ANSYS > Case Studies > Banco Products India Ltd.: Reducing Physical Prototyping with IoT

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

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 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.

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

The implementation of the ANSYS product family for simulation resulted in a significant improvement in Banco's operational efficiency. The Fluent model compared favorably to the test results, validating the model and further reducing the need for physical prototyping. This not only delivered cost savings but also allowed for higher performance and strength targets to be met. The engineering simulation approach developed using ANSYS software resulted in a substantial reduction in computational resources without compromising the accuracy of coolant outlet temperature results. Overall, the use of ANSYS software helped to reduce physical prototype testing and accelerated product development, leading to improved operational efficiency and product quality.

Quantitative Benefit

Significant reduction in computational resources without compromising the accuracy of coolant outlet temperature results.
Substantial reduction in physical prototype testing, leading to cost savings.
Accelerated product development due to the reduced need for physical prototyping.