Simulation of a Hydraulic Cam Phaser Motion with 6-DOF morphing and Overset mesh Thomas Fischer, Daimler AG Berlin Plant Kai Fellmann, Daimler AG Berlin Plant Vienna, 03/17/2014
Organization 1. Introduction − Design and Function of a Hydraulic Cam Phaser − Tasks for the CFD Simulation with STAR-CCM+ 2. CFD Simulation of the Cam Phaser − Design of the Simulation Model in STAR-CCM+ − Java Macro for Controlling the Simulation 3. Selected Results 4. Summary 2 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
1. Introduction Design and Function of a Hydraulic Cam Phaser Tasks for the CFD Simulation with STAR-CCM+ 3 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
1. Introduction Design and Function of a Hydraulic Cam Phaser Inlet Outlet Cylinder head of a 4-cylinder gasoline engine with two cam phasers Cam phaser inlet 4 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
1. Introduction Design and Function of the Hydraulic Cam Phaser Electro- magnetic valve actuator Sprocket Vane piston Camshaft Position valve with piston Lock pin 5 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
1. Introduction Design and Function of the Hydraulic Cam Phaser Electro- magnetic valve actuator Sprocket Vane piston Camshaft Position valve with piston Lock pin 6 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
1. Introduction Tasks for the CFD Simulation with -CCM+ 10 100 PhaseAngle Inlet R [[deg]] TV NW2 [%] Phasing Inlet right 120 0 75 T=90 degC 110 -10 n=1000 rpm p=1,8 bar(rel.) 100 -20 50 90 -30 25 80 -40 Measurement 70 -50 0 1D Simulation 60 Time [s] Temperature [°C] 10 2 50 Calculated PhaseAngle Inlet R [deg] Spool Lift:ZV_P-AdvCh-1 [mm] 1.5 40 0 1 30 Phasing speed [deg/s] -10 0.5 20 -20 0 10 -30 -0.5 0 -40 -1 -10 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 -50 -1.5 Crank speed [rpm] Time01 [sec] • How does the design of the oil chambers affect the "adjustment speed" target variable? • How can the performance of the system be improved by optimizing the oil chambers and the valve at the digital assembly stage? • Calibration of the 1D system simulation at the digital assembly stage Less time and effort involved in testing 7 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Java Macro for Controlling the Simulation 8 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Cam Phaser Cylinder Head 9 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Cam Phaser Chamber Cam Shaft Bearing with Groove 10 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Pressure Outlet Stagnation Inlet 11 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Fixed Regions Motion Specification: Stationary Region CamShaft Motion Specification: Rotation 12 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Region Chamber Motion Specification: DFBI Morphing 13 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Region LockPin Motion Specification: DFBI Morphing Interface: Overset Mesh 14 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in STAR-CCM+ Volume Mesh Lock Pin Background / Overset Mesh 15 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Design of the Simulation Model in Star-CCM+ Volume Mesh 16 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
2. CFD Simulation of the Cam Phaser Java Macro for Controlling the Simulation Start CurrentAngleRever se=CurrAngle CurrAngle < false MaxAngle? End of TimeStepForward Forward =CurrentTimeStep Movement true Start Reverse Run Movement false false Current Current Time Step= Time Step= … ? … ? false Current true true MinCell Quality Move Piston Move Piston <= … ? true Mesh Pipeline Mesh Pipeline Mesh Pipeline 17 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
3. Selected Results 18 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
3. Selected Results Flow Speed Value at Selected Intersecting Planes 19 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
3. Selected Results Flow Speed Value at Selected Intersecting Planes 20 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
3. Selected Results Pressure Distribution During Adjustment 21 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
3. Selected Results Pressure Distribution During Adjustment 22 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
3. Selected Results Comparative Presentation of the Phasing Angle over Time for Different Design Variants 23 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
4. Summary 24 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
4. Summary Summary • The hydraulic cam phaser can be simulated by means of different movements in STAR-CCM+. • A Java macro is used for controlling the required valve movements and the remeshing of the morphed region. • The modular simulation model can be easily adapted to new designs. • The impact of the design of the oil chambers on the "adjustment speed" target variable can be calculated and optimized at the digital assembly stage. • Calibrating the 1D system simulation at the digital assembly stage helps to generate reliable performance maps. The time and effort involved in testing is significantly reduced. 25 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
Thank you for your attention! Special thanks to the Nürnberg Support-Team! 26 2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014
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