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Banco Products India Ltd.: Reducing Physical Prototyping with IoT
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
- Sensors - Environmental Sensors
Applicable Industries
- Automotive
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Virtual Prototyping & Product Testing
- Virtual Reality
Services
- Hardware Design & Engineering Services
- Testing & Certification
The Challenge
Banco Products India Ltd., a leading manufacturer and supplier of equipment such as engine cooling systems and sealing gaskets, faced a significant challenge in the development of their radiators. Radiators, key components in automotive engine cooling systems, must be designed to meet a wide range of conditions due to the diversity of vehicles. The radiator's complex geometry, which includes several thin sheets with thousands of dimples in the radiator core, is required to meet cooling performance and strength requirements. This complexity made simulation difficult. Furthermore, radiator performance is usually determined by the coolant outlet temperature, and Banco designs several types of radiators to meet the cooling requirements of various vehicles. Physically testing each design was not only time-consuming but also costly.
About The Customer
Banco Products India Ltd. is a leading manufacturer and supplier of equipment such as engine cooling systems and sealing gaskets for commercial vehicles, passenger vehicles, and industrial products. The company is one of India’s largest exporters of aftermarket radiators to Europe, with a growing presence in North America, the Middle-East, Africa, and South America. They design a range of radiators that must operate reliably under a wide range of conditions, catering to the diverse cooling requirements of various vehicles.
The Solution
To overcome these challenges, Banco developed an engineering approach to effectively use simulation for design. They employed the ANSYS product family to prepare the complex geometry for simulation. The CAD geometry was cleaned up in ANSYS DesignModeler within ANSYS Workbench, and high-quality meshes were generated using ANSYS meshing capabilities to obtain accurate CFD results. The coolant outlet temperature was accurately predicted using ANSYS Fluent technology, accelerated by ANSYS HPC. Additionally, the natural frequency for the radiator was determined, and stress analysis of the radiator header tanks was performed using ANSYS Mechanical. This approach not only reduced the need for physical prototyping but also delivered cost savings, met higher performance and strength targets, and accelerated product development.
Operational Impact
Quantitative Benefit
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