Digital twins with the Ansys Hydraulic Library

Outline

• Introduction to Digital Twins

• Key Capabilities of Twin Builder

• Technical solution Architecture

• Hydraulic library overview

• Examples

• Hybrid Digital Twins

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 What is a Digital Twin?
Past, Present, Future, Simulate!

: “Virtual representation
of real-world entities and processes,

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costs high as
%
800
synchronized at a specified frequency
1.65
$
and fidelity” M
average margin for B
aftermarket services per year – an amount industrial assets under
Customer Value: Track the past, provide compared to %
10 equal to as much as % 3 condition monitoring
by 2025
deeper insights into the present, predict for new equipment of productive revenues
and influence future behavior

Gain
Increase
Reduce Costs Competitive
Revenue
Edge
Sources:
1. “Industrial aftermarket services: Growing the core.”, McKinsey.com
2. “Controlling Warranty Costs by Preventing No Fault Found”, WIKA Group
3..Total addressable market (TAM) and compound annual growth rate (CAGR) information throughout presentation is based on third party study completed by Evaluserve Inc. in 2019 commissioned by Ansys. Study was based on customer and industry expert
interviews and review of industry analyst reports and commentaries. Refer to Cautionary Statement for a discussion of factors that could impact future financial results.

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 Addressing challenges with Ansys Twin Builder
Deploy
System
Predictive Build
Maintenance

System
Connect the Twins to IIoT Simulation
Platforms and Deploy Run times
in operation
Build an accurate Physics-based
Validate Digital Twin in record time

System Validation
and Optimization

Validate and Optimize the Twin

4
Ansys Twin Builder: Capabilities and Strengths

Hybrid Analytics for most accurate Twin

State-of-the-art reduced order modeling

Ability to deploy runtimes for Digital Twin

Interoperability support

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Our Solution Architecture fits Seamlessly into our Customers’ Stack
1. Hybrid Calibration à Most accurate Twin
2. Best in class ROM capabilities à Easy Reuse
Twin Builder 3. Unique runtime model à Easy Scalability
4. Open architecture à Faster adoption
System Model

+ + ò Solver Twin Model for

Deployer
Services Hybrid
Existing System cloud/edge Python
Analytics
deployment integration, Pre- Fusion
Libraries
built agents, DTDL Hybrid Calibration
Export, Linux Data Integration,
compilation Auto-calibration, …
ROM Extraction
Capabilities Dynamic Static LTI/LPV FMU for simulation
workflows
Twin Deployer
FMI/FMU

Validated Ansys Physics Test Data, 3rd Party Software Digital Twin Partners

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Ansys Twin Builder Fluid Power Library

Hydraulics Library
• Powerful and easy-to-use tool for the modeling of hydraulics systems
• Ideal for all industry sectors that involve hydraulic components,
including machine tools, transmissions, and actuation systems Fluid Power
• Handles incompressible and compressible flows, and cavitation Library
• Supports thermo-hydraulic behavior

Pneumatics Library Ansys Twin Builder Fluid Library contains :

• Verify and optimize the design of your complete pneumatic system
from early design phases to production • Modelon Hydraulics Library
• Applications includes in particular construction equipment and • Modelon Pneumatics Library
suppliers, commercial vehicle design manufacturing companies and
the aerospace industry
• Supports thermo-pneumatic behavior
• Supports ideal and real gas assumption for six different gases

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HL Library overview
• High pressure (up to several hundred bar)
• Highly customisable flow components
• Pre-configured for efficient compressible flow modelling
• Simulation of hydraulic systems for
- Overall system dynamics
- Verification of dimensioning
- Testing of control strategies
• Easy-to-Use yet Powerful
- Wide range of predefined components
- New users get started quickly
- No limitations for experienced users

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HL Library overview 2
• Well suited for control design and validation
• True multi-engineering tool
- Modeling of multi-domain systems, combine with
multibody mechanics, control system etc.
- Easy to integrate with other available libraries
• Components
- Most models needed for fluid power applications available, both mobile and stationary
- More can be built from basic building blocks
- Includes:
• Cylinders: Differential cylinder, Single acting cylinder, Double acting dual rod, Plunger cylinder
• Directional valves
• Lines: Line, LongLine (could be flexible), LongLineTLM (Transmission Line Model, pressure wave)
• Sensors: mass flow rate, volume flow rate, pressure, and temperature
• Sources
• Restrictions
• Rotary actuators
• Valves: CheckValve, ReducingValve, ReliefValve, ShuttleValve, SpoolValve, etc.

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HL Library overview 3
Included medium property models
• Large set of oil models
- Equation based
- Equation based with no gas content
• Coefficient based: JetFuelA and JP8
• Tabular– Contains 16 predefined ISO standard hydraulic
fluids (tabular)
• ModelicaFluid – Interface with media models from
Modelica Standard Library (MSL)
• ModelonFluid – Interface with media models from
Modelon Standard Library (MBL)

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HL Library overview 4
Detailed component design
• Elements
- Provides a library of components for hydraulic component design
- Includes component models for a:
• Hydraulic volume, Piston, Spool and poppet valves, Hydraulic leakage component etc.

Hydraulics.DirectionalControl Hydraulics.Elements
Typical users For customers using the valves (when bought For suppliers constructing valves (like Bosch, Parker, Eaton etc…)
from suppliers)
Typical usage “System Design”. Usually when experimental “Component Design”. Usually when detailed geometric data is
data is available available
Conductance Defined using nominal point (flow rate and Valve geometry is defined. Pressure drop over the spool or poppet
pressure) as well as flow forces are used to calculate the conductance
Actuation Actuated with boolean inputs Actuated with mechanical flanges, possible to connect accurate
friction models, spring, dampers and end-stops.
Dynamics Simple dynamics with time constants Actuated with mechanical flanges, possible to connect accurate
friction models, spring, dampers and end-stops.

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Example 1: Water hammer

• Water hammer (Hydraulic shock)

- Is happening when the fluid is suddenly forced to stop
- Leads to a pressure wave will propagate in the pipe
- Can be modeled using LongLine

Valve closed suddenly

LongLine.PortA.m_flow LongLine.PortA.p
LongLine.PortB.m_flow LongLine.PortB.p

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Example 2: Hydraulic lift

• Model description:
- Pump speed is ramped up to 100 rad/s during the first 5 s.
- Lifting the 2000 N (200 kg) load on the plunger cylinder
- Valve1 will then cut the flow to the cylinder and Valve2 will
then open slowly to let the oil out to the tank
Cylinder.PortA.p

Cylinder.flange_b.s

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Example 3: Excavator

• Model description:
- Target: Evaluating several hydraulic control systems for a
new excavator to be designed
- Model contains 3-D mechanical and hydraulic components
• 3-D components of the excavator are modeled with the Modelica
MultiBody library
• The hydraulic system is controlled by a “load sensing” controller
- Hydraulic system
• Excavators have typically one Diesel engine, two hydraulic motors and
three cylinders
• The Load Sensing (LS) circuit: energy efficient and user friendly
• The idea is to have a flow rate control system for the pump such that it
delivers exactly the needed flow rate
• For more than one cylinder is used the circuit becomes more
complicated

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Example 3: Excavator
Bucket movement

• Simulation result:
- The following working situation is simulated

Pump.PortB.p

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Example 4: CRDI System

• Model description
- Common Rail Diesel Injection System: high-pressure pump, rail model and connection pipes
- The high-pressure pump consists of:
• Three piston - chamber assembly
• Each piston pump has an inlet check valve and outlet check valve
• The operation of these three piston pumps are separated by a phase of 120 deg

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Example 4: CRDI System

• Simulation
- The high-pressure pump receives fluid from a transfer pump (roughly 5 bar) and pumps it to the
required level (500 to 1500 bar)
- Engine speed is 3000 RPM and injection events are synchronized for this speed (4-cylinder engine)
- The hammer effect is observed in the connection pipe pressures when the injection stops

Cyl1.m_flow Cyl3.m_flow Cyl4.m_flow Cyl2.m_flow Pump_outlet_p

inletPipe1_p inletPipe3_p inletPipe4_p inletPipe2_p

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Example 5: ThermoFluid

• Heat exchanger model

- Warm side: Air using Modelon Base Library at 150 °C with
sinus shaped mass flow rate varying between 0.3 and 0.7kg/s
- Cold side: Water using Hydraulics Library at 45 °C and
120l/min (approx. 2 kg/s)

heatExchanger.distributedCounterFlow.Tout_prim
heatExchanger.distributedCounterFlow.wall.Tm[1]
heatExchanger.distributedCounterFlow.wall.Tm[2]
heatExchanger.distributedCounterFlow.wall.Tm[3]

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 Building a Hybrid Digital Twin – Two Approaches
Top Down Engineering
• Accuracy is achieved through model Specs
calibration based on experimental
System
data
Model
• Real-time simulation achieved
through light-weight system models AI/ML Calibrated
Model
Hybrid Digital
Data
Twin

ROMs

Bottom Up
3D Model
• Accuracy is based on high-fidelity
modeling of full physics equation and 3D Geometry
accurate geometry
• Real-time simulation achieved
through ROMs

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The Hybrid Approach
Accuracy:
• ML model: 0.016
Hybrid 98%
- Matches peak operation, but
deviates during low. 0.014

- Cannot predict flow and pressure 0.012 Model 90%

in downstream branches.

Flow Rate [kg/s]

0.01
• Nominal flow model: Data 80%
0.008
- Real-time calculation
- Predicts trends well, but shows 0.006

offset from data. 0.004

- Virtual sensors predict flow and
pressure in downstream branches 0.002

• Calibrated model 0
0 100 200 300 400 500 600 700 800 900 1000
- Matches data Time [s]

- Period recalibration allows twin to Data Nominal Calibrated ML Model

follow system aging. M. Adams, X. Li, L. Boucinha, S. S. Kher, P. Banerjee and J. -L. Gonzalez, "Hybrid Digital Twins: A
Primer on Combining Physics-Based and Data Analytics Approaches," in IEEE Software, vol. 39,
no. 2, pp. 47-52, March-April 2022, doi: 10.1109/MS.2021.3134042.

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Conclusion

• Introduction to digital twins and Ansys Twin Builder

• Introduction to Ansys Hydraulic Library

• Hydraulic library overview

• Examples

• Hybrid Digital Twin

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Mohammad Aghsaee

mohammad.aghsaee@ansys.com