Dongfeng Commercial Vehicle

Transcription

1 Automotive and transportation Dongfeng Commercial Vehicle Product Simcenter Leading truck manufacturer optimizes engine cooling controls strategies with Simcenter Amesim Business challenges Cut truck development costs and time Reduce the number of prototypes and the use of test benches Maintain a competitive edge by implementing energy recovery concepts Keys to success Design an efficient engine cooling system with advanced controls strategies Optimize existing diesel engines by considering different design options Analyze the impact of the exhaust heat recovery technology under real driving conditions Siemens PLM Software solution helps Dongfeng Commercial Vehicle investigate the Rankine cycle concept to boost truck fuel efficiency Quest for sustainable trucks The truck market is an excellent barometer for assessing the health of the global economy. This small but significant segment of the automotive industry provides transportation for all consumer and industrial goods by complementing other means of conveyance or by supporting the entire logistics chain. However, even though trucks represent a relatively small slice of the transportation market, they play an outsized role in energy usage and emissions. For instance, in 2010 heavy-duty trucks represented only four percent of registered vehicles in the United States, but accounted for approximately 25 percent of on-road energy use and greenhouse gas emissions. It is therefore not surprising that truck manufacturers have followed the lead of the automakers by shifting toward greener vehicle designs. Currently, nearly 60 percent of the energy contained in the fuel of a heavy-duty truck is wasted in the engine through pumping, friction, cooling and exhaust losses. Moreover, considering that fuel is the main expense for the truck fleets, the payback period for energy-efficient technologies is sometimes less than one year, which is 5 to 10 times faster than for cars. Results Optimized engine cooling controls strategies Analyzed behavior of the combustion, cooling and lubrication subsystems in the context of the entire vehicle Studied Rankine cycle technology before the first prototype was available As a leading transport service partner in China, DFCV is curren tly working on engine fuel efficiency to optimize freight transportation patterns.

2 We needed a simulation tool that would allow us to understand all of the technical issues of a complex system such as an engine, by modeling its combustion, cooling, lubrication subsystems and then integrating these subsystem models into the entire vehicle model. Performance and Controls Section Engine Development Department Using Simcenter Amesim helps DFCV validate advanced controls strategies of the modern diesel engine s cooling system. Thus, heavy-duty truck manufacturers, like their counterparts in the car industry, are accelerating their efforts to develop efficient energy recovery concepts. One of the most promising approaches for the truck industry is the exhaust heat recovery technology with a Rankine cycle system. In a closed Rankine cycle loop, the working fluid, heated by exhaust gases, turns into vapor. Then the fluid vapor runs a turbine, which can be directly linked either to the crankshaft of the engine or to an electric generator. In spite of controls and design complexity, there is rising interest in this technology because it would allow truck producers to improve overall fuel efficiency by approximately 5 percent. Conquering the largest market Due to its rapid economic growth, China has become the world s largest heavy-duty truck market, representing more than 40 percent of the global share. To gain access to the promising Chinese market and share development costs of new-generation engines, European and American truck manufacturers are establishing joint ventures with local truck producers. At the same time, this cooperation allows Asian truck original equipment manufacturers (OEMs) to reinforce their technical expertise and worldwide presence. In 2013, the Swedish auto manufacturer AB Volvo signed an agreement with the Chinese OEM Dongfeng Motor Group With Simcenter Amesim, we have reduced our development costs significantly because we no longer need to use a test bench to validate our controls strategies.

3 Best-of-breed truck manufacturers must take a sustainable path by offering innovative, greener engine designs. (DFG) to establish the joint venture Dongfeng Commercial Vehicle (DFCV). This agreement will make AB Volvo the world s largest manufacturer of heavy-duty trucks. Enhancing diesel engine control strategies To meet the strong demand of its domestic market, DFCV seeks to optimize the diesel engine development cycle while reducing the number of prototypes and the use of test benches in the early design phases. Acknowledged as a leading transport service partner in China, DFCV is currently working on engine fuel efficiency to optimize freight transportation patterns. The of the is dealing with increasingly complex control strategies that make it possible to optimize engine thermal management. In order to maximize engine fuel efficiency, the engineers of the Performance and Controls Section have to answer a number of questions, such as What is the best way to optimize fan controls to save fuel while maintaining cooling performance? and How could a controlled thermostat or water pump improve the cooling system performance? We needed a simulation tool that would allow us to understand all of the technical issues of a complex system such as an engine, by modeling its combustion, cooling, lubrication subsystems and then integrating these subsystem models into the entire vehicle model, says, a controls engineer in the Performance and Controls Section of the Engine Development Department of the DFCV Technical Center. We believe that our simulation approach, supported by Simcenter Amesim, contributes strongly to our future competitiveness.

4 The lubrication circuit is one of the engine subsystems that DFCV models with Simcenter Amesim in order to integrate it into the entire vehicle model. DFCV models the Rankine cycle loop using the two-phase flow library of Simcenter Amesim. The turned to Siemens PLM Software for help. Following a benchmark, DFCV was impressed by the unprecedented accuracy of results obtained with an engine thermal model built using Simcenter Amesim software. Using Simcenter Amesim, we now assemble all engine subsystems in one model in order to test controls strategies to assess fuel consumption via co-simulation between an Simcenter Amesim and Simulink models, says Xin. We can not only analyze the fuel efficiency of our existing architectures, but also capitalize and re-use the same model to optimize current designs. With Simcenter Amesim, we have reduced our development costs significantly because we no longer need to use a test bench to validate our controls strategies. Taking the lead with energy recovery concepts To stay in the global fuel-efficiency race, DFCV is currently investigating innovative energy recovery technologies such as a Rankine cycle-based system. The Rankine cycle concept requires even more complicated controls strategies and its behavior must be analyzed separately at first, and then integrated into the complete vehicle simulation model to assess the system performance on multiple driving cycles. We believe that our simulation approach, supported by Simcenter Amesim, contributes strongly to our future competitiveness, says Xin. Our research and development activity around the Rankine cycle technology wouldn t be possible without the two-phase flow library of Simcenter Amesim as well as other predefined and validated multi-domain Simcenter Amesim components, which allow us to analyze the effect of this innovative approach under real driving conditions before the first prototype has been produced.

5 Solutions/Services Simcenter Amesim simcenter-amesim Customer s primary business With eight plants and 28,000 employees, Dongfeng Commercial Vehicle is China s leading manufacturer of medium-duty and heavy-duty trucks. Customer location Wuhan China Our research and development activity around the Rankine cycle technology wouldn t be possible without the two-phase flow library of Simcenter Amesim Our research and development activity around the Rankine cycle technology wouldn t be possible without the twophase flow library of Simcenter Amesim as well as other predefined and validated multi-domain Simcenter Amesim components, which allow us to analyze the effect of this innovative approach under real driving conditions before the first prototype has been produced. Performance and Controls Section Engine Development Department Performing co-simulation with models utilizing Simcenter Amesim and the Simulink environment allows DFCV to save testing time. Siemens PLM Software Americas Europe +44 (0) Asia-Pacific Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. Femap, HEEDS, Simcenter 3D and Teamcenter are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Simcenter, Simcenter Amesim, LMS Samtech Samcef, LMS Samcef Caesam, LMS SCADAS, LMS SCADAS XS, LMS Smart, LMS Test.Xpress, LMS Soundbrush, LMS Sound Camera, LMS Test.Lab and LMS Virtual.Lab are trademarks or registered trademarks of Siemens Industry Software NV or any of its affiliates. STAR-CCM+ and STAR-CD are trademarks or registered trademarks of Siemens Industry Software Computational Dynamics Ltd. All other trademarks, registered trademarks or service marks belong to their respective holders A8 12/17 H