Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation

Exhaust line simulations using Star-CCM+ and automation

Yohann Perrot

22-March-2010

2Propertyof Faurecia -Duplication prohibited

Agenda

� Faurecia Emissions Control Technologies

� Exhaust line components

� Some correlations and investigations

� Enhancements

� Automation


Agenda




� Enhancements

� Automation


Emission limits – LDV Diesel

Europe

NOx

[g/km]

USA

0.2 0.3 0.4 0.50.1

JP 2005

JP 2002

JP 2009

PM [g/km]

0.02

0.03

0.04

0.01

0.05

NOx

[g/km] 0.4 0.3 0.2 0.10.5

Japan

Tier 2 / Phase In (2004)

Tier II Bin 8 (2004)

Tier II Bin 5 (2009)

EU 3 (2000)

EU 4 (2005)EU 5(2009)

EU 6(2014)

PM [g/km]

0.04

0.03

0.02

0.05

0.01


AMELI & AMELI & GTGT--PowerPowerTail pipe noiseTail pipe noise

FLOWMASTERFLOWMASTERBack pressure

AMELI & GTAMELI & GT--PowerPowerTL, EBP predictionTL, EBP prediction

Full validated exhaust

CustomerSpecif.Sheet

Vehicle LevelVehicle LevelVehicle LevelVehicle Level

System LevelSystem LevelSystem LevelSystem Level

Subsystem LevelSubsystem LevelSubsystem LevelSubsystem Level

Component Component Component Component LevelLevelLevelLevel

CFD/GTCFD/GTCFD/GTCFD/GT----PowerPowerPowerPower1D/3D coupling

FIREFIREDPF, SCR simulations

StarStar--CCM+CCM+Flow distributionFlow distribution

StarStar--CCM+, FIRECCM+, FIREHeat TransferHeat Transfer

SIMCPSIMCPCatalysts & DPF BackpressureCatalysts & DPF Backpressure

Development process


�When Faurecia develops a new product or an innovation, a corresponding CFD & FEA procedure must be created

� CAD templates have to developed and then deployed for each current and new product

� Communication between CAE software must be ensured automatically

� Thanks to this approach, among their activities, CAE experts will � Spend more time in analyzing the results than meshing or debugging

� Assist and help in defining where and what to measure during experimental tests

� Contribute in building the design know-how/guideline of their local customers

� Inform regularly the CAE coordinator of the future needs expressed by the customers and give update of their requirements

� Star tools participate to that vision

Global CAE vision


Agenda




� Enhancements

� Automation


Overview of exhaust activity

Cold EndAcoustic

Hot EndEmission control

Structural integrityDurability


Manifold & Turbo

Heat exchanger, EHRS

Fuel Vapo

3W catalyst,

DOC, DPF

SCR

Injector Vein, Mixers

LP EGR,

backpressure

valves

Muffler

3WV

Exhaust line components


Agenda




� Enhancements

� Automation


PPPPmeasmeasmeasmeas....= 463mbar= 463mbar= 463mbar= 463mbarPPPPStarStarStarStar----CCM+CCM+CCM+CCM+= 466mbar= 466mbar= 466mbar= 466mbar

TTTTmeasmeasmeasmeas....= 740= 740= 740= 740°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= = = = 827827827827°°°°CCCC(lack engine block cooling)(lack engine block cooling)(lack engine block cooling)(lack engine block cooling)

PPPPmeasmeasmeasmeas....= 469mbar= 469mbar= 469mbar= 469mbarPPPPStarStarStarStar----CCM+CCM+CCM+CCM+= 467mbar= 467mbar= 467mbar= 467mbar

TTTTmeasmeasmeasmeas....= 750= 750= 750= 750°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= = = = 840840840840°°°°CCCC(Presence of radiator not taken into (Presence of radiator not taken into (Presence of radiator not taken into (Presence of radiator not taken into account)account)account)account)

TTTTmeasmeasmeasmeas....= 663= 663= 663= 663°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 677= 677= 677= 677°°°°CCCC(Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken into account)into account)into account)into account)

TTTTmeasmeasmeasmeas....= 816= 816= 816= 816°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 800= 800= 800= 800°°°°CCCC

TTTTmeasmeasmeasmeas....= 802= 802= 802= 802°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 820= 820= 820= 820°°°°CCCC

PPPPmeasmeasmeasmeas....= 380mbar= 380mbar= 380mbar= 380mbarPPPPStarStarStarStar----CCM+CCM+CCM+CCM+= 377 mbar= 377 mbar= 377 mbar= 377 mbar

TTTTmeasmeasmeasmeas....= 737= 737= 737= 737°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 730= 730= 730= 730°°°°CCCC(Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken into account)into account)into account)into account)

Some correlations…


Catalytic converter simulations


Hot wire anemometry measurements

EOPEngine

�� 419 kg/h @ 560°C

Corresponding EOPFlow bench

(Reynolds analogy)

�� 207 kg/h @ 20°C


EHRS simulation – 810 kg/h @ 830°C – Bypass way


Tmeas. = 585°C

TStar-CCM+ = 602°C

Tmeas. = 398°C

TStar-CCM+ = 384°CTmeas. = 198°C

TStar-CCM+ = 216°C

Tmeas. = 598°C

TStar-CCM+ = 614°C


Transient manifold simulation (following the firing order)

Some investigations…


Velocity uniformity index vs. time

0.910.910.910.91


Full cold-end simulation (PSA EP6DTS)

Toward full exhaust line simulations…


Agenda




� Enhancements

� Automation


Enhancements

� Heat transfer simulation

� Purpose: To take into account the whole heat transfer (conduction, convection and radiation) without simulating the solid

� Heat exchanger simulation

� Basics in thermomechanics for fast & complete optimization (relative comparisons)


Agenda




� Enhancements

� Automation


Faurecia Emissions Control Technologies

� Simulation gain (ex: Catalyst-DPF fluid dynamics simulation):

� Pre-processing: 50%

� Running: 25%

� Post-processing: 10%

� Example…


Thank you for your attention

Documents

Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation