Real versus virtual prototypes

Once the final prototype has been obtained, manufacturing specifications are generated and the real device is built. The transition from virtual to real device calls for different manufacturing processes, which can have a direct impact on performance. In fact, during dimensioning stages such as simulation or optimization, geometric dimensions are usually considered nominal, i.e. without the uncertainties associated with the various manufacturing stages. However, during the various manufacturing stages, cutting tolerances and imperfections in shaping and assembly lead to deviations from these nominal dimensions (air gap inhomogeneity, imperfect rotor alignment, etc.), which can affect the quality of physical quantities. In addition, there are potentially non-negligible effects on the operating characteristics of materials, resulting in more or less significant degradation of the latter and,...