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B S H H O M E A P P L I A N C E S G R O U P
Using simulation tools for improvement of small home
appliances design
Ansys Convergence Conference
2016
25th May 2016
dr. Henri Orbanić, Marko Žilnik
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 2
©BSHHišniaparatid.o.o.Nazarje,2016
About BSH HOME APPLIANCE GROUP
 Founded in 1967 as a joint venture between
Siemens AG and Robert Bosch GmbH
 Since the beginning of 2015 BSH fully belongs to the
Bosch Group
 Market leader in Europe, No. 2 in the world
 Product portfolio: all modern home appliances
 Employees worldwide: 56,500
 Around 3,500 R&D specialists in BSH’s international
production and development network
BSH Hausgeräte GmbH
Founded in 1967
Robert Bosch
GmbH
100%
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 3
©BSHHišniaparatid.o.o.Nazarje,2016
BSH’s product portfolio covers the entire spectrum for daily life
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 4
©BSHHišniaparatid.o.o.Nazarje,2016
Short presentation of BSH Hišni aparati d.o.o Nazarje, Slovenia
 ~1200 employees
 ~7 million appliances produced
per year
Two branches:
 Food preparation
 Beverages preparation
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 5
©BSHHišniaparatid.o.o.Nazarje,2016
Products developed and produced in Nazarje – Food preparation
Food processors Kitchen machines Stick mixers
Hand blenders
Blenders
Juicers Citrus pressChoppersMeat grinders
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 6
©BSHHišniaparatid.o.o.Nazarje,2016
Using ANSYS in Food preparation department
 Personnel: two part-time simulation engineers
 Hardware:
– Two simulation workstations Dell T7910 with 16-cores each
 Software:
– Structural analysis:
– ANSYS Mechanical (Static structural, Transient structural, Modal, Thermal)
– ANSYS Explicit STR (Impact testing)
– CFD analysis:
– ANSYS Fluent
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 7
©BSHHišniaparatid.o.o.Nazarje,2016
Structural analysis simulation in
BSH Hišni aparati d.o.o. Nazarje
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 8
©BSHHišniaparatid.o.o.Nazarje,2016
Stick mixer drop test
 The user has to be prevented from touching live electronics if the appliance is
damaged after it is accidentally dropped on the floor.
 Thus the appliance housing must not open if it falls from the kitchen counter.
 One of our stick mixers had problems with this test.
 The goal was to have a solution which would be cheap and easy to implement as the
modifications to the moulding tools are expensive.
High speed camera – 1900 fps
t=0 t=2,63 ms t=4,74 ms
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 9
©BSHHišniaparatid.o.o.Nazarje,2016
Simulation setup
Cross section
Mass to
simulate motor
and electronics
Gravity +
initial
velocity
Fixed
floor
Housing
material: ABS
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 10
©BSHHišniaparatid.o.o.Nazarje,2016
The existing situation
 The simulation was performed in ANSYS Explicit STR.
 First the simulation of the existing situation was performed.
 The simulation showed similar opening of housing as in real drop. Thus we could proceed to
modifying of housing design.
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 11
©BSHHišniaparatid.o.o.Nazarje,2016
Solution
 After the modification of locks the housing did not open anymore
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 12
©BSHHišniaparatid.o.o.Nazarje,2016
Drop test of packed appliances
 Software: Before - outsourcing LS-DYNA,
Now – ANSYS Explicit STR
 Lateral drop test from the height of 50 cm,
v0 = 3,13 m/s, angle to the ground 10°
10°
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 13
©BSHHišniaparatid.o.o.Nazarje,2016
Drop test - plastic strain analysis
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 14
©BSHHišniaparatid.o.o.Nazarje,2016
Bosch MUM5 blender locking mechanism structural problem
 Problem: the geometry and material was changed. During usage the locking mechanism
broke.
 The problem was solved by the design change .
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 15
©BSHHišniaparatid.o.o.Nazarje,2016
CFD simulation in BSH Hišni aparati
d.o.o. Nazarje
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 16
©BSHHišniaparatid.o.o.Nazarje,2016
Stick mixer performance analysis
water
level
pressure
outlet
water
rotation zone
air
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 17
©BSHHišniaparatid.o.o.Nazarje,2016
Simulation parameters
 Two phase water-air VOF model
 High rotational velocity ~ 12000 rpm  turbulence
 Transient formulation
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 18
©BSHHišniaparatid.o.o.Nazarje,2016
Mixing analysis
 Inserting tracer liquid and observing the uniformity of mixing
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 19
©BSHHišniaparatid.o.o.Nazarje,2016
Bosch MCM6 food processor blender attachment
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 20
©BSHHišniaparatid.o.o.Nazarje,2016
Simulation parameters
 Two phase water-air VOF model
 0.75 l of water was simulated
 Rotational velocity – 6000 to 12000 rpm,
 Transient formulation
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 21
©BSHHišniaparatid.o.o.Nazarje,2016
Kneading bread dough
 Bread dough – mainly mixture of wheat flower and water.
 Depending on the flower-water ratio, the dough can be a
dry plastic ball or a soft sticky mass.
 Points of interest:
– obtaining load regime on the machine,
– studying the kneading process – kneading efficiency.
B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 22
©BSHHišniaparatid.o.o.Nazarje,2016
THANK YOU FOR YOUR ATTENTION

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Using simulation tools for improvement of small home appliances design

  • 1. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design Ansys Convergence Conference 2016 25th May 2016 dr. Henri Orbanić, Marko Žilnik
  • 2. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 2 ©BSHHišniaparatid.o.o.Nazarje,2016 About BSH HOME APPLIANCE GROUP  Founded in 1967 as a joint venture between Siemens AG and Robert Bosch GmbH  Since the beginning of 2015 BSH fully belongs to the Bosch Group  Market leader in Europe, No. 2 in the world  Product portfolio: all modern home appliances  Employees worldwide: 56,500  Around 3,500 R&D specialists in BSH’s international production and development network BSH Hausgeräte GmbH Founded in 1967 Robert Bosch GmbH 100%
  • 3. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 3 ©BSHHišniaparatid.o.o.Nazarje,2016 BSH’s product portfolio covers the entire spectrum for daily life
  • 4. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 4 ©BSHHišniaparatid.o.o.Nazarje,2016 Short presentation of BSH Hišni aparati d.o.o Nazarje, Slovenia  ~1200 employees  ~7 million appliances produced per year Two branches:  Food preparation  Beverages preparation
  • 5. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 5 ©BSHHišniaparatid.o.o.Nazarje,2016 Products developed and produced in Nazarje – Food preparation Food processors Kitchen machines Stick mixers Hand blenders Blenders Juicers Citrus pressChoppersMeat grinders
  • 6. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 6 ©BSHHišniaparatid.o.o.Nazarje,2016 Using ANSYS in Food preparation department  Personnel: two part-time simulation engineers  Hardware: – Two simulation workstations Dell T7910 with 16-cores each  Software: – Structural analysis: – ANSYS Mechanical (Static structural, Transient structural, Modal, Thermal) – ANSYS Explicit STR (Impact testing) – CFD analysis: – ANSYS Fluent
  • 7. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 7 ©BSHHišniaparatid.o.o.Nazarje,2016 Structural analysis simulation in BSH Hišni aparati d.o.o. Nazarje
  • 8. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 8 ©BSHHišniaparatid.o.o.Nazarje,2016 Stick mixer drop test  The user has to be prevented from touching live electronics if the appliance is damaged after it is accidentally dropped on the floor.  Thus the appliance housing must not open if it falls from the kitchen counter.  One of our stick mixers had problems with this test.  The goal was to have a solution which would be cheap and easy to implement as the modifications to the moulding tools are expensive. High speed camera – 1900 fps t=0 t=2,63 ms t=4,74 ms
  • 9. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 9 ©BSHHišniaparatid.o.o.Nazarje,2016 Simulation setup Cross section Mass to simulate motor and electronics Gravity + initial velocity Fixed floor Housing material: ABS
  • 10. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 10 ©BSHHišniaparatid.o.o.Nazarje,2016 The existing situation  The simulation was performed in ANSYS Explicit STR.  First the simulation of the existing situation was performed.  The simulation showed similar opening of housing as in real drop. Thus we could proceed to modifying of housing design.
  • 11. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 11 ©BSHHišniaparatid.o.o.Nazarje,2016 Solution  After the modification of locks the housing did not open anymore
  • 12. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 12 ©BSHHišniaparatid.o.o.Nazarje,2016 Drop test of packed appliances  Software: Before - outsourcing LS-DYNA, Now – ANSYS Explicit STR  Lateral drop test from the height of 50 cm, v0 = 3,13 m/s, angle to the ground 10° 10°
  • 13. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 13 ©BSHHišniaparatid.o.o.Nazarje,2016 Drop test - plastic strain analysis
  • 14. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 14 ©BSHHišniaparatid.o.o.Nazarje,2016 Bosch MUM5 blender locking mechanism structural problem  Problem: the geometry and material was changed. During usage the locking mechanism broke.  The problem was solved by the design change .
  • 15. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 15 ©BSHHišniaparatid.o.o.Nazarje,2016 CFD simulation in BSH Hišni aparati d.o.o. Nazarje
  • 16. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 16 ©BSHHišniaparatid.o.o.Nazarje,2016 Stick mixer performance analysis water level pressure outlet water rotation zone air
  • 17. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 17 ©BSHHišniaparatid.o.o.Nazarje,2016 Simulation parameters  Two phase water-air VOF model  High rotational velocity ~ 12000 rpm  turbulence  Transient formulation
  • 18. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 18 ©BSHHišniaparatid.o.o.Nazarje,2016 Mixing analysis  Inserting tracer liquid and observing the uniformity of mixing
  • 19. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 19 ©BSHHišniaparatid.o.o.Nazarje,2016 Bosch MCM6 food processor blender attachment
  • 20. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 20 ©BSHHišniaparatid.o.o.Nazarje,2016 Simulation parameters  Two phase water-air VOF model  0.75 l of water was simulated  Rotational velocity – 6000 to 12000 rpm,  Transient formulation
  • 21. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 21 ©BSHHišniaparatid.o.o.Nazarje,2016 Kneading bread dough  Bread dough – mainly mixture of wheat flower and water.  Depending on the flower-water ratio, the dough can be a dry plastic ball or a soft sticky mass.  Points of interest: – obtaining load regime on the machine, – studying the kneading process – kneading efficiency.
  • 22. B S H H O M E A P P L I A N C E S G R O U P Using simulation tools for improvement of small home appliances design | 25th May 2016 | Slide: 22 ©BSHHišniaparatid.o.o.Nazarje,2016 THANK YOU FOR YOUR ATTENTION