Virtual product development: a single prototype is all it takes
More simulation, more innovation
Inconspicuous and indispensable: hydraulic power packs ensure the reliable transmission of large forces. HAWE Hydraulik SE from Aschheim near Munich holds its own in global competition with pioneering solutions “made in Germany”. One key to this is the intensive use of simulation technology.
HAWE engineers use comprehensive simulations to systematically explore the optimization potential of the power packs; even where you would not expect them in the hydraulics sector.
“Whether new or further development, our goal is to get by with a single prototype before a product goes into series production,” emphasizes Stefan Macho, Head of R&D Simulation, who has been driving the use of simulation in the development area of HAWE Hydraulik SE for more than ten years. With great success: HAWE solutions are ready for the market faster and in a more cost-effective way, without compromising on quality. The virtual prototypes, which are modeled, analyzed, and optimized (or simulated) on the screen, contain all the details. The ability to modify them quickly and flexibly gives developers plenty of freedom for fresh, innovative approaches.
Mastering complexity
Hydraulic power packs are far from simple products. In fact, the reliable and intelligent interaction of mechanical, fluid dynamic, acoustic and control effects is mandatory. Not only must each physical domain be managed, but the interactions between them must also be recognized, evaluated, and coordinated. This is possible with digital tools using simulation. Prototypes on the test stand quickly reach their limits. At HAWE, these test are carried out for the final validation of the digitally developed product.
With simulation, complexity becomes an opportunity for improvement, for the realization of new approaches, and for innovation. Small but important details are recognized, correlations become transparent, ideas are quickly tried out, even in areas that are not addressed by a classic development process.
HAWE Hydraulik for the highest demands
Traditionally, the components and systems from HAWE are characterized by their steel construction, suitable for extremely high pressures (up to 800 bar) and very compact design. This is achieved through a high level of vertical integration, which, among other things, ensures virtually leak-free products. Structured according to a comprehensive modular principle, HAWE hydraulic components can be found in a wide variety of application scenarios.
Virtually developed: The compact power pack type InKA
The compact hydraulic power pack InKA is characterized by its modular design. This allows different usage volumes and delivery flows to be realized quickly and easily. The example of this new development shows the contribution of various simulation applications.
InKA is compact, robust, and considerably quieter than comparable products, in part because many of the load-bearing components were calculated and virtually optimized during the development phase. Stefan Macho adds, “such a development in a narrow time window is a special challenge, considering the high demands placed on the unit. Considering its versatility and modularity, this includes thermal state behavior as well as compactness and tightness, noise reduction and reliability, not to mention the cost-conscious yet appealing design.”
Mechanics and materials
In order to achieve these goals, the stress distributions in the endplates and in the pressure collection channel were analyzed using Ansys Mechanical and also optimized by determining the best possible material for the specified pressure range.
Compactness due to flat seal
The possibility of surface pressure on seals was also analyzed and optimally designed. This is because InKA was the first in this category to be equipped with a flat seal, which contributes to the compact design. For this purpose, a reliable surface pressure had to be applied in each area. If the surface pressure were to fall below the critical level, leakage would occur, and oil would escape.
Reduced noise emissions
InKA also offers features that are often neglected in the development of the power pack but are welcome by the customer. A potential for less structure-borne noise and more efficient temperature distribution was identified in modified stiffening geometries and also realized using Ansys Mechanical. Result: InKA is approx. 7dB quieter than previous power packs in its performance class of the HAWE brand.
Thermal behavior under control
After unfeasible temperature layers appeared in the power pack during the oil recirculation process, their formation could be identified using a simulation-supported detailed analysis with Ansys Fluent and suitable measures could be taken that lead to mixing. The thermal behavior of the entire power pack is examined using a network model through system simulation, taking various defined load cycles into account.
Innovation as a fundamental approach
Click or tap here to enter text.All the optimizations mentioned (and not mentioned) are part of the overall InKA system. “Eventually, you get to the point where you realize that simulation can do more, meaning the domains have to move closer together to get even more benefit from the individual domains,” says Stefan Macho. In summary, each optimized variant can actually only be implemented once it has also proven itself in interaction with the other components and physical processes within the complete product system. Handling these interactions is practically impossible without reliable simulation technology.
The targeted further development of the hydraulic power pack type InKA is an example of the commitment to innovation embedded in the corporate principles of HAWE. The use of simulation technologies is one of the keys to this, and the close partnership with CADFEM specialists underscores HAWE's claim to always be on the cutting edge of technology and methodology. Because innovation not only refers to the products, but rather to all processes and systems at HAWE.
HAWE Hydraulik and CADFEM
For the introduction and expansion of simulation, those at HAWE Hydraulik rely on the partnership-based support of CADFEM Germany GmbH. This ranges from consulting and the procurement of the necessary Ansys software, to user support, training, and further education, to the configuration and set-up of the suitable hardware solutions. Because this system works, HAWE is always available as a reference customer.
HAWE Hydraulik SE
Author: Gerhard Friederici, Alexander Kunz
(CADFEM Germany GmbH)
Stefan Macho
(HAWE Hydraulik)
Cover Images:
Right:© HAWE Hydraulik SE
Left: © HAWE Hydraulik SE
Published: September, 2023
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