Thermal Management, 22.10.2012,

AUTOMATION OF THERMAL MANAGEMENT SIMULATIONS.USING GTISE

AUTOMATION OF THERMAL MANAGEMENT SIMULATIONS.

-Process of Thermal Management Development

-Automation of Thermal Management Development

- Overview on Automation

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- Overview on Automation

- Requirement: Modeling in Modular Blocks

- Input data check and conversion

- Projekteditor: Management ofvariants

- Conclusion

REQUIREMENTS FOR PROCESS OFTHERMAL MANAGEMENTDEVELOPMENT

Vehicle Size andDesign Engine

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Country

Dynamic (low/high?)

Best adapted CoolingSystem

Other components

Efficiency Functions

PROCESS THERMAL MANAGMENTDEVELOPMENTIN TERMSOFCOOLING SIMULATION

Requirements

Country

Vehiclesize

Trailer

High Dynamics

Hardware to cool: Engine, Gearbox,

ConceptDevelopment

Cooler size / # Coolers

Cooling system(Pumps, Piping, Regulation)

Selection ofSupplier

Data for biddingprocedure

Evaluation of bids

Updated data

Series Development

Test/Validation withPrototypes

In-depth data

High quality results

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Challenges for simulation- Documentation of files (used components/parameters, results) ; Hundreds of

Parameters- Easy handling of multiple simulations/comparisions with one click and without

errors- Rocognisable format of results for internal/external communication- Multiple engineers- Continuous process

Engine, Gearbox, Electric

components.Little data

Updated data High quality results

Final Application

OVERVIEWON AUTOMATION PROCESS

SimulationCoolingSystemsDepartment

New input datafrom supplier orinternal department

Check and Creation ofComponents

Restricted Results

Componentdesign

Impact on vehicle

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Automation (Other)

Department

Suggestions on cooling concepts

Creation or change ofvariants to proof orrefuse suggestions

Internal Discussions or with otherdepartments

ResultsPresentation

Results

Create, startand extractdata fromSimulations

Compare results

Automation Projekteditor

REQUIREMENT: MODELING IN MODULAR BLOCKS

Engine

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Physikal components represented by external subassemblies� easy model creationand component swappingComponents with different data class and modeling (simple/complex) stored in network file system� share components to different users

Engine

Documented common interface of inputs/outputs

Modular block containing data and modeling

INPUT DATA CHECK ANDCOMPONENTCREATIONEXAMPLE: HEAT EXCHANGER

Physically consistencycheck to avoid slow

Supplier

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Standartized Form forheatexchanger

check to avoid slowsimulations and errors

Visual check and modification

Ready to use HeatExchanger as GTM-File

PROJEKTEDITOR: MANAGEMENT OF VARIANTSFUNCTIONS

ProjekteditorCreate models

• Modify GT Template: Change Parameters and externalsubassemblies

Write results

• Exceltemplate forstationary results

• Same output format asused measurement

Compare results

• Menu for choosingdesired Variable.

• Table with all Variantsand Use Cases

Share data

• Same file layoutcontaining relevant information forcommunication

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Projekteditor: VBA script which can handle ASCII based GTM-Files

subassemblies• Check Parameter consitency

• Send to Distributed Server

used measurementsystem for dynamicresults

• Suitable for all coolingconfigurations andexpandable in anydirection(circuits/coolers/heatsinks)

and Use Cases communication• Configuration ofSheets for sharingrestricted data

• Extract Data for 3D Simulation

Storage and Documentation: List of variants

PROJEKTEDITOR: MANAGEMENT OF VARIANTSEXAMPLEOFVARIANT LISTAND FUNCTIONS 1/2

Parameters: weight cwValue, Country

Filenames of template andexternal subassemblies

Cases/ customVar

Link toresults

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ServerGT-Model

Each Variant represented by one line

Uniform result

PROJEKTEDITOR: MANAGEMENT OF VARIANTSEXAMPLEOFVARIANT LISTAND FUNCTIONS 2/2

Parameters: weight cwValue, Country

Filenames of template and external subassemblies

Cases/ customVar

Link toresults

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3D Simulation SupplierUniform presentationlayout

Each Variant represented by one line

PROJEKTEDITOR: MANAGEMENT OF VARIANTSCOMPARE RESULTS

Circuit

Variable

Part/Heatexchanger

Inlet/Outlet, max. Values

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Inlet/Outlet, max. Values

CONCLUSION

− Modeling with modular blocks (external subassemblies) offers exchanging components with complete data sets and modeling.

− The Projecteditor with the central document „Variantenliste“ enables an easy documentation and handling of multiple simulations without oversight. Furthermore it produces recognible format of results for

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oversight. Furthermore it produces recognible format of results for internal and external use

− Automation based on standardized models and data increases speed and quality which is key requirement to use the full potential of 1D Simulation for the development of cooling systems