In today’s market, end users are always demanding more from their pumps. New technologies must meet specific system requirements, keep maintenance costs low, ensure long product life and save energy. Manufacturing companies face increasing costs for material and energy in a market that has become competitive on a global scale. As industrial, agricultural and pharmaceutical applications become more complex, manufacturers strive to keep up by designing more advanced equipment and filling the market gap as quickly as possible. Few manufacturers know the installation or application environment before designing their pumps. Desert or ocean, high-density seawater or freshwater—the challenge for designers is to build a product that can adapt to multiple applications while still meeting requirements. This calls for proper product validation and verification.
SaaS platforms break down IT infrastructure barriers for designers and engineers.
12/16/2014
Figure 1. CAD model of an adapted design (Images and graphics courtesy of SimScale)
From an early-stage evaluation of a new product design to a final manufacturing test, simulation aids manufacturers in determining the product’s effectiveness and range of applications. Simulation software allows engineers to test their products under near-real-life conditions, such as different operating points or fluid types.
The simulation results reveal the feasibility of a particular design and often influence the final technical parameters of a new pump product.
Manufacturers can identify and correct design flaws early in the development process. Modern simulation software demonstrates results in 3-D so that data sets are easier to understand and analyze.
Figure 2. Streamline visualization of the velocity field
Figure 3. Pressure distribution in the middle section of the fan, where red indicates high pressure and green indicates low pressure
Confronted with these costs, small and midsized companies hesitate to invest in large-scale simulation capacity.
Figure 4. CAD model shown via Web browser
A SaaS software product can be accessed via a Web browser. When logged into the online simulation platform, engineers can upload their 3-D design model, set simulation conditions and create as many simulation runs as possible within the total computing power. These simulations are carried out in remote computing centers. As soon as the simulation is finished, the results can be viewed in 3-D on the same webpage.
Web browser capability means the local computer is no longer blocked by running the simulation. The engineer can flexibly switch to the next task or work on the next simulation. When notifications are activated, an email will inform the engineer once the simulation is complete. Because projects differ in size and time requirements, manufacturers can also choose the amount of computing power they need, from one computing core over several workstations to complete clusters. Core computing time can be customized from several months to years, and storage space can be expanded from several gigabytes to unlimited capacity. This flexible, pay-as-you-go model can better fit the users’ needs.
Figure 5. Streamline visualization of fluid velocity
In the following case study, design changes to an existing radial fan were analyzed using the flow simulation capabilities of a SaaS platform. The most important question was whether the new fan design would meet the expected performance characteristics.
Figure 6. Glyph visualization of the velocity direction with color indicating pressure level
Figure 3 shows the pressure field in the middle section of the fan housing. Red indicates high pressure, green low pressure. The pressure clearly increases across the rotating fan blades. According to the simulation, the design changes led to the desired higher volume flux while respecting power consumption and pressure requirements.
Figure 7. Streamline visualization of the fluid velocity in cut view
As SaaS becomes more prevalent in general software domains, the technology will spread further into engineering work.
Pump designers and manufacturers can benefit from lower costs, greater efficiency, faster product development and higher product performance. For this reason, more and more engineers are joining this new trend, testing the software for themselves and considering it a valid option to use in their development projects.