital twins, allow engineers to design better models based on flaws in existing ones.

Build the Technology of the Future

The online Master of Science in Mechanical Engineering program from Case Western Reserve University can equip you with the skills and knowledge you need to become an innovative leader in mechanical engineering. You can advance your career from the convenience of your home while you learn from industry experts. Our rigorous curriculum is taught by expert faculty and provides practical, hands-on experience with relevant projects. With a tuition reduction for new online students, it’s never been more affordable to take your career to the next level.

Making connections with peers, faculty, and alumni during your master's program will lead to relationships that will last throughout your career. Throughout your program, you can build your network while you gain a deep technical expertise. Contact one of our admissions outreach advisors today to learn more.