AVL BUSINESS UNIT AST Advanced Simulation Technologies SOFTWARE - PowerPoint PPT Presentation

AVL BUSINESS UNIT AST Advanced Simulation Technologies SOFTWARE SOLUTIONS AND METHOD DEVELOPMENT

CONTENT Content  Overview on AST and AST Tools & Services  CRUISE  From concept to testing  EXCITE  Durability and NVH of Power Unit and Drivelines  1D CFD  BOOST  1D Thermodynamic Simulation  HYDSIM  Injector Simulation  FIRE  3D CFD Thermodynamic Simulation AVL List GmbH, 2009 2

AST INTRODUCTION Basics  AST is separate business unit within AVL and works close together with the other business units ITS and PTE (even shares simulation teams)  AST actually as about 140 employees worldwide  AST has local support and development teams  AST tasks:  Software development  Simulation services (technical and customer oriented support, method development (R&D, J&R) and problem solving projects)   AST support engineers have a lot of engineering and project experience AVL List GmbH, 2009 3

THE POWERTRAIN DEVELOPMENT PROCESS The Challenge: Cover all simulation requirements for power train development Thermodynamics, Development Tasks combustion, emission Multiphysics simulation models Mechanics to support development tasks Virtual thermal management (VTMS) Energy management Consistent simulation models for Functional development all development phases Calibration Development Process Concept Layout Detail Produc- Cali- Design Design tion Dev. bration Simulation models for system and component simulation AVL List GmbH, 2009 4

THE SOFTWARE SOLUTIONS TO SUPPORT THE POWERTRAIN DEVELOPMENT PROCESS Advanced Simulation Technologies- Simulation models for system and component simulation Complete IC-engine simulation platform Driving performance & emission analysis Powertrain & drive line durability and NVH analysis ….. interfacing and integrating other AVL software and 3 rd party software AVL List GmbH, 2009 5

AST SOFTWARE PRODUCTS / MECHANICAL APPLICATION OVERVIEW AST – The Products Structure Dynamics Hydraulics Crank Train Valve Train Analysis, Piston Dynamics Injection System Simulation NVH of Power Units and Drive Lines, Design Analysis Timing Drive Dynamics Oil Consumption Durability of Engine Components, EXCITE Timing Drive, EXCITE Piston & Rings and HYDSIM are Used for Advanced Bearing Design Pre-Calculation of Necessary Additional Excitations EXCITE is the Central Tool for NVH and Durability Drive Cycle Simulation Analysis Vehicle Simulation: Driving Performance, Fuel Consumption, Emissions AVL List GmbH, 2009 6

CRUISE – VEHICLE SYSTEM AND DRIVELINE ANALYSIS FROM CONCEPT TO TESTING

CRUISE VEHICLE SYSTEM SIMULATION – FINDING THE BEST COMPROMISE FOR YOUR TARGETS AVL List GmbH, 2009 8

CRUISE SYSTEM SIMULATION – AN INTEGRATED PART OF THE DEVELOPMENT PROCESS Consistent simulation models for all development phases The Benefit:  Component and subsystem testing by Hardware-in- the-Loop (HiL) & test bed integration Simulation model complexity available since Q2/2008 Layout Detail Production Concept Design Design Dev. Calibration time  Phases of the development process Usage: intensive medium available future AVL List GmbH, 2009 9

CRUISE SYSTEM SIMULATION – AN INTEGRATED PART OF THE DEVELOPMENT PROCESS One System Model Target Definition Fleet Test Optimization Concept Development In Vehicle Test Loop Powertrain Design Powertrain Test Component Specification Component Integration Component Design Component Test Realisation / Implementation Office Realtime AVL List GmbH, 2009 10

SOME EXAMPLES OF VEHICLE SYSTEM MODELS Conventional Passenger Cars Hybrid Vehicles Advanced Transmission Concepts Motorbikes CVT-Scooters Trucks Busses Special Purpose Vehicles Trailers AVL List GmbH, 2009 11

FUEL CONSUMPTION CYCLE CALCULATION Input / Model Analysis Results Task description / Input, Output Development value / insight • Prediction of drive cycle fuel consumption and raw emissions Influence of vehicle parameters (vehicle weight, wheels, of passenger cars, commercial vehicles and other engine final drive, etc.) on expected FC and emissions applications, based on measured or predicted steady state • Influence of powertrain (topology -manual vs. automated FC and emission maps within legal or custom defined driving transmission, auxiliaries, hybrids, etc.) or operation cycles; • Optimization of powertrain & auxiliary operation strategy Results are limited by the steady-state maps of the engine; (gear shifting program, ..) • Definition of steady state test-bed load points (prediction of cycle results) AVL List GmbH, 2009 12

ALL STANDARD VEHICLE ANALYSIS METHODS INCLUDES FULL LOAD FUEL ECONOMY CONSTANT SPEED ACCELERATION DUTY CYCLES PART LOAD ANALYSIS HILL CLIMBING TRACTION FORCE TRACTION PERFORMANCE PERFORMANCE DIAGRAMS ANALYSIS AVL List GmbH, 2009 13

APPLICATION EXAMPLES FUEL ECONOMY CONCEPT POTENTIAL DRIVEABILITY PERFORMANCE BENCHMARK SHIFTING QUALITY Fuel Consumption Potential (%) NEDC hot 100 Baseline 90 HIGH 80 70 60 50 LOW 40 30 Optimised Driver Demand 20 10 Acceleration 0 Baseline Belt Transm. 1-Clutch integr. 2-Clutch Power- Serial Ideal Velocity Parallel Hybrid Split Hybrid Hybrid TRANSMISSIONS CONTROL FUNKTIONS ENERGY FLOW HYBRID SYSTEMS CALIBRATION LOSS POWER AVL List GmbH, 2009 14

HYBRID POTENTIAL ESTIMATOR Strategy: NOx optimised Potential (%) 100 Best FC 90 80 Best 70 Fuel Consumption 60 NOx 50 40 30 20 10 0 Base HEV0 HEV1 HEV2 HEV3 HEV4 HEV5 HEV6 Ideal Vehicle (BSG) (CSG1) (CSG2) (TISG) (TTR) (PS) (SH) Hybrid Input / Model Analysis Results Task description / Input, Output Development value / insight • Estimation of the fuel consumption and emissions potential of Influence of different hybrid topologies based on a CRUISE simulation of a • topology conventional, baseline vehicle • component performance Input: conventional vehicle model, driving and duty cycles • basic control functions and strategy Output: prediction of fuel consumption and emissions on fuel consumption and emission AVL List GmbH, 2009 15

CRUISE THE SUB-SYSTEM INTEGRATION CONCEPT AVL BOOST MATLAB/SIMULINK Flowmaster, KULI AVL DRIVE Vehicle Dynamics C, FORTRAN Codes AVL List GmbH, 2009 16

CRUISE SYSTEM SIMULATION AN INTEGRATED PART OF THE DEVELOPMENT PROCESS One System Model Target Definition Fleet Test Optimization Concept Development In Vehicle Test Loop Powertrain Design Powertrain Test Component Specification Component Integration Component Design Component Test Realisation / Implementation Office Realtime AVL List GmbH, 2009 17

INMOTION-CRUISE THE VEHICLE TESTING SYSTEM AVL InMotion RT Node RealTime Powertrain Vehicle, Tire, Road, Driver Testbed DRIVE AVL XCU AVL List GmbH, 2009 18

COMPONENT TEST ELECTRIC MOTOR TESTING InMotion e-Motor Torque [ Nm ] 60 30 ms 40 Set value Actual value 20 0 3.5 4 3,3 Time [ sec ] AVL List GmbH, 2009 19

AVL CRUISE THE VEHICLE SYSTEM ANALYSIS ENVIRONMENT § Flexibility to change driveline configurations within minutes  Hybridization of a conventional vehicle with a few mouse clicks  Advanced transmission concepts (AMT, DCT, …)  Electrical components esp. designed for HEVs  More time to focus on HEV engineering tasks § System model fidelity can easily be adjusted  Starting with only a few input parameters in the early phases  Model maturity is growing during the development process § Database functionality for an efficient exchange of data between teams § All application tasks are fully implemented § Streamlined workflows included  Parameter optimization  Component matching  Sub-system integration AVL List GmbH, 2009 20

AVL EXCITE DURABILITY AND NVH OF POWER UNITS AND DRIVELINES

EXCITE DESIGNER POWER TRAIN DESIGN ANALYSIS Calculation model and main capabilities  Torsional mass – spring system  Linear calculation model – solution in frequency domain  Hydrodynamic radial slider bearing Area of application Layout and design of crank train  Torsional crankshaft vibrations  Hydrodynamic bearing analysis  Crankshaft fatigue strength  Ignition timing, cylinder deactivation, misfiring Vehicle drive line & test bed analysis  Torsional vibrations of drive lines  Torsional stresses in drive train shafts  Optimization of test bed shaft couplings AVL List GmbH, 2009 22

EXCITE POWER UNIT FLEXIBLE MULTI-BODY DYNAMIC ANALYSIS Oscillating Structure Parts Solution Vibrating, Rotating, Vibrating Structure Parts  Elastic/rigid bodies interacting via non- Nonlinear Bearing Forces and Moments calculated due to linear joints Actual Dynamics of Parts  Vibrating, rotating and oscillating elastic Radial Slider Bearing, Axial Thrust Bearing, structure parts represented by Piston / Liner Contact, Rotational Coupling, ... condensed FE models (CMS)  Various contact models up to highly Excitation Forces and Moments complex thermo elasto-hydrodynamic joints including mixed lubrication Gas Excitation  Non-linear transient forced vibration analysis in time domain Valve Train Excitation  Excited by external forces Piston Slap Excitation from Injection System AVL List GmbH, 2009 23