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Simulation Templates Promote Consistent Simulation Methods and Accuracy

ANSYS ACT simulation templates standardized the simulation methods at WEG.

As companies grow, they will need to ensure that new employees are quickly up to speed with their simulation standards and methods. However, relying on simulation experts to teach this new crowd can become cumbersome or introduce variability into workflows. Additionally, what do you do when those experts retire?

The motor design team at WEG Industries is one of the countless organizations dealing with this challenge.

“WEG is continuously increasing its development team around the world and most of our engineers are able to perform simulations,” said Anne Karollyne Petry, development engineer at WEG. “However, we were having trouble making sure our engineers would follow the same simulation methodologies. This was concerning as our structural analyses make sure that our motors are optimized, safe and of high quality.”

To address this challenge, Petry coordinated a team that created ANSYS ACT simulation templates to assess motor components. The simulation expertise passed on through these templates ensure that methodologies are standardized indefinitely. By standardizing these simulation methods, the ACT simulation templates ensure motor part quality.

How to Prioritize Which Simulations to Template

ACT simulation templates help WEG designers follow proper methodologies, so their results are similar and closer to reality.

Petry´s team performed a benchmark analysis to assess motor components simulation results from different members of the development team.

“The results were a wake-up call: simulation results would differ from experimental data and between users from 42% to 85%. We were really concerned about it,” says Petry. “Even with internal standards and written procedures, our engineers could still simulate the problems — and process the results — in different ways.”

First, the team divided the simulation template project into stages to ensure that the greatest number of simulations performed at WEG would fall into scope. Then, the team prioritized which simulations would be made into ACT templates based on how often they were used and how much they contributed to a motor’s safety and quality.

Once these simulation templates were completed, the team trained other designers to use them. As each batch of simulations are made into ACT templates, the motor design team’s productivity, consistency and accuracy will improve.

“The same users performed the same analysis once the ACT simulation template was created,” says Petry. “This time, the results differed from experimental data, and between users, by 11% to 13%. Therefore, we are able to guarantee that our simulation processes and criteria are standardized, precise and reliable.”

The Benefits of Standard Simulation Methods Using Simulation Templates

WEG ACT simulation templates standardize reporting so it’s easier to compare results.

Simulation accuracy and consistency weren’t the only benefits from WEG’s ACT simulation templates. WEG also found that engineers using the templates needed to perform 58% less steps than if they performed the same simulation manually.

The templates also standardized how WEG designers pre-process, post-process and report the simulation results.

The templates simplify the design process, reducing the chance of introducing errors into the simulation. They also cut the processing time by reducing the number of steps to set up and post-process the data.

In fact, the team noted that the time to simulate components fell by about 66%. That represents up to 10,000 work-hours in one year.

“Having a standard simulation method for everyone to simulate, process and report results also made it easier to optimize and compare results,” says Petry. “In general, simulation templates really streamlined development.”

To learn more about ANSYS ACT simulation templates, read the product page. Or, watch one of WEG´s templates in action below:

Watch a WEG simulation template in action.