The Role of Simulation at Change Full Vehicle Thermal Management - PowerPoint PPT Presentation

The Role of Simulation at Change

Full Vehicle Thermal Management (VTM) Are simulation and testing equivalent ? What are the success factors of simulation of today? How is simulation integrated into the development process? Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 2

First Generation of Simulation Model for Underhood (1990) ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role of simulation: nice to have • Daimler AG Seite 3 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /

Second Generation of Simulation Model for Underhood •1.4 Mio cells in total •1.0 Mio engine compartment •0.2 Mio underbody •0.2 Mio external region •Role of simulation: treated more serious Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 4

Latest Generation of Simulation Model for VTM •120 Mio cells (Hexahedral mesh) •40 Mio cells (Polyhedral mesh) •Role of simulation: fully accepted Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 5

Latest Generation of VTM Physical Modeling Dynamic load cases � � Reproduction of the time depend temperature behavior of all thermal relevant components � Vehicle components � Exhaust system Heat exchange package � � engine Daimler AG Seite 6 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /

Full VTM Process Testing Load Cases - vmax, up hill drive, etc. Load case up hill drive Load case vmax Simulation - which boundary conditions ? Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 7

General Requirements on Full VTM Simulation Safety of Prediction Flexibility Efficiency Omission of Vehicle Shortening and Modifications of “Mass Production of VTM Hardware Substitution Development Process Simulation” by Simulation Duration of a CFD Simulation [days] 70 60 50 40 30 20 10 0 8 Seite 8 Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /

Continuous Improvement Process for VTM Simulation Dissertation Mario Disch Simulation Transient Driving Up hill � Dissertation Frau Urban Dissertation Herr Enriquez-Geppert � „Modeling Full Exhaust System“ „Water Separation“ � � � Dissertation Dr. Weidmann Dissertation Frau Michel Dissertation Frau Pulz „Engine Soak“ „Transient Load Cases TAG E/E“ „Modeling Full Engine/Transmission“ 115 40 PHASE 1 PHASE 2 PHASE 3 Aufheizung stationär Nachheizen 35 105 30 Geschwindigkeit [km/h] Temperatur [°C] 25 95 20 15 85 10 5 75 0 300 600 900 1200 1500 1800 2100 Zeitachse [s] Source: M. Disch (upcoming Ph.D thesis, FKFS) Oberflächentemperatur Bauteil Geschwindigkeit The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 9 Daimler AG

Generic Digital Prototype Process Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 10

Full Vehicle Thermal Management Process Digital and Physical Digital Assessment Assessment Tandem of simulation engineer and testing engineer is responsible for VTM Start of Project SoP Digital Phase 1 Digital Phase 2 Digital E-Vehicle Digital B-Vehicle E-Vehicle- B-Vehicle- Testing Validation Optimization Component Temperatures Evaluation Evaluation Evaluation Global Concept Local Concept Component Temperatures Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 11

VTM Co-Simulation Thermal Convection Change from pure CFD • engineer towards VTM engineer Increase of the complexity • Thermal Conduction of simulation Thermal Radiation Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 12

Costs of VTM Engineer service costs ? License costs Engineer service costs ? Flow Mesh Result Analysis Generation Preparation CoSim CAD data Result preparation Assessment Solid Mesh Result Analysis Generation Preparation Reducing the number of physical prototypes increases costs for digital prototypes Daimler AG Seite 13 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /

Efficient Full VTM Simulation Process CAD-Preparation Pre-Processing Tool used: Model Manager** Tools used: TIG** , STAR-CCM+ Need for Automation Need for Automation • • Investment in Software Investment in Software • • Number of Referenz Vehicles per DPT Loop Number of Components per Vehicle 14 12 8000 7000 10 6000 8 5000 6 4000 3000 4 2000 2 1000 0 0 2008 2009 2010 2011 2012 Vehicle 1 Vehicle 2 Vehicle 3 Vehicle 4 Processing Post Processing Tools used: Event Manager,** Tools used: Post Tools,** STAR-CCM+ STAR-CCM+ Need for Automation • Need for Automation Investment in Software • • Investment in Software • **Customized Software Tools for Daimler 14 Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 14

Imprinting of adjacent Component Parts by means of LFE Tools 15 Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 15

Full VTM Post Processing Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 16

Key Factors for successful VTM simulation • Geometrical Data for Pre processing • Powerful Simulation tool • Post processing • Simulation process Robust and flexible Costs effective • External Costs for VTM License Fee • Engineering Services • Software Development • Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 17

New Role of Full VTM Simulation Simulation is • dominating the development process • accepted by the management • under costs and time pressure more than ever • comparable to testing Simulation engineers have more responsibility Daimler AG The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 18

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