1D/3D Computational Analysis of a V6 S.I. Variable Intake Manifold
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1 V6 S.I. Variable Intake Manifold Christof Schernus, Thorsten Märtens, Werner Willems, FEV Motorentechnik GmbH & Co. KG Martin Hopp, Lehrstuhl für Verbrennungskraftmaschinen, RWTH Aachen Heijo Oehlschlegel, FEV engine technology, Inc. Presentation at the GT-Suite User Conferences November 2, 1998 Wings Hotel, Raunheim, Germany November 16, 1998 Hilton Northfield, Troy, MI, U.S.A. 1d3d.ppt - TBM/Scher 1
2 Introduction Why use 1D-3D coupled simulation? High computational effort Long CPU time reduced number of analyzed operating points / variations. Increased development efficiency Deep insight in flow phenomena and easier understanding Immediate feedback about design modifications Cost-benefit ratio has to be analyzed at the beginning of a Simulation Task to select appropriate tools Complexity of flow domain Applicability of pure 1D simulation Desired kind and detail of results 1d3d.ppt - TBM/Scher 2
3 Contents Introduction 1D-3D Modeling Strategy Base Engine and Development Goals Intake Manifold Concept Calibration of GT-Power Model with Measured Data Packaged Intake Manifold 1D/3D-Simulation and Results Conclusions 1d3d.ppt - TBM/Scher 3
4 1D-3D Modeling Strategy Calibrated 1D Base Engine model concept study CAD CFD Experimental Data Experimental Data Hybrid model (1D+3D) of new design Experimental Data Flow Characteristics of new design Optimized Virtual Intake System 1D investigation multiple speed multiple load Representative 1D model of the 3D domain 1d3d.ppt - TBM/Scher 4
5 Base Engine and Development Goals Base Engine V6 S.I. passenger car engine Fixed intake manifold & valve timing 42 kw/l (56 bhp/l) 85 Nm/L (63 ft-pds/l) Development Goals: 100 Nm/L (74 about 2500 rpm 55 kw/l (74 about 6000 rpm Variable intake manifold Package Minimum number of valves/variabilities 1d3d.ppt - TBM/Scher 5
6 Intake Manifold Concept Ideal Switch System (Sim.) Component Intake System (Exp.) Realistic Variable Intake System +» Torque Runners Power Runners Switched Branched Intake System 1d3d.ppt - TBM/Scher 6
7 Packaged Intake Manifold Plenum Chamber Torque Runners Shifting Drum Power Runners 1d3d.ppt - TBM/Scher 7
8 Calibration of GT-Power Model with Measured Data Pressure [bar] Intake Runner Cyl. 6 Cylinder 6 Exhaust Cyl. 6 Measured Calculated Crank Angle [ ATDC Cyl. 1] 1d3d.ppt - TBM/Scher 8
9 Validation of GT-Power Model by Measurement 1.1 Component Intake System Measured Predicted Volumetric Efficiency Engine Speed [rpm] 1d3d.ppt - TBM/Scher 9
10 1D/3D Simulation and Results 1d3d.ppt - TBM/Scher 10
11 1D/3D Simulation and Results 1d3d.ppt - TBM/Scher 11
12 Velocity in Intake Manifold at 2800 rpm 1d3d.ppt - TBM/Scher 12
13 Velocity in Intake Manifold at 2800 rpm 1d3d.ppt - TBM/Scher 13
14 Pressure in Intake Manifold Cylinder 6 at 6000 rpm 1d3d.ppt - TBM/Scher 14
15 Velocity in Intake Manifold Cylinder 6 at 6000 rpm 1d3d.ppt - TBM/Scher 15
16 1D/3D Simulation and Results Intake Runner Cyl Intake Runner Cyl Cylinder Cylinder 6 Pressure [bar] rpm Pressure [bar] rpm Exhaust Cyl. 6 1D+3D pure 1D Exhaust Cyl. 6 1D + 3D pure 1D Crank Angle [ ATDC Cyl. 1] Crank Angle [ ATDC Cyl. 1] 1d3d.ppt - TBM/Scher 16
17 Optimization Results Torque [Nm/l] Base Optimized Power [kw/l] Engine Speed [rpm] 1d3d.ppt - TBM/Scher 17
18 Summary and Conclusions The 1D-3D link of STAR-CD and GT-Power is a useful tool to investigate details of dynamic flow in a subdomain of the intake or exhaust manifold The pressure oscillation behavior of all gas columns outside the 3D domain is considered by the 1D model Impact of design modifications can be evaluated immediately regarding engine fuel economy, and/or performance 3D CFD can be used to calibrate a pure 1D model, that is required to investigate the engine performance in a larger number of operating points. 1D-3D analysis results in deeper understanding of complex flow phenomena. Therefor, the application of this method can increase the efficiency of the development process, if costbenefit ratio is considered carefully. 1d3d.ppt - TBM/Scher 18
Christof Schernus, Frank van der Staay, Hendrikus Janssen, Jens Neumeister FEV Motorentechnik GmbH
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