Fewer development loops, more flexibility

Thomas relies on simulation in product development

Simulation is an important strategic component in product development at Thomas. The advantages are obvious: shorter development times, more flexibility and reduced development costs. CADFEM supports Thomas in the development of sophisticated simulation workflows. The latest project: an NVH analysis using acoustic simulation.

Product development and simulation go hand in hand at Thomas. “We integrate simulation tools as early as possible in product development in order to create the optimal design virtually,” says Dr. Jochen Hebel, Simulation Engineer at Thomas. Throughout the agile development process, simulation engineers cooperate and interact with designers, test engineers and process planners. Advantages of this interdisciplinary approach include high-quality prototypes, more flexibility in development, and the ability to quickly meet specific customer requirements. In addition, Thomas can benefit from reduced development costs. “Everything that we try out and clarify in advance in the simulation, we no longer have to test in prototyping. This allows us to save development loops, time and costs,” explains Dr. Hebel.

CADFEM and Ansys: Partners for Simulation

Simply remaining status quo is not an option for the company. Thomas manufactures products that control fluids in the customer's system. The company is now a holistic system supplier for customers in various technology-intensive industries, such as the automotive and mobile hydraulics industries. “We are constantly developing. In recent years, we have increasingly integrated the topic of simulation into our everyday work. CADFEM has accompanied us on this journey as a reliable partner,” explains Dr. Matthias Krug, Director of Simulation and Development Testing at Thomas. Together with CADFEM and the tools from Ansys, Thomas focuses on simulation in electromagnetics, system simulation and structural mechanics, which also includes acoustics.

NVH analysis through acoustic simulation

Having attended several seminars at CADFEM in the field of acoustic simulation, employees came up with the idea of performing an NVH (Noise, Vibration, Harshness) analysis using simulation. “Through our seminars, we help our customers become champions. In concrete terms, we pick them up where they are at the moment. Then we provide them with knowledge that will ultimately enable them to use the appropriate simulation tools themselves,” explains Dr. Marold Moosrainer, Head of Professional Development at CADFEM. CADFEM was also able to fulfil this requirement with Thomas. Through the acoustics training courses, employees built up know-how in the field of acoustic simulation, giving them fresh impulses and the idea to use this technology for the tank leakage module as well.

This project required more than standard knowledge; CADFEM, building on Ansys simulation tools, supported us with a creative, technically beautiful and feasible approach.

Dr. Matthias Krug, Director of Simulation and Development Testing at Thomas

Agile development with interdisciplinary teams

“We started talking to CADFEM and together we found out whether and how they could support us with these questions about the tank leakage module, which went far beyond standard simulations,” says Dr. Hebel. The two partners quickly launched the agile project when it became clear that a simulation workflow was the right solution. On Thomas’ side, agile development means that, depending on the issue, interdisciplinary teams form to responsibly make goal-oriented decisions or work out recommendations for action. The knowledge of this project team perfectly complemented the know-how of CADFEM’s simulation experts.

Acoustic simulation: creative solution

“This project required more than standard knowledge; CADFEM, building on Ansys simulation tools, supported us with a creative, technically beautiful and feasible approach,” says Dr. Krug. Specifically, the solution consisted of a sequence, starting with a transient workflow and ending with an acoustic simulation with various intermediate steps. Above all, the evaluations beyond the transient simulation to get at the core acoustic variables were of particular importance. “We discussed our requirements and workflow, shared our models, materials and measurement data accordingly. CADFEM then provided the solution for the implementation,” says Dr. Hebel. The tool is already in use at Thomas: “We can use it to specifically analyze which components contribute to structure-borne noise,” explains Dr. Hebel. This gives developers quick and valuable insights that would be difficult to capture through testing.

We integrate simulation tools as early as possible in product development in order to create the optimal design virtually.

Dr. Jochen Hebel, Simulation Engineer at Thomas

Open exchange and proactive knowledge sharing

Thomas also feels this passion for details and the success of simulation in everyday work. “We have appreciated the helpful and open exchange with CADFEM for many years. We are not only provided with software, but also experience real knowledge transfer in the form of trainings and support. Furthermore, we appreciate the proactivity of CADFEM. Our contact person in the sales department constantly updates us and we receive first-hand news. This is what a really successful partnership looks like,” Dr. Krug sums up. The successful and sustainable use of simulation requires more than “just” the right software. It requires a holistic concept, forward-looking action and the cumulative know-how of a successful cooperation.

Shared corporate values - successful partnership

“Our corporate values are Honesty - Courage - Helping. We live them every day. We feel that partners like CADFEM act according to these same principles,” says Dr. Krug. Thomas and CADFEM have a partnership that extends beyond specific projects. The companies are in constant exchange via CADFEM sales and support, as well as through training offerings. “It is exciting to accompany Thomas over so many years and to follow the development in terms of simulation in the company. Thomas recognized the fundamental strategic value of simulation many years ago, both in terms of technological and economic benefits. With the support of the entire technical expert team, we assist them in bringing the appropriate simulation tools into the company. Development engineers and decision-makers at Thomas are always open to an exchange with CADFEM,” says Dr. Dirk Peters, Account Manager at CADFEM.

Simulation tool adaptable to other prototypes

Convinced by the result, Dr. Hebel states, “we can use this workflow in the future to further advance the field of acoustics simulation and will adapt the tool to other prototypes in future developments.” Support from CADFEM is also available beyond the project, allowing Thomas to benefit from a sustainable build-up of knowledge. The company sees the basis for long-term partnerships above all in shared values and goals.

We can use this workflow in the future to further advance the field of acoustics simulation and will adapt the tool to other prototypes in future developments.

Dr. Jochen Hebel, Simulation Engineer at Thomas

Holistic projects for sustainable simulation successes

As with all projects that CADFEM accompanies, the focus was on knowledge transfer. “For us it is important not only to provide the right solution for our customers, but also the necessary know-how. The workflow we developed for Thomas did not yet exist in this form. That’s why we combined a great deal of theoretical knowledge and software expertise. It was important to think about the transfer of know-how right from the start… we also developed a solution that Thomas can now use itself, and adapt for various applications,” says Markus Meingast, Team Leader of Technology at CADFEM in Grafing. In the acoustics project, knowledge transfer took place through constant exchange between the project partners, as well as in the form of a workshop and detailed project documentation.