“FROM THE ENGINEERING OFFICE TO THE TEST BENCH: APPLYING SIMULATION IN-HOUSE"
PART 3
Introduction
In recent years, simulation has become an increasingly widespread tool in companies operating in the hydraulic sector.
However, in most cases, its use remains confined to specific moments: isolated analyses, standalone validations, or preliminary studies.
The real step forward occurs when simulation is no longer treated as a separate activity, but becomes an integral part of the company workflow.
In this article, we explore how lumped-parameter dynamic simulation can be applied throughout the entire process—from the engineering office to the test bench, and even in customer support—based on a real use case developed in collaboration with VIS Hydraulics.
The limits of the traditional approach
In many companies, the development process still follows a well-established pattern:
- design based on experience and sizing
- prototype development
- validation on the test bench
This approach is effective, but it has a structural limitation:
issues often emerge only during testing.
This leads to an iterative cycle:
design → test → modification → re-test
resulting in longer development times and uncertainty in performance.
The critical issue is not the lack of tools, but the lack of continuity between the different phases.
Simulation as a connecting element
An alternative approach is to use simulation as a thread connecting the different phases.
The goal is not to create separate models for each activity, but to use the same model—adapted to the required level of detail—across multiple contexts:
- design
- testing
- system simulation
- customer support
This enables:
- consistency across analyses
- reduced information loss
- improved understanding of component behavior
Two modeling levels: simplified and detailed
To enable this approach, it is essential to work with models at different levels of detail:
- Simplified models, based on catalog data, suitable for fast system-level simulations
- Detailed models, based on the physical description of the component, used in design and in-depth analysis
These two levels are not alternatives, but complementary.
In the case developed with VIS Hydraulics, this approach has been applied to the valve catalog, creating both simplified and detailed versions for each component.
Application in the engineering office
The most immediate impact can be observed during the design phase.
Simulation allows engineers to anticipate analyses that would otherwise be performed later, reducing the number of iterations.
Prototyping
Using detailed models and CFD simulations, it is possible to:
- analyze pressure losses
- evaluate the impact of internal geometry
- optimize component behavior
Re-design
By integrating experimental data, the model can be calibrated to accurately represent real behavior.
This enables:
- evaluation of design modifications
- comparison between simulation and test results
- improved model accuracy
System simulation
The same component can then be integrated into more complex system models, using:
- simplified versions for functional and performance validation
- detailed versions for deeper analysis
From test bench to test simulation
A further step is to model the test bench itself.
This makes it possible to:
- virtually reproduce test conditions
- predict results
- improve repeatability
Simulation therefore becomes a complementary tool to experimental testing—not a replacement.
In the case developed with VIS Hydraulics, this approach has been applied to the valve catalog, creating both simplified and detailed versions for each component.
Decision support
Simulation can also support technical decision-making for the customer.
Using simplified models, it is possible to:
- verify circuit functionality
- analyze performance
- evaluate alternative solutions
This enables faster and more reliable responses based on data.
Extending simulation to the customer: three scenarios
Simulation does not stop within the company.
By exchanging the necessary information, it is possible to perform simulations internally and provide results to the customer.
Alternatively, models can be shared directly.
Three scenarios are possible:
- Same software (OpenModelica + SmartFluidPower library) → direct plug & play integration
- Different software (lumped-parameter simulation tools) → use of FMU (protected black box)
- No simulation software → use of open-source tools and FMU models
In all cases, the model can be made usable while preserving intellectual property.
Real case: VIS Hydraulics
The experience of the VIS Innovation Center demonstrates how this approach can be applied in practice.
In recent years:
- modeling has been integrated into the design process
- models are developed in parallel with components
- a progressive reuse of model libraries has been established
This has led to:
- reduction in design variants
- improved understanding of component behavior
- better support for testing and development activities
Conclusions
Integrating simulation into company workflows does not simply mean introducing a new tool—it requires a change in approach.
The model becomes:
- a shared element across departments
- a link between design and validation
- a support tool for customer interaction
Adoption can be gradual, starting from a pilot case and progressively expanding the process.
It is through this integration that simulation delivers its real value.
Want to go deeper into the topic?
Watch the video recording
Download the in-depth slides here
Was this useful for your work?
Fill out the questionnaire to get the extra resources. It only takes 2 minutes!
Go for the next part!
Turn simulation data into concrete design decisions, optimizing both performance and energy efficiency of a hydraulic system.
Through real-world case studies, you’ll see how to test and compare alternatives before physical implementation.
