Schlemmer GmbH: Achieving Zero-Defect Goal with Simulation in Cable Protection
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
- Cybersecurity & Privacy - Intrusion Detection
Applicable Industries
- Automotive
- Life Sciences
Applicable Functions
- Quality Assurance
Use Cases
- Digital Twin
- Virtual Reality
Services
- Testing & Certification
About The Customer
Schlemmer GmbH is a company that develops, produces, and sells cable protection systems for automotive and industrial applications. Their traditional portfolio consists of corrugated, smooth, and protective tubes, manifolds, and connector interfaces, plus customized cable ducts and cable conduits. The company also operates in other business segments, including connection systems with gland technology, mechatronics systems with probes and sensors, and air and fluid systems with conveying lines, line systems, and reservoirs. Turning parts also play a significant role in expanding the company's business. The company's goal is to maintain its leadership and quality in cable protection systems.
The Challenge
Schlemmer GmbH, a leader in cable protection systems, faced a significant challenge in testing the stiffness and deformation behaviors of their cable protection hoses. These tests, which include bending and crush tests, are crucial in determining the hose's ability to withstand combined tension, bending, and mechanical compression. However, these tests required the production of expensive prototypes, which was not cost-effective. Furthermore, the simulation of large deformations, material behavior, and nonlinear contact of the hoses required robust nonlinear capabilities. The company needed a solution that could provide valuable information early in the concept phase of a new product to reduce the number of prototypes required.
The Solution
Schlemmer GmbH adopted ANSYS Mechanical software to model and simulate bending and crush tests. The software allowed them to define the hose as a nonlinear elastic-plastic material and perform simulations with large deformation and nonlinear contact. This enabled them to compare results for alternate designs. ANSYS Mechanical provided a simple and fast setup for contact definition and nonlinear simulation. Its robust contact algorithms delivered short solution times and required little user input. The software's ability to simulate various conditions allowed engineers to improve the final design, thereby reducing the number of expensive prototypes. This solution helped Schlemmer maintain its leadership and quality in cable protection systems by improving product robustness.
Operational Impact
Quantitative Benefit
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