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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles STAR Global Conference 2014 Wien, March 17th 2014 Mario Disch, Walter Bauer, Daimler AG Agenda How do computational methods contribute to the prototype development

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SLIDE 1

A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

STAR Global Conference 2014 Wien, March 17th 2014 Mario Disch, Walter Bauer, Daimler AG

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Agenda

How do computational methods contribute to the prototype development process at Mercedes-Benz?

  • Motivation
  • Vehicle Thermal Management Approach
  • Transient Simulation vs. Measurement
  • Conclusions and Future Work

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Motivation

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Malaucène 410 m a. s. l.* Mont Ventoux 1433 m a. s. l. t T

Vehicle Thermal Management (VTM) for dynamic driving cycles οƒ  Transient thermal analysis of temperature components for a passenger car

Source: Google Earth * meters above sea level

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Co-Simulation of a transient Solid Model (conduction and radiation) with a steady state Fluid Model (convection)

Fluid Model (STAR-CCM+) Detailed modelling of the

  • Underhood flow
  • Coolant circuit
  • Exhaust flow
  • Oil circuit,

in order to capture the internal heat transfer of the engine and the exhaust system.

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Co-Simulation of a transient Solid Model (conduction and radiation) with a steady state Fluid Model (convection)

Fluid Model (STAR-CCM+) Detailed modelling of the

  • Underhood flow
  • Coolant circuit
  • Exhaust flow
  • Oil circuit,

in order to capture the internal heat transfer of the engine and the exhaust system.

thermostat valve

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SLIDE 6

A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Co-Simulation of a transient Solid Model (conduction and radiation) with a steady state Fluid Model (convection)

Fluid Model (STAR-CCM+) Detailed modelling of the

  • Underhood flow
  • Coolant circuit
  • Exhaust flow
  • Oil circuit,

in order to capture the internal heat transfer of the engine and the exhaust system.

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SLIDE 7

A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Co-Simulation of a transient Solid Model (conduction and radiation) with a steady state Fluid Model (convection)

Fluid Model (STAR-CCM+) Detailed modelling of the

  • Underhood flow
  • Coolant circuit
  • Exhaust flow
  • Oil circuit,

in order to capture the internal heat transfer of the engine and the exhaust system.

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SLIDE 8

A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Co-Simulation of a transient Solid Model (conduction and radiation) with a steady state Fluid Model (convection)

Detailed modelling of 4821 parts and 151 material properties. Prediction of the heat transfer mechanisms taking place inside the vehicle structure based on the heat released inside the combustion chamber. Solid Model (STAR-CCM+)

𝑅 π·π‘π‘œπ‘’π‘£π‘‘π‘’π‘—π‘π‘œ 𝑅 𝐷𝑝𝑛𝑐. 𝑅 𝑆𝑏𝑒. 𝑅 π·π‘π‘œπ‘€π‘“π‘‘π‘’π‘—π‘π‘œ

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Transient Simulation vs. Measurement

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Replicated Up-hill Drive

  • Test car – Mercedes-Benz E-Class 220 CDI – in the climatic wind tunnel
  • The driving cycle is derived from the Mont Ventoux test track. It consists of a sequence of12 full

throttle acceleration phases. length /km

v

1 2 12 11 preconditioning steady state transient

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Transient Simulation vs. Measurement

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Replicated Up-hill Drive

Temperature prediction of the turbocharger housing

* Referenced Temperature: delta T= T-Ttest_initial

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Transient Simulation vs. Measurement

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Replicated Up-hill Drive

Temperature prediction of the cylinder head

* Referenced Temperature: delta T= T-Ttest_initial

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Transient Simulation vs. Measurement

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Replicated Up-hill Drive

Temperature prediction of the right and the left engine mount

* Referenced Temperature: delta T= T-Ttest_initial

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Transient Simulation vs. Measurement

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Replicated Up-hill Drive (real time=740 s)

  • Turn-around time

April 2013 August 2013 104 CPU 104 CPU 104 CPU (shared) >104 CPU >6 CPU 6 CPU 6 CPU 1 CPU March 2014

(multiple fluid computation)

Prediction

(event driven fluid computation)

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Conclusions and Future Work

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Conclusions

  • Transient VTM approach combines transient solid computation with a sequence of steady state fluid

computations including all the inner circuits.

  • The new VTM approach provides a good predictability for temperature, which has been validated with

experimental data, especially for parts dominated by radiation and conduction.

  • High turn-around time is addressed by:
  • multiple fluid coupling scenario
  • parallelized solid computation
  • increasing computing performance
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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Conclusions and Future Work

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Future Work

  • Simulation of further driving cycles (urban driving cycles, stop & go, race track, …)
  • More detailed modeling of the coolant circuit (water pump as MRF-zone)
  • Adding the charge air path into the simulation

water pump (MRF) dual stream T_compr.

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Thank you !

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

BACKUP

17 Thorsten Schmitt, RD/FNE, xx.012.2014

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Co-Simulation Coupling Procedure

Time / s

steady state transient

SOLID 1x Ξ”t=10 s FLUID

Init. ~1000 Its*

Dynamic BC (1D GT-Suite)

Time 𝑔

(𝑒)

[𝑑] [𝐿, 𝑙𝑕 𝑑 , 𝑄𝑏]

π’ˆ(𝟏)

10 𝑔

(10)

t+1 𝑔

(𝑒+1)

FLUID π‘ˆπΊ β„Žπ‘’π‘ π‘π‘œ π‘ˆπ‘‹ π‘’π‘œ+1 = π‘’π‘œ + βˆ†π‘’

~1000 Its

Dynamic BC (1D GT-Suite)

Time 𝑔

(𝑒)

[𝑑] [𝐿, 𝑙𝑕 𝑑 , 𝑄𝑏] 𝑔

(0)

10 π’ˆ(𝟐𝟏)

t+1 𝑔

(𝑒+1)

π‘’π‘œ π‘ˆπΊ

  • The dynamics of the flow field are approximated by a sequence of steady state computations
  • 1D simulation results are applied as dynamic boundary conditions

β„Žπ‘’π‘ π‘π‘œ

* Its: Iterations

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A Numerical Approach to Vehicle Thermal Management of Dynamic Driving Cycles

Vehicle Thermal Management Approach

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Model information Models Solid Uhood Exhaust Coolant Circuit Oil Circuit Charge Air Number of Cells (Mio.) 39.84 38.51 3.43 2.04 0.48 2.86 Mesh topology polyhedral hexahedral polyhedral polyhedral polyhedral hexahedral