Holistic 1D-Model for Cooling Management and Engine Analysis of a Heavy-Duty Truck

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1 Holistic 1D-Model for Cooling Management and Engine Analysis of a Heavy-Duty Truck Dominik Renner Dr. Alexander Schydlo 26 th October 2015 MAN Truck & Bus AG < 1 >

2 Agenda 1 Introduction 2 Model Description and Results 3 Summary and Outlook < 2 >

3 Introduction Simulation Tools and Methods 3D -CFD Underhood Engine Data and Models Boundary Conditions Cooler and Fan Data Thermal Hydraulic Simulation (GT-SUITE ) Characteristics of Cooling System Fan Speed Maximum Engine Heat Flow < 3 >

4 Introduction New Work Flow Software Platform GT-SUITE (POWER ) Previous Cooling Circuit PTM Cooling System Cooling Circuit One way interface EDC Engine as heat source Simple cooling circuit for cooling design in steady-state full load engine operating points No influence of cooling power on engine behaviour Physical heat transfer between heat source and fluid are not considered No accurate transient simulation possible Robust model for a rough estimation of required cooling size in the predevelopment phase Up-to-date Powertrain Simulation Cooling System Cooling Circuit Water Jacket GT-SUITE Injection System Physical engine model Gas Dynamic EDC PTM co-sim e.g. Simulink Validated engine model Fluid dynamics, injection, mechanics, closed-loop control (EDC) and the heat transfer are considered in one model Coupling of the cooling circuit and the engine model in one software Cooling circuit (water jacket, heat source, pipes, components) is modeled with calibrated heat transfer Detailed numerical engine analyses are possible Steady-State as well as transient simulation possible < 4 >

5 Introduction Work Flow Software Platform GT-SUITE (POWER ) Engine Model GT-SUITE Cooling Circuit Water Jacket Model FE Cylinder Structure < 5 >

6 Agenda 1 Introduction 2 Model Description and Results 3 Summary and Outlook < 6 >

7 Model Description and Results Detailed Engine Model CAC-HP HP-Stage Charge Air Exhaust Gas CAC-LP LP-Stage < 7 >

8 Model Description and Results FE Cylinder Water Jacket Thermal Mass Cylinder Head Cylinder Head Flow Crank Case Flow Thermal Mass Crank Train < 8 >

9 Model Description and Results Cooling Circuit EGR Main Thermostat LT - Cooler HT - Cooler Water Jacket Model Water Pump CAC-LP Charge Air High Temp.- Circuit Low Temp. - Circuit CAC-HP Cooler Fan < 9 >

10 Model Description and Results Steady-State Investigation Investigated Engine Concepts: Goal of steady-state operating point investigation: Comparison of direct and indirect cooling concepts for engines with singlestage and two-stage turbo-charger Verification of thermal load of different cooling components and cooling circuits Optimization of the max. fan speed for different cooling systems < 10 >

11 Model Description and Results Engine Concept full load: < 11 >

12 Agenda 1 Introduction 2 Model Description and Results 3 Summary and Outlook < 12 >

13 Summary and Outlook Checklist Engine and Water Jacket Model Cooling Circuit Model Steady-State Validation with Test Rig Data Comparison of different Engine Concepts Next steps short term : Transient Full Vehicle Model in GT-Suite Next step medium term : Implementation of more detailed vehicle components via FMU < 13 >

14 Summary and Outlook Mean Value Engine with Full Vehicle Model Engine and Water Jacket Model Cooling Circuit Model GT-SUITE Boundary Conditions Route Profile Longitudinal Dynamics Gear Shift Calibration Full Vehicle Model < 14 >

15 ATS. Summary and Outlook Mean Value Engine with full Vehicle Model and FMUs Engine and Water Jacket Model Cooling Circuit Model GEARBOX Boundary Conditions Route Profile Longitudinal Dynamics Gear Shift Calibration Detailed FMU Models Full Vehicle Model < 15 >

16 Thank you for your attention MAN Truck & Bus Dominik Renner 1D-Model for Cooling Management and Engine Analysis < 16 >

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