Enabling Advanced Vehicle Heat Protection Through the Digital Prototype

Frederick J. Ross Director, Ground Transportation

Agenda

STAR-CCM+ Designed for Vehicle Heat Protection Over 25 years of experience STAR-CCM+ Design Focus on VTM Benefit of Siemens

Automation tools to help reduce turn-around time

Vsim: Automating Front End Air Flow C2M: Automating Component Modeling

Case Studies

STAR-CCM+ For Vehicle Thermal Management v2.0 was first enabler using client-server with mesh generation

Solver Team

New Client Server

Cell Quality Remediation

Heat Exchanger Models

Fast S2S Radiation

Shell Conduction

Co-Simulation

Parts Based Profile

Mesh Development Team

Surface Wrapping: Clean Surface

Bring in CAD Tree

Imprint/Boolean Operations

Thin Mesher

Parts Based Meshing

Parallel Trimmer

Concurrent Meshing

STAR-CCM+V2:2006

STAR-CCM+V11:2016

Robustness Job needs to run with minimum user interaction.

1

Reduce Turn Around Automation Ease-of-Use Quick Modifications

2

Accuracy Need to simulate real world test conductions

3

Goals 1

1 2

2

2

2

2

3

2

3

2

3

2

2

1 1

Vehicle Thermal Management Maturity Roadmap

1 2 3 4 5 Complexity

FullVehicleThermalManagement•  4000+solids•  Coolant/Oiletc•  DriveCycleSimula?on

5

PowerTrainCooling•  EngineCHT•  Coolant•  Oil,Intake/ExhaustFlows

4

BrakeCooling•  Radia?on&CHT•  Rota?ngParts/Fric?onHea?ng•  Op?mizeCooling

2

ExhaustSystemCHT•  100-400Solids•  Radia?on&CHT•  HeatShieldDesign/

Placement

3

FrontEndAirFlow•  TopTankTemperature

Predic?on1

Level 1 •  Fully automatic •  Single or Dual Stream •  No Solid Modeling •  Fast turn-around time

Level 2: Simulation of Systems •  Automating Procedures •  40-400 Solids + Radiation

Level 3: Virtual Prototype •  Working from CAD to Simulation •  Simulating Systems: Solids/Fluid

•  4000 + Solids with Radiation & co-sim

Generation of a Digital Prototype Producing a digital twin   CAD Data Freeze defines digital prototype

–  As with a real prototype, design teams work together to meet a goal for the design freeze.

–  Review board checks, to make sure all components are fitted together and data pool is complete.

  Data Filter: Filters data for simulation –  Data needed for simulation is filtered from the overall

data pool, and provided for the virtual simulation. •  Key component for data transfer

–  PLM (product lifecycle management) tools enable communication between different tools.

  Analysis Response –  Feeds back into the data pool for design improvement.

0

500

1000

1500

2000

2500

3000

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8

Deflection speed v Dam

ping

forc

e F

Grade 1

Grade 2

Geometrical Data Functional Data

The clear leader amongst PLM solution providers in simulation and test software, and associated services.

Siemens PLM Software + CD-adapco: Market Leader in Systems Driven Product Development

§  Computational Fluid Dynamics (CFD), Computational Solid Mechanics (CSM), heat transfer, particle dynamics, reacting flow, electrochemistry, acoustics and rheology.

§  Multidisciplinary optimization and design space exploration §  Electric machine simulation and design

STAR-CCM+ HEEDS

Optimate SPEED

BDS

§  Behavioral simulation: 1D cross-discipline simulation, like mechanical and electrics, e.g. fuel economy & range simulation for hybrid vehicles

§  3D mechanical simulation: e.g. stiffness, noise, vibration §  Testing: Solutions for prototype testing (stationary & mobile)

Virtual.Lab Samtech

Imagine.Lab Test.Lab

§  Streamlines and accelerates the product development process in a collaborative environment

§  Includes a modern, multi-discipline CAE environment

NX CAD NX CAE Nastran

Teamcenter Tecnomatix

Generation of a Digital Prototype Producing a digital twin TeamCenter

Allows user to sort throw CAD, pick assemblies to be modelled Export PLMXML data with JtOpen

Coarse/Medium/Fine Tesselation Brep: Passing geometry Material Properties linked to parts

AmeSim 1D tool for modeling cooling circuit Helps predicting top tank temperature

  STAR-CCM+ Read CAD and prepare mesh for simulation Simulate 3D flow field Post results

Geometrical Data

0

500

1000

1500

2000

2500

3000

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8

Deflection speed v Dam

ping

forc

e F

Grade 1

Grade 2

Functional Data

CADImport

•  ParasolidFiles•  TeamCenterInterface•  STLData

FrontEndAirFlow

•  Setupairstreamthroughenginecompartment• Definezonesforheatexchangers/fans• Connectto1Dtoolsforcoolantcircuitifneeded

SolidCHT

• CADcleanup• BuildInterfacesbetweenparts• Concurrentmeshing

Co-simulaPon

•  ParallelSurface-2-SurfaceRadiaPon•  Solidsrunfullthermaltransient•  Fluideithersteadyortransient

STAR-CCM+ Workflow

8

Computational Process & Tools

radiation

conduction

convection

oil coolant exhaust

driving cycle 1D thermal network Source: M. Disch (upcoming Ph.D thesis, FKFS)

Import CAD Separate region for fan/heat exchangers Underhood Regions:

Group surfaces for underhood region Separate by mesh and physics size:

Set prevent contact for important gaps Close large holes? Use gap closure/anti seed point to prevent leakage into main cabin Wrap Region

Setup heat exchanger/fans: Create interfaces for sub-regions Wrap fan region, if needed. Just remesh heat exchangers

Create physics continua (including material properties) Create all reports, monitors, plots for monitoring convergence Use parallel trimmer to reduce mesh generation time.

Front End Air Flow Workflow

Page 9 April 3, 2014

Solid Conjugate Heat Transfer Model

Goal Predict local component temperature

Typical Applications Components Surrounding Exhaust Brake Cooling

Important Physics Convection Conduction Radiation

Solutions Convection: Vsim Conduction: Parts Based Meshing Framework

C2M: Cad to Mesh Tool

Radiation: Parallel Surface-to-Surface

2

Import CAD Check CAD

Check fit and completeness multiple components per leaf-level part and split into separate parts Check for duplicate parts and tag / delete

Repair CAD problems Extrude parts without thickness Clean CAD surface errors (pierced faces, free edges, non-manifold) Replace or fix gross non-fitting CAD Wrap poor quality parts Boolean subtract all intersecting components Split part surfaces at special internal BC locations

Create physics continua Apply physics to regions Set material properties for each region Apply all radiative surface properties to boundaries

Create all reports, monitors, and plots for monitoring convergence Mesh using parts based meshing to allow multiple pipelines

Enable concurrent meshing to reduce meshing time

Solid Conjugate Heat Transfer Workflow

April 3, 2014

Agenda

STAR-CCM+ Designed for Vehicle Heat Protection Over 20 years of experience Focus of STAR-CCM+ since version 2.0 Benefit of Siemens

Automation tools to help reduce turn-around time

Vsim: Automating Front End Air Flow C2M: Automating Component Modeling

Case Studies Note:

TheautomaPontoolscanbeprovidedbyCD-adapcoasexamplesforclientstouse.Theyaremaintainedforeachrelease,andaslongastheyaremaintained,clientscangetupdated.

VSim: Aero/Thermal Automation STAR-CCM+ reading setup information directly from excel

Automated Process from CAD to Report Reads CAD from subdirectory Spreadsheet Contains Settings

•  CAD Grouping to CFD Boundaries •  Heat Exchanger/Fan Information •  Thermal Boundary Conditions

Run: Mesh/Solve/Post Output: PowerPoint Input: Cad/Excel

Run: Mesh/Solve/Post

1

VSim: Aero/Thermal Automation STAR-CCM+ reading setup information directly from excel 1

1•  OperaPngCondiPons

2•  GroupCADtoBoundaries

3•  MeshSeYngs

4•  Fan/HeatExchangerProperPes

5•  MonitorsandPostProcessing

Automation: C2M Toolbox

Checks Surface for errors Repair parts with severe errors

Move into surface repair Alternatively wrap/replace part

Generate Volume mesh Sets up parts based meshing tree

Find and Generate Interfaces between components

2

Agenda

STAR-CCM+ Designed for Vehicle Heat Protection Over 20 years of experience Focus of STAR-CCM+ since version 2.0 Benefit of Siemens

Automation tools to help reduce turn-around time

Vsim: Automating Front End Air Flow C2M: Automating Component Modeling

Case Studies

Case Study:

Challenge: Investigation of overall aerodynamic drag reduction impact on front end cooling is difficult to predict experimentally.

Solution: Simulation can be used to look at cooling drag at both 55mph and 120mph to ensure aerodynamic drag reduction still meet cooling requirement.

Impact: Digital prototype can aid engineer to reduce overall energy used by vehicle, including aerodynamics drag to front end cooling.

Full Vehicle Aero-Thermal Cooling Drag Sensitivity Analysis

Cranfield Univ., Jaguar Land Rover SAE 2016-01-1578

CustomerSuccess:MulPobjecPvedesignexploraPon}  Challenge:

}  OpPmizeacrossmulPplecompePngobjecPves}  Minimizevehicledrag}  Minimizeradiatorinlettemperature

}  Whilevaryingthesedesignvariables:}  Geometryofgrillandbumpervents}  Radiatorfangeometryandspeed

}  Subjecttoconstraints

}  OpPmate+Results:}  Dragreduced5.4%}  Radiatortemperaturedecreased11.3%}  Evaluated120designs;135hourson128cores

18 | Copyright 2014 - Red Cedar Technology: All Rights Reserved

A U T O M O T I V E

Baseline Optimized

Optimization process

Vehicle Drag Load Case Radiator Temp Load Case

1

Case Study:

Challenge: Use computational methods for prototype development Reduce turnaround time for prediction of thermal behaviour in driving cycles

Solution: Transient Vehicle Thermal Management approach in STAR-CCM+ Co-Simulation of a transient solid model with steady state fluid model Comparison with measurements

Impact: Turnaround time of two weeks for full vehicle transient VTM Good prediction of temperature Optimization of thermal management through computational methods Reduction of testing/prototypes

Thermal Management of Dynamic Driving Cycles Daimler AG 3

Steady-State Full VTM Simulation Airflow + Solids using Co-Simulation

•  Airflow model is 50+ million cells. •  Solid Model is 40+ million cells. •  Over 5000 solid components modeled in the simulation

Case Study:

Challenge: Use simulation to replace endurance testing for source of component temperature failure.

Solution: Use 3D simulation of solids and air to run repeat real world test conditions.

Impact: Digital prototype helps reduce costs and design time from physical testing.

Simulating the Idle: A New Load Case for Vehicle Thermal Management Daimler AG SGC 2016 3

Virtual Powertrain Development Combines work done by individual analysis to accurately predict metal temperature

Concept: Bring models from different simulations to the same detailed engine CHT model to accurately predict metal temperature

Engine Thermal Prediction

In-Cylinder Simulation Coolant Circuit Oil Circuit Crankcase Breathing Piston Cooling

FEA model

Exhaust/Intake Ports

Exhaust/Intake Manifold

3

Challenge Engines that pass the dynamometer still fail when installed into the vehicle. Once vehicle design has been finalized, it can be costly to adjust cooling to the engine. At early design stages, it is important to determine possible thermal issues.

Solution

Use existing geometry of the engine in dynamometer and place engine in vehicle.

Impact Reduce prototype of engine/vehicle construction. Reduce time to find out thermal failures. Reduce cost Reduce time to production. Improve information on failure cause.

In-Vehicle Engine Testing Simulation General Motors

23

3

Maturity of VTM Easy to automate front end air flow CAD improving making solid conduction easier and improving component prediction.

STAR-CCM+ Key Features Java based interface, easy to automate steps CAD structure to match material properties Parts based meshing to enable easy part replacement Fast surface-to-surface radiation Co-simulation to enable drive cycles

Vehicle Heat Protection Toolbox Vsim: Automate aerodynamics/front end cooling C2M: Helps automate modeling solid assemblies

Summary

Case Study:

Thank You!