Flow meters designed by VSE Volumentechnik help customers around the world to ensure that their technical systems and processes are running smoothly, by measuring such fluid characteristics as volume flow rates, pressure, temperature and materials concentrations. These sensitive measurement systems indicate whether hydraulics are operating under optimal conditions, whether pipelines are running at maximum capacity, and whether additives are being properly injected into primary fluids, among other industrial applications.
While there are many ways to measure fluid flows, VSE instruments are based on the positive displacement principle. The fundamental design of these flow meters includes a pair of gears that are continually rotated by the fluid flowing through the instrument. The gear rotation is detected, producing a pulse output, the frequency of which is proportional to the flow rate.
Gear-based flow meters provide a precise and efficient fluid measuring system, but have traditionally included some application drawbacks; specifically, these have included noise, vibration and pressure loss across the gear/fluid interface. This can cause discomfort for personnel working nearby as well as excessive wear on flow meter gears and bearings. VSE Volumentechnik technical director, Axel Vedder takes up the story.
“Because our instruments are designed to operate in small, fluid-filled spaces, it is difficult to analyse them under actual working conditions. The Ansys software has allowed us to assess the performance of our flow meters in a virtual environment that accurately replicates real-world operating conditions. We were quickly able to identify, and address, the relevant design issues.”
With the help of the Ansys simulation software, VSE has been able to address these user concerns and introduce new product features that have significantly reduced noise output, vibration and negative pressure effects. Ansys meshing technology enabled the product development engineers to create three-dimensional virtual models of flow meters and then animate gear movement within a typical customer application. They were then able to isolate those gear surface segments that were creating the greatest torque and contributing to the noise, vibration and pressure loss problems.
The German firm intends to continue using software from Ansys to assess and improve specific aspects of its product designs. The ultimate goal is to optimise the performance of its flow meters, creating a significant competitive advantage and potentially creating new applications for this fluid measurement technology. Dipankar Choudhury is vice president, corporate product strategy and planning at Ansys.
“There is little room for error in this industry, as many industrial processes around the world rely upon highly accurate fluid flow measurement,” he says. “To fulfil this demand, flow meters must meet stringent requirements and be robust and reliable, all the time providing precise measurements. The design enhancements that VSE engineered are certain to have a far-reaching impact. Ansys technology has helped this leading instrument manufacturer to virtually assess all the detailed aspects of its products, under real-world operating conditions, and then arrive at design improvements that will only reinforce its leadership position.”