Simulation is more than Software

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Identification and optimization of important influencing variables

Parameters put to the test

GEMÜ is one of the top choices globally for process media control. The development of valve, measurement and control systems is carried out according to the latest methods. Innovation, digitalization and Industry 4.0 are standard practice and numerical simulations are firmly established – for example, to optimize the performance of products and processes based on parameters.

The response spectrum is clearly displayed

As an innovative partner of the global process industry, the GEMÜ Group stands for efficient solutions in the field of valve, measurement and control technology for liquids, vapors and gases. The owner-managed company, headquartered in Ingelfingen in Baden-Württemberg, Germany, is active on all continents. With more than 2,400 employees, the GEMÜ Group is continuously growing and investing in the company's future. This philosophy is demonstrated, among other things, by the founding and promotion of start-ups, the development of state-of-the-art manufacturing, logistics and administrative infrastructures, and renowned industry awards such as the “ACHEMA Innovation Award”.

At GEMÜ, digital transformation can be felt everywhere, as clever digitized processes, virtual reality (VR) and forward-looking Industry 4.0 solutions have long been a reality. For example, GEMÜ uses VR applications for interactive, virtual training of its customers’ service technicians. This promotes handling and understanding when dealing with GEMÜ products.

> 50
Countries
Presence as of 2022
> 2400
Employees
as of 2022
> 450
€ Mio Turnover
2021

Simulation in research and development

GEMÜ has been using digital tools in the research and development area for quite a while now. At the development site in Niedernhall-Waldzimmern, new trends and developments are closely followed by engineers, evaluated and - if they prove successful - quickly put into practice.

This is where CADFEM comes into play. GEMÜ has had a partnership with the simulation specialist since 2017, whereby the efficient use of Ansys solutions has been continuously intensified and expanded. This wide simulation spectrum ranges from structural mechanics with Ansys Mechanical, to flow with Ansys Fluent and electromagnetics with Ansys Maxwell, to system and multiphysics applications.

Optimization of key influencing factors

Ansys optiSLang was introduced at the beginning of 2020. The reason for this was the belief that the significant parameters of products and systems must be known very early and very clearly in order to achieve the best possible performance at the end of the development process.

Precisely this identification of the relevant influencing factors and their subsequent robust optimization that is the task of Ansys optiSLang. The integration of the solution in Ansys Workbench also paves the way for the simple coupling of different physical domains and opens up enormous optimization possibilities for the GEMÜ team in the development and evaluation phase across the entire product range.

With the combination of simple parameter handling in the workbench and Ansys optiSLang, even coupled simulation models can be examined and optimized without any problems.  

Range of applications of Ansys optiSLang

Ansys optiSLang is used in various technical departments at GEMÜ. The special feature – the application of the software is not limited to the field of numerical simulation. In order to address experimental questions and issues, Ansys optiSLang is repeatedly used by test engineers. Within the framework of numerical simulation in the product development process, GEMÜ developers carry out complex sensitivity studies with Ansys optiSLang.

The stochastically generated design space is represented automatically and extremely efficiently with the help of the software, even when a very large number of relevant input variables is involved. The relationship between inputs and outputs of a physical system to be examined can already be reliably evaluated with a manageable number of calculated design points. 

 Marco Wissinger<br />Development Engineer Global R&D, Research & Pre-Development General, GEMÜ Group
Marco Wissinger
Development Engineer Global R&D, Research & Pre-Development General, GEMÜ Group

"Ansys optiSLang enables us to identify the relevant product performance parameters early in the development process and thus perform robust optimizations."

The value of Ansys optiSLang

Ansys optiSLang also turns out to be the right tool when evaluating the generated results. In addition to the previously mentioned integration into the Ansys Workbench, the standalone version of the software offers a very big advantage in terms of creating automatic workflows for simulations.

Before the use of Ansys optiSLang, the systematic analysis of geometrical or physical variables influencing the products or processes at GEMÜ was usually a tedious process. With the help of the software, you are now able to create a meaningful sampling in a fast and efficient way, which is suitable for the analysis of both the numerical and the real, i.e. the experimental world.

Direct integration in Ansys Workbench

Ansys optiSLang can be used directly in connection with Ansys Workbench. Thus, the software represents a great added value, especially for Ansys users. The information that Ansys optiSLang supplies is based on a set that consists of extremely powerful, but also very complex algorithms in the background. Users at GEMÜ particularly appreciate that the software architects at Ansys have managed to offer a clear and self-explanatory user interface and display of results.

Even first-time users find it easy to use Ansys optiSLang. Thanks to the Ansys optiSlang Excel add-in, the results obtained can also be made available to a wide range of people for active use in a well-known format.

Use case: Additive manufacturing

A current application of Ansys optiSLang at GEMÜ is about parameter characterization in an additive manufacturing process. With the help of the software, the process parameters are varied in a targeted manner and their influence on the quality of relevant process variables is determined. The aim is to determine the optimal process parameter setting for the individual application.

The role of CADFEM in connection with optiSLang

As with all topics relating to Ansys and simulation, at GEMÜ, CADFEM is a sought-after source of knowledge and advisor for Ansys optiSLang, so that such a solution can be used in the most optimal way. Particularly when complicated support requests arise, it becomes apparent how important it is to have quick and direct access to experienced experts. It will also be crucial for future development projects to work with CADFEM to solve problems that arise and to discuss new concepts. In the case of Ansys optiSLang, GEMÜ has had the experience of being able to use the full potential of the software with this support and thus to distinguish itself from the competition through new developments with unique selling points.

GEMÜ and CADFEM

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG and CADFEM have been working together in the field of simulation since 2017. The starting point of the partnership was a project on the simulation-based digital twin for real-time monitoring of plants. Since then, simulation with Ansys and CADFEM has been rapidly expanded at GEMÜ and, in addition to structural mechanics and flow, also includes applications in the areas of electromagnetism, systems, and additive manufacturing. To ensure smooth use of the software, GEMÜ takes advantage of training offers via the CADFEM Learning Subscription, user support and consulting offers, when new simulation fields are tackled.

www.gemu-group.com

Authors:
Marco Wissinger (GEMÜ)
Alexander Kunz (CADFEM GmbH)
Images: © GEMÜ
Published: October, 2022

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