Ansys + Grundfos

“Simulation is critical R&D infrastructure for Grundfos. It is one of the key components of our ability to be a market leader in efficiency, robustness, and sustainability. During the last 10 years of simulation adoption, we have scaled from a few specialists to hundreds of engineers adopting simulations, and thereby transformed how we conceptualize, design, and verify our products.” 

— Anders Bøge Jensen
Head of Mechanical Module Technology, Grundfos

Engineering Solutions 

During the last decade, Grundfos has integrated tools that democratize simulation, including the Ansys Workbench simulation integration platform, Ansys Mechanical FEA software, Ansys Discovery 3D product simulation software for conceptual design, and Ansys optiSLang process integration and design optimization software. EDRMedeso, an Ansys Elite Channel Partner, has provided training and support.

For example, Grundfos engineers developed what they call a “virtual product simulator” based on the Workbench platform, Microsoft Excel inputs, and integrations with Grundfos’ native computer-aided design (CAD) platform. Team members select the variant, and the application automatically configures correct loads and materials, running different load cases to verify structural robustness, including durability and static strength for a complete pump. It automates verification across thousands of pump variants, reducing manual effort and improving consistency.

Other vertical apps created for FEA simulations include tools for reports, impellers, pump housing, and composite components. They also use Ansys HPC solutions for scalability.

Benefits

Grundfos ensures robust and efficient products with less reliance on physical testing by integrating simulation and workflow automation throughout their concept, design, and verification phases. They realized:

• Accelerated simulation workflow for select vertical apps, including up to an 85% reduction in simulation efforts and a 95% reduction in simulation lead time.
• Improved product reliability with lower warranty rates and fewer market failures
• Greater scalability with the ability to evaluate thousands of product configurations virtually
• Increased sustainability with fewer prototypes, reduced test energy consumption, and more energy-efficient pump designs

“We have one example where we can produce to stock maybe half a year earlier than if we didn’t use the simulations because we trust the simulation so much that we can build up the stock in advance, go to market earlier, and save money in that way,” says Brian Lundsted Poulsen, Chief Mechanical Simulation Specialist at Grundfos. “We can also cut down on some of the tests, which can be really expensive for these products and consume a lot of power. So, if we can just take out a few of these robustness tests, it will have a large impact on sustainability and operational R&D costs.”

Images and graphics