ANSYS Case Studies Culligan's Innovative Water Softener: A Balance of Hydrodynamic Performance and Structural Integrity

	Culligan's Innovative Water Softener: A Balance of Hydrodynamic Performance and Structural Integrity ANSYS

Culligan's Innovative Water Softener: A Balance of Hydrodynamic Performance and Structural Integrity

ANSYS

Technology Category	Analytics & Modeling - Digital Twin / Simulation Sensors - Utility Meters
Applicable Industries	Equipment & Machinery
Applicable Functions	Product Research & Development
Use Cases	Intelligent Urban Water Supply Management Leakage & Flood Monitoring
Services	Testing & Certification
Challenge	Culligan Matrix Solutions, a leader in water treatment, faced a significant challenge in developing a new water softener. The company aimed to create a device that used less salt than any other product on the market, minimized water pressure losses, and utilized the least amount of material possible. This ambitious project required a delicate balance between hydrodynamic performance and structural integrity. The R&D team needed to employ both fluid dynamics and structural mechanics simulations to achieve these goals. The challenge was not only to meet these stringent requirements but also to do so in a cost-effective and time-efficient manner. Read More
About Customer	Culligan Matrix Solutions is a renowned leader in the water treatment industry with a history spanning 75 years. The company is known for using state-of-the-art analysis, engineering tools, and testing facilities to develop some of the most advanced water treatment products globally. Culligan products are sold in over 90 countries, with a strong market presence in France, Italy, the United Kingdom, Spain, Belgium, and Holland. The company holds an impressive portfolio of over 300 patents, further cementing its position as a pioneer in water treatment solutions. Read More
Solution	Culligan partnered with QuEST Global, a provider of a wide range of engineering solutions, to tackle this challenge. They utilized ANSYS software tools, which could be applied to both fluid dynamics and structural mechanics simulations. ANSYS geometry tools simplified the geometry, reducing the time required to obtain simulation results. The team used ANSYS CFX, a two-phase fluid dynamics capability, to model the movement of brine and water in the valve. This allowed them to capture the suction effect while modeling a multicomponent mixture of raw water and brine solution. The pressure results from the fluid simulation were then transferred to ANSYS Mechanical software to predict stresses and deflections within the valve. This comprehensive approach enabled the team to balance design trade-offs between hydrodynamic performance and structural integrity. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Sensors - Utility Meters

Applicable Industries

Equipment & Machinery

Applicable Functions

Product Research & Development

Use Cases

Intelligent Urban Water Supply Management

Leakage & Flood Monitoring

Services

Testing & Certification

Challenge

Culligan Matrix Solutions, a leader in water treatment, faced a significant challenge in developing a new water softener. The company aimed to create a device that used less salt than any other product on the market, minimized water pressure losses, and utilized the least amount of material possible. This ambitious project required a delicate balance between hydrodynamic performance and structural integrity. The R&D team needed to employ both fluid dynamics and structural mechanics simulations to achieve these goals. The challenge was not only to meet these stringent requirements but also to do so in a cost-effective and time-efficient manner.

About Customer

Culligan Matrix Solutions is a renowned leader in the water treatment industry with a history spanning 75 years. The company is known for using state-of-the-art analysis, engineering tools, and testing facilities to develop some of the most advanced water treatment products globally. Culligan products are sold in over 90 countries, with a strong market presence in France, Italy, the United Kingdom, Spain, Belgium, and Holland. The company holds an impressive portfolio of over 300 patents, further cementing its position as a pioneer in water treatment solutions.

Solution

Culligan partnered with QuEST Global, a provider of a wide range of engineering solutions, to tackle this challenge. They utilized ANSYS software tools, which could be applied to both fluid dynamics and structural mechanics simulations. ANSYS geometry tools simplified the geometry, reducing the time required to obtain simulation results. The team used ANSYS CFX, a two-phase fluid dynamics capability, to model the movement of brine and water in the valve. This allowed them to capture the suction effect while modeling a multicomponent mixture of raw water and brine solution. The pressure results from the fluid simulation were then transferred to ANSYS Mechanical software to predict stresses and deflections within the valve. This comprehensive approach enabled the team to balance design trade-offs between hydrodynamic performance and structural integrity.

Impact #1	The partnership with QuEST Global and the use of ANSYS software tools resulted in a successful project outcome. The new water softener not only met but exceeded the initial project goals. It uses less salt, minimizes water pressure losses, and uses the least amount of material possible, all while maintaining structural integrity. The results obtained using ANSYS CFX fluid dynamics software matched very well with the test data, giving Culligan engineers confidence in the use of fluid flow software from ANSYS for design improvement. The use of engineering simulation also allowed the QuEST team to perform many design changes quickly, further enhancing the product's efficiency and effectiveness.

Impact #1

The partnership with QuEST Global and the use of ANSYS software tools resulted in a successful project outcome. The new water softener not only met but exceeded the initial project goals. It uses less salt, minimizes water pressure losses, and uses the least amount of material possible, all while maintaining structural integrity. The results obtained using ANSYS CFX fluid dynamics software matched very well with the test data, giving Culligan engineers confidence in the use of fluid flow software from ANSYS for design improvement. The use of engineering simulation also allowed the QuEST team to perform many design changes quickly, further enhancing the product's efficiency and effectiveness.

Benefit #1	The new water softener uses significantly less salt than any other device on the market.
Benefit #2	The use of ANSYS geometry tools led to a significant reduction in design cycle time.
Benefit #3	The simulations saved Culligan hundreds of thousands of dollars in injection molds.

Benefit #1

The new water softener uses significantly less salt than any other device on the market.

Benefit #2

The use of ANSYS geometry tools led to a significant reduction in design cycle time.

Benefit #3

The simulations saved Culligan hundreds of thousands of dollars in injection molds.

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Overview

Culligan's Innovative Water Softener: A Balance of Hydrodynamic Performance and Structural Integrity

Operational Impact

Quantitative Benefit