Fabiano Bet Gerald Seider Marcel Hülssiep Berlin, March 7, 2017 InDesA GmbH Carl-Zeiss-Ring 19a D-85737 Ismaning Phone +49 (89) 552 7978-10 Fax +49 (89) 552 7978-29 www.indesa.de
Consulting, Engineering Services & Virtual Bench Testing Simulation and Design Analysis of complex systems for engineering and industrial applications fluid flow, hydro-/aerodynamics heat transfer, thermal management air-borne acoustics, sound design Virtual Performance and Functional Testing for automotive accessory units Engineering automotive 3D CFD/CHT STAR-CCM+ 1D Systems GT-SUITE InDesA GmbH Carl-Zeiss-Ring 19a D-85737 Ismaning Phone +49 (89) 552 7978-10 Fax +49 (89) 552 7978-29 www.indesa.de
page 3 Introduction Request: Reduction of CO 2 emission. Way: Reduction of consumption. Demand: Increasing/Maintain Performance. Engine Downsizing Instruments: Displacement downsizing by increasing Efficiency. Tech. Solution: Reduction internal Friction e.g. coupling Low Friction Materials Reduction moved masses e.g. less number of cylinder Increase Combustion Pressure e.g. Turbocharger
page 4 Introduction PV- Diagram. P Turbocharger introduce energy also at suction phase. Increase internal- and combustion-pressure. Higher load-pressure higher intake temperature Cooling Charge Air Increase Compression Ratio Increase Efficiency. V
page 5 InDesA s Virtual Vehicle Pandora GT Designed to demonstrate thermal simulation techniques.
page 6 InDesA s Virtual Vehicle Pandora GT Designed to demonstrate thermal simulation techniques. Exterior Design (Bodywork) Power Train and Chassis Cooling Circuits (HT, LT,Oil) Exhaust System The virtual Vehicle include all relevant features for thermal management studies.
page 7 InDesA s Virtual Internal Combustion Engine Designed to demonstrate thermal simulation techniques with options for different thermal management technologies: Split Cooling Integrated Exhaust Manifold (water cooled) Engine oil Cooler (Heater) Integrated Thermal Management Module Compared to real engines the virtual engine shows a simplified design but with all relevant features to allow for thermal management studies.
page 8 InDesA s Virtual Charge Air Cooler Water Cooled Charge Air Integrated with Intake Manifold Close to Intake ports: minimize Re-Heating Cross Flow for more Efficiency
page 9 InDesA s Virtual Charge Air Cooler Definition of Engine Characteristic: (Power, Torque, Pressure etc.) knowledge of requested air mass and conditions (Density, pressure and Temperature) Design definition of Charge Air Cooler. Thermodynamics Conditions of Intake Air Change during operation
page 10 InDesA s Virtual Charge Air Cooler Heat Exchanger under Operating Conditions: Under Hood Temperature Steady State @ 80 kph. Ambient T = 28 C
page 11 InDesA s Virtual Charge Air Cooler Suction Pipe: T = 27 C P = -0,078 bar Pressure Pipe: T = 174 C P = 2,479 bar Suction Pipe: T = 36 C P = -0,077 bar Pressure Pipe: T = 162 C P = 2,392 bar Steady State Simulation Full Load @ 180 kph
page 12 InDesA s Virtual Charge Air Cooler Simulation with Adiabatic Condition Simulation with Thermal Condition Solid Temperature Distribution @ Steady State
page 13 InDesA s Virtual Race Track Short Track: Length 2470 m Less Curves Allow Accelerations-, Break-Down, High- and Low-speed Sections Start Line
page 14 InDesA s Virtual Race Track Dynamic Operation Conditions from 1D Simulation Preconditioned Warm Up Hot End Solids Included UH-Transient Simulation
page 15 InDesA s Virtual Test Track Result for Charge Air Cooler: Comparison Adiabatic Simulation Vs. Conductive Simulation Ambient Temperature: 28 C Air Mass flow Enforced from 1D Coolant Volume Flow: Constant (el. Water Pump)
page 16 InDesA s Virtual Test Track
Thank you for your attention! InDesA GmbH Carl-Zeiss-Ring 19a D-85737 Ismaning Phone +49 (89) 552 7978-10 Fax +49 (89) 552 7978-29 www.indesa.de