Computer modeling is hot in a variety of industries that need to work out part construction and placement prior to building a physical model. In the hydraulics industry, computer modeling applications are used to design important parts like cylinders and couplers.
In the hydraulics industry, computer modeling provides an advantage by increasing accuracy and solving complex problems like fluid leaks.
Computer modeling, sometimes called computer aided process engineering, is the backbone of the hydraulics industry and provides the following advantages:
- Cost savings by preventing leaks
Companies that rely on hydraulic-powered machinery and equipment can’t afford to use inferior or ill-fitting parts. However, standard parts don’t always work for every piece of equipment. Using the wrong part can result in uncontrollable leaks. That’s why companies like Stucchi USA build high-quality custom specialty couplers to meet specific customer needs.
Hydraulic leaks are costly
Nothing costs companies more than major hydraulic leaks and spills. In addition to replacing multiple components, a company might face hefty fines for contaminating the environment. For instance, an energy company in Pennsylvania was fined more than $1 million for contaminating county water supplies. While this fine was admittedly larger than usual, even a $10,000 fine can harm a business.
Not all leaks are caused by human error. Computer modeling helps reduce the potential for leaks by ensuring hydraulic parts are a perfect, leak-free fit.
- Better research and design
Computer modeling is used throughout the research and design phases of a project. Engineerlive.com explains the various tools used throughout a project. Specifically, parts like valves, actuators, and manifolds are designed using CAD (Computer Aided Design) and CFD (Computational Fluid Dynamics) software while the design is refined with FEA (Finite Element Analysis).
CFD utilizes numerical analysis and data structures to optimize the way fluid moves through a hydraulic system. To solve a fluid flow problem, the computer makes calculations based on input data that simulates how particular fluids flow and interact with different materials.
Using advanced FEA is equally critical to hydraulic performance. For example, when a hydraulic cylinder fails, there might be a design flaw. FEA software can help determine that flaw. For example, FEA modeling will uncover a cylinder’s weakness and determine how it will be affected when the machinery is in use. FEA software provides a detailed visual of components, including where they bend, how the stress is distributed, and any displacements that may occur.
Getting a visual of components is critical because sometimes a cylinder fails simply because it was faulty and it just needs to be replaced. Other times, there’s a deeper reason for the failure and replacing the cylinder won’t fix the problem.
Solving problems with CAD, CFD, and FEA software will not only save a company money, but will prevent unnecessary leaks that can turn into costly environmental disasters.
- Seamless systems integration
Hydraulics companies use their own proprietary modeling systems alongside other software programs to integrate hydraulic, mechanical, and electrical systems. All of these components need proper integration to avoid problems and it’s all accomplished with computer modeling software.
- Extended system life
Hydraulic systems don’t typically last forever, but the life of a system can be optimized and increased using computer modeling.
The computers used in computer modeling programs are powerful enough to crunch large amounts of data and provide insights that improve durability and performance. A model of an existing system can be created to simulate usage over time under specific conditions to predict what parts will fail first and how those parts will fail. This provides the insight necessary to construct more durable parts that won’t fail as fast. Or, at minimum, companies can expect to replace those parts every so often.
- More certainty
In a world where uncertainty lies around every corner, computer modeling software – especially CFD – provides more certainty around the final design. Nobody can ever have 100% certainty, but computer modeling drastically reduces a large amount of uncertainty in the design process before the hydraulic components are built and tested in the physical world.
Computer modeling is the future
In addition to hydraulics, many industries have already embraced using computers to build and assemble components. The benefits are clear and computer modeling is the future of the industrial world.