Case Study

Going global with confidence

Dae Han Control

Solid Edge, Femap and NX Nastran help Dae Han Control take its pressure valve product line worldwide; bottom line is up

Global designs

Dae Han Control designs and manufactures electro-pneumatic valve positioners (including linear types and rotary types) that are widely used by control valve manufacturers. Established in 1995, the company’s products serve a range of markets including water and sewage, nuclear power, shipbuilding and heavy industries. Dae Han has been successful in establishing a very positive reputation, which the company credits to its strict quality control system.

Dae Han carved out an enviable position in the Korean market while expanding to international markets, including Japan, Southeast Asia and Europe. Its major customers include POSCO Co., Ltd., Hanjin Heavy Industries & Construction Co., Ltd., Hyosung Co., Ltd. and Korea Hydro & Nuclear Power Co., Ltd. With a new Dae Han location opening in Singapore, the company is well positioned to become a major exporter of pressure valves serving a broad, global market.

Demanding market, need for 3D

Dae Han recognized that its existing 2D design methods were inadequate considering its aggressive growth plans and today’s overall market demands for high-quality valves. Development data for its various products could not be accessed for re-use in new product scenarios; and physical testing not only adversely affected development time but also required the purchase of expensive testing equipment. Dae Han quickly realized that resolving these issues would become a core element in its drive for global competitiveness.

Dae Han’s management formulated a plan to evaluate a CAD/CAE solution to meet its development requirements. Along with data re-use and eliminating physical testing constraints, the company identified the need for reducing design time and errors. In addition, the company recognized the benefits of being able to extract analytical data for modeling, simulation and reviewing product performance results.

“After careful review, we established a set of criteria for evaluating new technology to meet our specific needs,” says In Won Park, project manager, Dae Han Control. “We needed to be able to move from 2D to 3D with minimal disruption, and the new software had to be easy to use as we had a very short implementation timeframe. We also wanted a solution with outstanding 2D drawing functionality and close compatibility with analysis software.”

Another set of criteria was used in evaluating Dae Han’s CAE needs. Here, Dae Han required very high analysis reliability, as well as an easyto- use solution to meet its tight timelines. Dae Han also requested and received various references, confirming that the chosen solution’s capabilities would support the company’s primary need to design and manufacture valves.

With this in mind, Dae Han carefully reviewed its CAD/CAE software options and made a decision to deploy Solid Edge® software to meet its CAD requirements and Femap™ software to meets its CAE needs. Both systems were provided by Siemens PLM Software.

Protecting the company‘s reputation

Dae Han’s products are often required to operate under extraordinarily challenging conditions, including extreme temperatures, high vibration and corrosive environments. At the same time, these products are expected to perform to the highest standards and remain maintenance-free. Even with these tough requirements, the company has won a solid reputation in its market. “To protect our reputation, we were strongly committed to choosing a technology partner that could demonstrate reliability, stability and strong market standing,“ explains Park. “Siemens PLM Software was able to provide us with first-rate references, including other companies in our industry that successfully migrated from 2D to 3D with Solid Edge. This gave us confidence in their technology.”

The tight integration of Solid Edge and Femap was also a deciding factor. Femap demonstrated a long history of working as a pre- and postprocessor for NX™ Nastran® software, providing the flexibility and scalability needed to extend this technology to the most advanced types of analysis. In addition, customized training and customer support from Dawoo Tech, Siemens PLM Software‘s distributor, contributed favorably to the selection process.

Dawoo Tech proposed personalized 3D training for Dae Han‘s current 2D design organization with dedicated support and maintenance; this was yet another strong factor leading to Dae Han’s decision.

Early concerns eradicated

As with many companies making the transition from 2D to 3D, Dae Han had major concerns, including asking: How quickly can we adapt our valve designs using 3D? Can the analysis results be trusted? Is there really an optimal CAD/CAE solution for the valve industry?

These queries were soon resolved as Dae Han realized immediate benefits in deploying Solid Edge and Femap. “I was very concerned about the move to 3D,” says Kim Yong Gab, president, Dae Han Control. “I have seen other companies attempt to deploy a new design program and fail to use the technology. I am extremely happy with the results of our move to Solid Edge, as well as with the personalized training and support.”

Special valve project, big improvements

The introductory project using the new software had to satisfy all of Dae Han‘s selection criteria, as well as provide direction for Dae Han’s new 3D workflow process. It also was essential that the project generate solid, reliable analysis data.

Training was an essential part of the program, including training specific to valve 3D modeling. The initial estimation was for five days of customized training and two days of valve training. However, Dae Han completed the full training requirement in a total of five days – with the two days saved attributed to the easeof- use of Solid Edge. Other key Solid Edge benefits also became apparent.

Converting 2D data to 3D: Dae Han selected a metal seat valve as the initial model for conversion from 2D to 3D. The seat valve was a flagship product for Dae Han and one targeted for export to the Japanese market. Using the Solid Edge Create 3D application, the conversion was quick and seamless, even with very tight adherence specifications. As a result, the conversion only took two days because of the high compatibility of the 2D-3D data.

Reducing design errors: Before it switched to 3D technology, Dae Han had been unable to completely satisfy the evolution of its metal seat valve from a double offset to a triple offset. Dae Han engineers had difficulty confirming the flexible response and interruption frequencies when design errors occurred in their earlier 2D valve design – issues that also had been experienced by other valve companies. With the interruption check functionality in the Solid Edge Motion task, the engineers were able to determine the number of interruptions during valve operation, which facilitated design error verification and faster response to design changes.

Robust 2D: When moving to a 3D solution, some companies worry about maintaining a robust 2D drawing capability – often an essential element of the product communication process. Solid Edge provides a robust 2D drawing capability that easily resolved Dae Han’s concerns. In addition, the robust BOM function of Solid Edge significantly reduced the design process timeline.

Rendering and animation: Using the rendering capabilities of Solid Edge, Dae Han easily developed a highly satisfactory catalog without additional costs and manpower. In addition, the animation and robust library functionality of Solid Edge was also effectively used for advertising and marketing.

“The initial project conducted within the Dae Han design organization achieved excellent results,” says Park. “We incurred no additional costs for testing equipment, and the noticeable improvement of the design group was certainly recognized.”

Importance of reliable CAE

Once the modeling functions of the metal seat valve were under control, the next step was to perform the structural analysis of both low- and high-temperature exposure of the component using Femap and NX Nastran. In a joint project between Dae Han and Dawoo Tech, limitations were set for temperature variations based on independent pressure conditions and temperature distribution, as well as simultaneous pressure and temperature data. It was essential to verify the results against existing physical valve test equipment scenarios, and the results held true. The software provided analytical data that was completely in line with previous physical testing, proving its reliability.

The new software delivered the results needed to meet the expectations of the Dae Han metal seat valve project – zero leakage under higher temperature and pressure. The flexibility for design changes and the significantly fast results afforded by the software again confirmed the viability of the new technology.

Confidence, strength and profitability

Based on the results of the initial project, Dae Han implemented a completely new design process using Solid Edge, Femap and NX Nastran. Park notes, “With confidence, we have converted our existing 2D data to 3D, and we are happy to confirm the further export of our products to Japan, which strengthens our position in the global market. Profitability has been favorably impacted by significantly reducing existing valve test equipment expense. And concerns have been replaced with keen optimism for the future.”

Future plans

Dae Han Control continuously strives to operate a company that stands for the highest quality and technology standards in its industry – conforming to all demands of the global environment. “There are endless markets available to us,” says Yong Gab. “With the implementation of Solid Edge, Femap and NX Nastran, we intend to capitalize on further penetration into Europe and Southeast Asia, the Middle East, and more!”

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