AUTOMATED CFD-SIMULATION OF A TURBOCHARGER ON A HIGH PERFORMANCE BMW DIESEL ENGINE BY USE OF DFBI M. REICHHART

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1 STAR Global Conference 2016, Prague BMW Group, March 7, 2016 AUTOMATED CFD-SIMULATION OF A TURBOCHARGER ON A HIGH PERFORMANCE BMW DIESEL ENGINE BY USE OF DFBI M. REICHHART

2 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

3 TURBOCHARGER On a high performance BMW diesel engine COMPRESSOR Increases the density of the air engine more efficient TURBINE Driven by the engine's exhaust gas drives the compressor

4 TURBOCHARGER On a high performance BMW diesel engine Up to rpm VNT variable geometry turbocharger High velocity High level of CFD Max. time step

5 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

6 FORMER WORKFLOW Compressor Mass flow inlet Mass flow rate 3D simulation compressor (cold side) Pressure outlet Boost pressure Rotation speed n turbo target manual P actual Pressure Rotation speed, Torque f -shaft, adiabatic f Boundary condition Evaluation parameter Control variable Target value

7 FORMER WORKFLOW Turbine manual 3D simulation turbine (hot side) Torque VNT position Rotation speed, Torque f Rotation speed Engine back pressure -shaft, adiabatic f Mass flow inlet Mass flow rate Pressure outlet Exhaust pressure Boundary condition Evaluation parameter Control variable Target value

8 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

9 VNT MOTION with Overset Mesh Method Size of the overset boundary Mesh size Detailed focus on the vane side clearance Workflow for the motion Background mesh Overset mesh boundary Wall boundary

10 VNT MOTION with Overset Mesh Method Size of the overset boundary Important to have comparable mesh size Mesh size Detailed focus on the vane side clearance Workflow for the motion

11 VNT MOTION with Overset Mesh Method Size of the overset boundary Mesh size Volumetric Control Specified Prism Layer Mesher Detailed focus on the vane side clearance Workflow for the motion

12 VNT MOTION with Overset Mesh Method Size of the overset boundary Mesh size o One cylindrical coordinate system for each guide vane o User defined vertex motion for the motion (allow the specification of a rotation angle) o Time step as trigger Detailed focus on the vane side clearance Workflow for the motion

13 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

14 AUTOMATION 1. PI-Controller 3D simulation compressor and turbine Pressure outlet Target mass flow Boost pressure Torque Pressure outlet Exhaust pressure VNT position Rotation speed Rotating speed Stagnation inlet Pressure Rotation speed, Torque f -shaft, adiabatic f Mass flow inlet Mass flow rate Engine back pressure Boundary condition Control variable Target value Evaluation parameter PI-Controller

15 AUTOMATION 1. PI-Controller n new = Y k p p target pactual p target + k i error Y 0 = 1 error = error + p target p actual p target Pressure outlet Target mass flow k p = 0.5 k i = 0.2 1_p20_target Expression Report 2_p20_actual Mass Flow Average Report Boost pressure 3_p20_error skalare Field Function 4_p20_sumerror Field Sum Monitor 7_n_new skalare Field Function 8_n_new Expression Report 5_p20_sumerror Surface Average Report 6_n_initial Expression Report Stagnation inlet Pressure Rotation speed

16 rotation speed [rpm] Boot pressure [bar] Torque [Nm] VNT position [ ] AUTOMATION 1. PI-Controller PI-Controller for the boost pressure PI-Controller for the toque End Start Rotation speed 2.47 Boost pressure Iteration VNT position 8 Torque Timstep

17 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

18 AUTOMATION 2. DFBI (Dynamic Fluid Body Interaction) Benefit: o Rotation speed => an additional degree of freedom o Rotation speed => a result of the thermodynamic o Performance balance between compressor and turbine o Improved presentation of operational details for compressor and turbine and it`s interaction

19 AUTOMATION 2. DFBI (Dynamic Fluid Body Interaction) 3D Simulation compressor and turbine Pressure outlet Boost pressure Pressure outlet Exhaust pressure Torque Rotation speed Torque, Moment of inertia Rotation speed Comp. torque Comp. moment of inertia Turb. moment of inertia Thermodynamic Mass flow inlet Mass flow -shaft, adiabatic f Mass flow inlet Mass flow rate Engine back pressure Boundary condition Evaluation parameter DFBI

20 Angular velocity [s -2 ] Rotation speed [rpm] Angular velocity [s -2 ] Rotation speed [rpm] AUTOMATION 2. DFBI (Dynamic Fluid Body Interaction) Starting from: => good steady state solution! Starting from: => low steady state solution! ~183300rpm Angular velocity Rotation speed Angular velocity Rotation speed Time step Time step SLOW => Just ~600 rpm after 1000 time steps To find steady operating points, it is possible to reduce the moment of inertia This is not possible for acceleration evacuation

21 rotation speed [rpm] pressure ratio AUTOMATION 2. DFBI (Dynamic Fluid Body Interaction) ~ rpm Time Step mass flow kg/h

22 AUTOMATION 2. DFBI (Dynamic Fluid Body Interaction) 3D Simulation compressor and turbine Pressure outlet Boost pressure VNT position Pressure outlet Exhaust pressure Target mass flow Torque Rotation speed Torque, moment of inertia Rotation speed Comp. torque Comp. moment of inertia Turb. moment of inertia Thermodynamic Stagnation inlet Pressure -shaft, adiabatic f Mass flow inlet Mass flow rate Engine back pressure Boundary condition Control variable Target value Evaluation parameter DFBI PI-Controller

23 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

24 CONCLUSION PI-Controller: o o o o o DFBI: o o o o o o For transient and steady simulation Easy to adapt existing simulations Fast results Automation for steady operating points Currently used system Workflow, adjustment, physic are similar to the car and test bench. Comparable thermodynamically shortcomings to the real engine Show cross influences between compressor and turbine Thermodynamically shortcomings are easier assignable to parts. Slow and time-consuming Automation for steady operating points and acceleration evacuation

25 CONTENT TURBOCHARGER FORMER WORKFLOW VNT MOTION AUTOMATION 1. PI-Controller 2. DFBI (Dynamic Fluid Body Interaction) CONCLUSION OUTLOOK

26 OUTLOOK 2-stage Turbocharger High pressure VNT Exhaust control valve Low pressure VNT Compressor bypass

27 OUTLOOK 2-stage Turbocharger controlled High pressure VNT closed Exhaust control valve controlled Low pressure VNT closed Compressor bypass

28 OUTLOOK. 2-stage Turbocharger open High pressure VNT controlled Exhaust control valve controlled Low pressure VNT closed Compressor bypass

29 OUTLOOK 2-stage Turbocharger open High pressure VNT open Exhaust control valve controlled Low pressure VNT open Compressor bypass

30 THANKS FOR YOUR ATTENTION

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