Exhaust line simulations using Star-CCM+ and automation Yohann Perrot 22-March-2010
Agenda Faurecia Emissions Control Technologies Exhaust line components Some correlations and investigations Enhancements Automation 2
Agenda Faurecia Emissions Control Technologies Exhaust line components Some correlations and investigations Enhancements Automation 3
Emission limits LDV Diesel PM [g/km] USA Tier 2 / Phase In (2004) 0.05 EU 3 (2000) Europe 0.04 Tier II Bin 5 (2009) Tier II Bin 8 (2004) NO x [g/km] 0.5 0.4 0.3 0.2 0.1 0.03 0.02 0.01 EU 4 (2005) 0.1 EU 5 (2009) EU 6 (2014) 0.2 0.3 0.4 0.5 NO x [g/km] 0.01 Japan JP 2005 0.02 JP 2009 0.03 0.04 JP 2002 0.05 PM [g/km] 4
Development process Customer Specif. Sheet AMELI & GT-Power Tail pipe noise FLOWMASTER Back pressure AMELI & GT-Power TL, EBP prediction SIMCP Catalysts & DPF Backpressure Vehicle Level System Level Subsystem Level Component Level Full validated exhaust CFD/GT-Power 1D/3D coupling FIRE DPF, SCR simulations Star-CCM+, FIRE Heat Transfer Star-CCM+ Flow distribution 5
Global CAE vision When Faurecia develops a new product or an innovation, a corresponding CFD & FEA procedure must be created CAD templates have to developed and then deployed for each current and new product Communication between CAE software must be ensured automatically Thanks to this approach, among their activities, CAE experts will Spend more time in analyzing the results than meshing or debugging Assist and help in defining where and what to measure during experimental tests Contribute in building the design know-how/guideline of their local customers Inform regularly the CAE coordinator of the future needs expressed by the customers and give update of their requirements Star tools participate to that vision 6
Agenda Faurecia Emissions Control Technologies Exhaust line components Some correlations and investigations Enhancements Automation 7
Overview of exhaust activity Hot End Emission control Cold End Acoustic Structural integrity Durability 8
Exhaust line components Muffler Manifold & Turbo 3WV Fuel Vapo SCR Heat exchanger, EHRS 3W catalyst, DOC, DPF LP EGR, backpressure valves Injector Vein, Mixers 9
Agenda Faurecia Emissions Control Technologies Exhaust line components Some correlations and investigations Enhancements Automation 10
Some correlations P meas P Star-CCM+ meas. = 463mbar CCM+= = 466mbar T meas. = 740 C T Star-CCM+ CCM+= 827 C (lack engine block cooling) P meas P Star-CCM+ meas. = 469mbar CCM+= = 467mbar T meas. = 750 C T Star-CCM+ CCM+= 840 C (Presence of radiator not taken into account) T meas. = 663 C T Star-CCM+ CCM+= = 677 C (Presence of radiator not taken into account) P meas P Star-CCM+ meas. = 380mbar CCM+= = 377 mbar T meas. = 737 C T Star-CCM+ CCM+= = 730 C (Presence of radiator not taken into account) T meas. = 816 C T Star-CCM+ CCM+= = 800 = 800 C T meas. = 802 C T Star-CCM+ CCM+= = 820 = 820 C 11
Some correlations Catalytic converter simulations EOP Engine 419 kg/h @ 560 C Corresponding EOP Flow bench (Reynolds analogy) 207 kg/h @ 20 C Hot wire anemometry measurements 12
Some correlations EHRS simulation 810 kg/h @ 830 C Bypass way T meas. = 398 C T meas. = 198 C T Star-CCM+ = 216 C T meas. = 585 C T Star-CCM+ = 602 C T Star-CCM+ = 384 C T meas. = 598 C T Star-CCM+ = 614 C 13
Some investigations Transient manifold simulation (following the firing order) 14
Velocity uniformity index vs. time 0.91 15
Toward full exhaust line simulations Full cold-end simulation (PSA EP6DTS) 16
Agenda Faurecia Emissions Control Technologies Exhaust line components Some correlations and investigations Enhancements Automation 17
Enhancements Heat transfer simulation Purpose: To take into account the whole heat transfer (conduction, convection and radiation) without simulating the solid Heat exchanger simulation Basics in thermomechanics for fast & complete optimization (relative comparisons) 18
Agenda Faurecia Emissions Control Technologies Exhaust line components Some correlations and investigations Enhancements Automation 19
Faurecia Emissions Control Technologies Simulation gain (ex: Catalyst-DPF fluid dynamics simulation): Pre-processing: 50% Running: 25% Post-processing: 10% Example 20
Thank you for your attention 21