COOLING SYSTEM SIMULATION USING COMPUTATIONAL FLUID ... · Desenvolvimento do Produto B-TPG:...
Transcript of COOLING SYSTEM SIMULATION USING COMPUTATIONAL FLUID ... · Desenvolvimento do Produto B-TPG:...
Desenvolvimento do Produto B-TPG: Powertrain Concept
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COOLING SYSTEM SIMULATION USING COMPUTATIONAL FLUID DYNAMICS AND EXPERIMENTAL IMPUT DATA
Vehicular cooling system analysis: Gol - 1.6L TF.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Agenda
CFD – Analysis Overview on Gol Analysis – Engine: EA111 - 1,6L; Cooling System Simulation (GT-Cool) Heat rejection measurements on EA111 1,6L; Vehicular measurements; GT-Cool Simulation of VW 230 GP – EA111 1,6L w/ E22.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Methods of 3D simulation (CFD) and 1D simulation (GT-Cool)
The same input data from suppliers are used by both simulations.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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CFD Method
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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CFD Method: Air flow and thermal characteristics (opportunities)
When the CFD supports a cooling analysis, the focus is the powertrain underhood simulation especially the air flow properties passing through the radiator.
Temperature
Pressure
Velocity
Tunnel, fuel tank, bumper, etc temperatures
Cooling of engine compartment components (wires, sensors, alternator, etc)
Points of underpressure in the engine compartment
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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CFD Data to GT- Cool Analysis
Radiator
Radiator Temperature (ºC) Pressure (Pa) Ram Air pressure
Coefficient
Downstream 36 101366,3 0,97
Upstream 89 101272,1 -0,99
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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GT-Cool data from CFD
before the radiator
after the radiator
The 36ºC is the air temperature downstream of the condenser (that is: before radiator).
This estimation considered the air mass flow through the condenser which is warmed by the heat rejected in the AC system.
This heat rejection was estimated though the condenser map from Denso and the refrigerant mass flow derived from experimental data of the AC system.
Ambient temperature: 26,85ºC (300K)
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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GT-Cool Components Coolant - Distributor
Hoses Fan
Heat Transfer Module
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Heat Rejection Measurement
otoP
heat. specificcerature;inlet temp tperature;outlet temtrate; flow massm
rejection;heat Q
:Where
).(.
p
i
o
=====
−=
iop ttcmQ
In order to improve the accuracy of the simulation, the engine was instrumented and tested in different conditions (heat rejection/ pressure drop map).
pressure;inlet Ppressure;outlet P
drop pressure P:Where
i
o
===∆
−=∆ io PPP
Parts specially designed for the test
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Measurements on dyno bench w/ EA111 1,6L
Flow Rate device and engine speed measurement with grounding isolation system (designed by us)
Pressure, temperature and flow rate upstream of
the water pump
Assembling Engine Speed
- Pressure
- Temperature
- Flow rate
Inlet and outlet temperature and pressure Pressure after
the pump
Data aquisition
C-Daq
The instrumentation must be done specifically for each engine. The same instrumentation used on the dyno bench was transferred to the vehicle.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Input data: Drop pressure curves – Heat Exchanger
y = 0,0553x2 - 0,0164x - 0,0083R2 = 0,9945
y = 0,0868x2 - 0,0317x + 0,0027R2 = 0,9995
y = 0,137x2 + 0,2668x - 0,1746R2 = 0,9963
y = 0,0257x2 + 0,0182x - 0,0185R2 = 1
0,000
0,200
0,400
0,600
0,800
1,000
1,200
1,400
0,500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000Mass Flow Rate (kg/s)
Dro
p P
ress
ure
(bar
)
100% openned 66% openned 33% opennedVehicular test: 3th gear 100km/h Free Throttle: 1000 to 6000 rpm Poly. (100% openned)Poly. (66% openned) Poly. (33% openned) Poly. (Free Throttle: 1000 to 6000 rpm)
100% 66%
33% 0%
Vehicle measurement
The press. drop in the vehicle is lower than any position of the valve in dyno. To increase representativeness, it’s necessary to reduce restriction on dyno heat exchanger.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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y = 0,0956x2 - 0,038x - 0,0289R2 = 0,9963
y = 0,1146x2 - 0,0116x - 0,0608R2 = 0,9993
y = 0,1257x2 + 0,3648x - 0,2783R2 = 0,9949
y = 0,0505x2 + 0,0338x - 0,1091R2 = 0,9999
0,000
0,200
0,400
0,600
0,800
1,000
1,200
1,400
0,500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000Mass Flow Rate (kg/s)
Dro
p P
ress
ure
(bar
)
100% openned 66% openned 33% opennedVehicle Test - 3th Gear 100 km/h Free Throttle: 1000 to 6000 rpm Poly. (100% openned)Poly. (66% openned) Poly. (33% openned) Poly. (Free Throttle: 1000 to 6000 rpm)
Input data: Drop pressure curves – Engine Block
100% 66%
33% 0%
The press. drop through the engine block is influenced by the dyno heat exchange pressure drop.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Input data: Dyno Map of Heat Rejection to the Coolant
Kennfeld of Heat Rejection
y = 0,0533x + 9,3788R2 = 0,3719
y = 0,0862x + 15,625R2 = 0,8959
y = 0,1219x + 27,19R2 = 0,8364
y = 0,1599x + 42,615R2 = 0,9458
y = 0,2151x + 47,88R2 = 0,8572
y = 0,2071x + 68,755R2 = 0,9038
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Torque (Nm)
Hea
t Rej
ectio
n (k
W)
1000 rpm 2000 rpm 3000 rpm 4000 rpm 5000 rpm 6000 rpmLinear (1000 rpm) Linear (2000 rpm) Linear (3000 rpm) Linear (4000 rpm) Linear (5000 rpm) Linear (6000 rpm)
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Input data: % of throtle x torque Kenfeld of Torque
0
20
40
60
80
100
120
140
160
0 10 20 30 40 50 60 70 80 90 100
% of Throtle body's opening
Torq
ue (N
m)
1000 rpm1250 rpm1500 rpm1750 rpm2000 rpm2250 rpm2500 rpm2750 rpm3000 rpm3250 rpm3500 rpm3750 rpm4000 rpm4250 rpm4500 rpm4750 rpm5000 rpm5250 rpm5500 rpm5750 rpm6000 rpm
This map is necessary in order to the GT-Cool to determine the the engine load.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Link between GT-Cool and GT-Drive
Dyno Data and GT-Drive Interaction
CFD Input Data
CFD Input Data
Subassemblies
3rd Gear – 100km/h
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Parameters of reference – 3rd Gear – 100km/h – E22
Engine Speed = 4922 rpm
Heat Rejected =52,45 kW
Average Engine Speed = 4657 rpm
Average Heat Rejected = 50,8 kW
The heat rejected was measured in the vehicle. The value is similar to that predicted by the GT-Cool for this condition.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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ETD for 3rd Gear - 100km/hr – E 22 - Comparison
Ambient temperature =26,85 ºC
Steady temperature= 102.60 ºC
ETD = 75,75 ºC
TMeasured= 101,27 ºC
Tambient= 26,44 ºC
ETD= 74,83 ºC
Error% = 1% Tmáx=103,17ºC
evaluated range
The predicted stabilization (outlet engine) temperature is close (1% difference) to the measured value in the vehicle.
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Desenvolvimento do Produto B-TPG: Powertrain Concept
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Conclusion
•The next step will expend time on the heat rejection simulation;
•Improve the 1D underhood simulation, in order to reduce CFD dependency;
•1D simulation is faster then CFD, but 1D depends of CFD data.