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Development of Tools to Automate

the Analysis of Turbo-Machinery

 om nco n a eep anga

Cooper Standard / Altair Engineering, Inc.

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Executive Summary

• Cooper Standard (CS) Corporate Overview

• History of CFD at Cooper Standard

• Cooper Standard adoption of AcuSolve for enhanced CFD efficiencies

and accuracy

• Additional AcuSolve Applications at Cooper Standard

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About Cooper Standard

Our Mission

Headquarters: Novi, MI

Established: 1960

Employees: 21,500+

Locations: 70+ in 19 Countries

Provide outstanding service, support

and innovative solutions to our

customers benefiting all stakeholders

of Cooper Standard.

2010 Top 100Global Suppliers: Rank 62

2010 Top 100North American Suppliers: Rank 35

2011 Sales: $2.85 B

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History

2011

2012

2005

2006

2007

2007

1960 1999 2000 2004

2010

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Strategic Footprint

North America

Europe Asia Pacific

HeadquartersSales / AdministrationTechnical CenterManufacturingManufacturing / Technical Center

Key

South America

AustraliaBelgiumBrazilCanadaChina

JapanKoreaMexicoNetherlandsPoland

CountriesCzech RepublicFranceGermanyIndiaItaly

RomaniaThailandUnited KingdomUnited States

2012 - Located in 19 Countries 2004 - Located in 14 Countries 

Cooper-Standard Saiyang Wuhu 94% /6%

Cooper-Standard NISCO 40% / 60%

Cooper Hubei Jingda 37% / 63%

Metzeler India 74% / 26%

Cooper Hasco China 47.5% / 47.5% / 5%

Guyoung Tech Korea 20% / 80%

Cooper Standard France 51% / 49%Nishikawa Tachaplalert Cooper Limited 20% / 80%

Joint Ventures

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Global Customers

RENAULT

HYUNDAI 

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Breadth of Product & Segments

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Thermal Management – Key Capabilities

Heating and coolingmanagement systems for

hybrids, electric vehicles andinternal combustion engines

Electromechanical DevicesThermal DevicesThermal Integration

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Technology

• Automotive News PACE Award

Honorable Mention

• Electric Water Valve Assembly• Thermoplastic Rear Door Glass

Seal Assembly

• Metal to Plastic Fluid Connection with

Overmolded Anti-Rotation Retainer

Global Six Sigma Award BestAchievement of Design for SixSigma

• Coolant Water Valve

Over 500 Patents Globally

• Daylight Opening Modules

• Engineered Stretched Plastics

• Occupant Detection Systems

•

• Day Light Opening (DLO) System• Society of Plastics Engineers

Most Innovative Use of Plastic: Finalist

• Electric Water Valve Assembly

• Transmission Thermal Valve Assy

• Electric Brushless Pump

 

• Quick Connect Fluid Couplings• Core process methods

cooperstandard

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Cooper Standard’s History With Pumps

• Cooper Standard identified a market for electrically driven coolant

pumps.

• Development began in 2005, CFD was used from the start.

• Cooper Standard offers pumps to replace the vehicle main water pump

and auxiliary supplemental flow.

 • Wattages range from <20 W to 1 kW.

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Early CFD Analyses – August 2005

• Combination Tet and Hexcells

• Uniform mesh size• Significant time to set-up

manually

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CFD Analyses – June 2010

• ~5M cells ranged from 0.2 mm to 2 mm

• Manual set-up required a full day and 6-10 hours to converge each flow point

0.00

0.20

0.40

0.60

0.80

1.00

1.20

5000 7000 9000 11000 13000

   P  r  e  s  s  u

  r  e   G  a   i  n

Flow Rate

Comparison Between Measured Data andCFD Prediction

MeasuredPressureGainPredictedPressureGain

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Early CFD - Challenges

• Results were good but

• Model set-up would take 8+ hours

• Each flow point would take 4 – 10 hours to converge• 6 flow points for one pump = 40+ hours

• Meshing was manual and required expertise to generate a good mesh

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AcuSolve Process Automation

Import CAD /HM mesh

Define• Solids• Stationary Fluid• Rotational Volume

• Angular velocity• Rotation axis

• Process intelligence

• Fast setup: 4 steps 

• Auto meshing

• Auto solving strategy

• Auto Time ste s calculation

11

22

BoundaryConditions

Inlet / Outlet

Automeshing

Auto time stepcalculations

SOLVE

10minutes

Setup time

 

• Setup multiple flow pointsand run it batch mode

44

33

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Cooper Standard Pump Analysis

• Goal: Predict pump performance,Flow Curve

• Reduce Setup and Solution time

• Enable CSA Engineering team to

Meshed Impeller

Pump – Meshed Model

 

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AcuSolve’s Rotating Machinery Process

• First run

• Very fast setup and solution

• Helped understand process and setup before adding more

details• Setup Time: 1 hour from receipt of CAD impeller

• Solution Time: 12 flow points – 10 hours

0.000

0.200

0.400

0.600

0.800

1.000

1.200

0.000 0.200 0.400 0.600 0.800 1.000 1.200

TestFirst Run

16

Boundary Layer = 1.4 mmMesh Size 7 mm

Flow

   P  r  e  s  s  u  r  e   G  a   i  n

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AcuSolve’s Rotating Machinery Process

• Refined Mesh

• Analysis converged in 9th iteration

• AcuSolve results matched test results

• Setup Time: Unchanged

• Solution Time: 12 flow points-24 hours1.200

17

Boundary Layer = 0.1 mmMesh Size 2 mm (on Impeller)

Flow

   P

  r  e  s  s  u  r  e   G  a   i  n

0.000

0.200

0.400

0.600

0.800

1.000

0.000 0.200 0.400 0.600 0.800 1.000 1.200

Test Pressure Gain

Final Converged Run

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AcuSolve Results

Contours of Static Pressure Contours of Velocity

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AcuSolve Results

 

Pressure Distribution

 

Pressure Distribution – fluid

volume

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AcuSolve Results

Contours of Pressure on

Planes Cut Through a Pump

Contours of Velocity onPlanes Cut Through a Pump

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AcuSolve Results

Pressure Distribution Velocity Profile

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AcuSolve Results

Pressure Distribution Velocity Profile

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Additional Collaboration - Thermal Analysis –Pump

• Cooper Standard engaged Altair in a consulting project to set-up the

initial AcuSolve models

• Altair transferred knowledge to Cooper Standard for future product

development

3D CAD Model Simplified FEA 3D Model

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Additional Collaboration - Thermal Analysis -Pump

IR Camera Image AcuSolve Thermal Analysis results

AcuSolve predicted high temperature component locations and were laterconfirmed by IR camera

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AcuSolve Results

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Thank You