KULI Overview 20110720 BRG
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Transcript of KULI Overview 20110720 BRG
© ECS / Disclosure or duplication without consent is prohibited www.ecs.steyr.com
„Comprehensive Software for Thermal Energy
Management Optimization“
© ECS / Disclosure or duplication without consent is prohibited
Who we are?
Who we are?
25.01.2011 3 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Who we are? – The Company
Gregor Breuer 4 08.12.2011
ECS – Engineering Center Steyr
• Complete Vehicle Engineering
• Technology & Software Development
• Vehicle Testing
Magna
Seating
Seating
Systems
Cosma
International
Body & Chassis
Systems
Magna Exteriors and Interiors
Exterior
Systems
Interior
Systems
Vision
Systems
Closure
Systems
Magna Mirrors &
Magna Closures
Powertrain &
Engineering
Electronic
Systems
Magna Powertrain Magna Steyr
Engineering
& Assembly
Roof
Systems
E-Car Systems
(J.V.)
Hybrid &
Electric
Vehicles
MAGNA International
© ECS / Disclosure or duplication without consent is prohibited
ECS @ a Glance
Author: W. Dantendorfer 5 Oct. 2013
World leading engineering service provider focused on:
Innovation
System Engineering
Commercial Vehicle Engineering
Improved transport efficiency
Execution within a global network
Range of Services:
Commercial Vehicle Engineering
Powertrain Systems
Software & Simulation
Electronics & Electric
Testing Services
Low Volume Production
e-drive
IMG
HCU
© ECS / Disclosure or duplication without consent is prohibited
Thermal- and Energy- Management
Author: Clemens Gamsjaeger Date: May 2013
Thermal Management HVAC Energy Management
• Simulation / Testing: - under hood flow - component temperatures - coolant/oil circuits - charge air circuits • Optimization of VTMS • Operating Strategies
• Product Specification
and Testing: - Fan/Cooler - Pumps (oil/coolant) - Entire Cooling Package - Thermostat / Valves • Vehicle testing: - chassis dynamometer - test track - on track
• Driving Performance
• Consumption
• CO2 – Optimization
• Energy Balance
• Operating Strategy
• Alternative Powertrains
• Aerodynamics:
- under hood
- circulation
- lift / drag
• AC Concepts
• AC Power
(Heating/Cooling)
• Comfort
• Deicing / Demisting
• HVAC Measurements
(test rig / road)
• Battery conditioning
• Operating strategy
• Component specification
© ECS / Disclosure or duplication without consent is prohibited
Who we are? – The KULI Team
Gregor Breuer 7 25.01.2011
Department Energy & Fluid Simulation
Software Developers and Software Users exist under one umbrella!
Services
Dr. Christoph Stroh
Department Leader
E&F Simulation
Christian Rathberger
Sales
Rolf Salomon
Software
Thomas Naderhirn
© ECS / Disclosure or duplication without consent is prohibited
What is KULI?
What is KULI?
25.01.2011 8 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Powertrain Cooling Air Conditioning
• Temperatures
• Pressures
• Mass flow
• Heat flow
• Other Energy flows
Consideration of all Thermodynamic Key Values
Thermal Management Software
Gregor Breuer 9 25.01.2011
Windows Desktop Software for the 1D-Simulation of the Vehicle Thermal Energy Management
© ECS / Disclosure or duplication without consent is prohibited
Thermal Management Software
25.01.2011 10 Gregor Breuer
Component
& Function
Toolbars
Project
Organization
Analysis
Progress
Info
3D Air
Network
View
2D Fluid
Network
View
1-dimensional Fluid Network Analysis – Quasi 1-dimensional Air Flow Network Analysis
© ECS / Disclosure or duplication without consent is prohibited
Energy Management Software
COM-Interface
Transient Conditions
Engine Model
E-mobility recuperation
Co-Simulation
CFD Analysis
Optimization
Cooling System
AC System
25.01.2011 12 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited Gregor Breuer 13 15.04.2011
Typical
Applications
© ECS / Disclosure or duplication without consent is prohibited
• KULI data for fans and coolers
• Volume flow data for all participating fluids
• Ambient temperature
• Driving velocity
• Rejected heat by the condenser
• Amount of glycol in the coolant
Input
• Top tank temperature
• Air to boil
• Analysis of the operating points of the fans/coolers
Additional results:
• Parameter variation (fan speeds, volume flows,...)
on the above mentioned measurable variables
Results
Typical Application – Top Tank Temperature
25.01.2011 15 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Typical Application – Concept Studies
• Compare direct and indirect charge air cooling
conventional CAC
water-cooled CAC
low temperature
radiator
25.01.2011 16 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
297 mm
259 mm
Typical Application – Minimize Package Size
Gregor Breuer 17 08.07.2011
• Reduce heat exchanger sizes
according to performance
limits
400 mm
300 mm
© ECS / Disclosure or duplication without consent is prohibited
Typical Application – Transient Simulation
• Avoid oversizing of components due to steady state operating points
Gregor Breuer 18 08.07.2011
RPM_#ECU [1/min]
In
BMEP_#ECU [bar]
Out
RPM_#Amb [1/min]Out
BMEP_#Amb [bar]
Out
1.49
Out
2OutIn
OutIn
[Water]
Exit temperature OM
SP
RPM
Ambient pressure
Mean eff. pressure
Ambient temperature
Speed
In
SPEED_#ECU [km/h]In
SPEED_#Amb [km/h]Out
p_#Amb [hPa]Out
T_#Amb [°C]
Out
xOut
X1
X2
xOut
X1
X2
Out
In
CA
Out
In
CF
X3
X2
X1
Out
Out
In
Pressure
Temperature
Volume flow IM
Oil
In 2
In 1
Out In 2
In 1
Out
ECU
Pressure
SPEED
RPM
BMEP
Temperature
p_#Ambient
SPEEDcorrected
RPMcorrected
BMEPcorrected
Airpath
ThermostateCoolerCAC
Oil
Zusatzwasserkühler
Thermostat ByPass
Out 2
Out 1
In
KULI Engine Model
Thermal capacities
considered
© ECS / Disclosure or duplication without consent is prohibited
Typical Application – Cool Down Simulation
• Find evaporator heat load
such that passenger cabin
cool down requirements
are met
25.01.2011 19 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Typical Application – Energy Management
Energy Management Simulation for a Hybrid Truck
Parallel Hybrid Vehicle
Driving Cycle (HUDDS) Heavy-Duty Urban Dynamometer Driving Schedule
Fuel Saving Potentials
Battery, Coolant Temperature
25.01.2011 21 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
• Battery type (Li-Ion, NiMh,…)
• Internal resistance
= f(current, temperature, SOC)
• Open circuit voltage characteristic
= f(temperature, SOC)
• Heat source
= f(current, internal resistance)
• Cell cooling
• Thermal network
Application – Cell Temperature Optimization
25.01.2011 22 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Why to use KULI?
Why to use KULI?
25.01.2011 23 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited Author:
Why Thermal Energy Management?
Engine power increasing
Inlet area decreasing (design)
New technologies (e.g. hybrid)
More components / auxiliaries
Legislative Standards
Em
issio
ns
Fu
el C
on
su
mp
tio
n
Co
mfo
rt
Du
rab
ility
Co
sts
25.01.2011 24 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Why to use Computer Simulation?
• Understand complex component interactions easily
• Effects of single measures can be within measurement accuracy
System Comprehension
• Fast analysis and solutions: “Rapid Prototyping”
• Save time and cost (test bench, prototypes) Concept Studies
• Improve test quality through plausibility checks
• Reduce hardware test loops Support Test Bench
• Quickly find measures for improvement
• Find control strategies for auxiliaries
• Computation only possibility of optimum validation
System Optimization
• Easy handling of engine upgrades
• Component replacements: compare different suppliers
Minor Model Update
25.01.2011 26 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Why to use KULI? – Low Hardware Demands
November 2010: KULI on iPad
• Works on any Laptop
Desktop Application
• Steady state results within seconds
Quick Simulation
25.01.2011 27 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Why to use KULI? – Realistic Results at Low Effort
Component
& Function
Toolbars
Project
Organization
Analysis
Progress
Info
3D Air
Network
View
2D Fluid
Network
View
Learn to use within 2 days of Training
25.01.2011 28 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Why to use KULI? – Tailored to Customer Needs
COM-
Interfa
ce
500
1000
1500
2000
0 200 400 600 800 1000 1200 1400 1600 1800
Time [s]
Transient
Conditions
Engine Model
Driving Cycles
Co-Simulation
CFD Analysis
Optimization
Cooling System
AC System
„From Engineers for Engineers“ Specialized: Automotive Industry
Modular Structure Flexible Software: simple & complex
25.01.2011 29 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Why to use KULI? – Multitude of Features
• Output Analysis
• Presentation Material for Management
Postprocessor
Uniform Component Library
• Water/Glycol, Oil, Exhaust, Refrigerant
Extendable Media Library
Unit Converter
• Optimization, Parameter Variation
Optimization Package
• Excel, Matlab, CFD codes,…
Software Interfaces
25.01.2011 30 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
– Global Presence
Gregor Breuer 31 22.10.2014
Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers
INDIA
SOUTH AMERICA
CHINA
SOUTH KOREA
JAPAN
NORTH AMERICA
EASTERN + WESTERN EUROPE
Enterex America
© ECS / Disclosure or duplication without consent is prohibited
Why to use KULI? – Best Software Support
• Expertise through product overview
• Expertise though product insight
• Expertise through product practice
Support is given by all members of the KULI Team
• Working to YOUR advantage
Friendly and personal
• usually within 24 hours
Quick response
• Paid services for quick and reliable solutions
Facility to “enhanced” support
25.01.2011 32 Gregor Breuer
Services
Department
E&F Simulation
Sales Software
KULI Team
© ECS / Disclosure or duplication without consent is prohibited
Low hardware demands
• Desktop PC
• Short analysis time
Realistic results at low effort
• Clear and brief GUI
• Easy to learn: “fit in 2 days”
• No “hidden” data
Tailored to customer needs
• “from Engineers for Engineers”
• Specialized Software
• Flexible Software
• Modular structure
Multitude of features
• Uniform Component Library
• Extendable Media Library
• Postprocessor
• Optimization Package
• Software Interfaces
Worldwide usage
• KULI data available from majority of suppliers
Best software support
• Quick response
• Expertise through practical use
• Facility of “enhanced” support (simulation services)
Why to use KULI?
25.01.2011 33 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Who to use KULI?
Who to use KULI?
25.01.2011 34 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Who to use KULI?
Engineers related to Thermal Management (not restricted to Automotive Industry)
OEMs Suppliers Researchers Engineering Service
Companies
Design-Engineers CAE-Engineers Test-Engineers
25.01.2011 35 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
When to use KULI?
When to use KULI?
25.01.2011 36 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Concept Development
Product Specification
Virtual Model
Product Design
1. Prototypes / Mules
E K PT1 P PPAP Disp SOP PT2 B R@R
Simulation / DMU / Validation
2. Prototypes / Pre-Production
Program Management
Functional- / Fatigue- / Vehicle Testing
Key Milestones:
Product Definition Product Creation Industrialization
Product Validation
When to use KULI? - Product Development Process
Funct. Testing Vehicle Testing Simulation Concept Prototyping
25.01.2011 37 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
How to use KULI?
How to use KULI?
25.01.2011 39 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited Author:
How to use KULI? – Data Structure
Simulation Model
Component Data
• Dimensions
• Characteristics
Vehicle Data
• Design
• Engine
Simulation Conditions
• Ambient
• Operating Status
Boundaries & Targets
• Max. Dimensions
• Max. Top Hose Temperatures
SUPPLIER
OEM
25.01.2011 40 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
How to use KULI? – Workflow
Component Setup
Input data (Geometry,
Characteristic)
Save in Component
Library
System Setup Load
components (from Library)
Define Media Properties
Position and Connect
Components
Input Simulation Parameters
Simulation Run Analysis Optimize, Vary
Parameters
Results
Get Output from
Postprocessor, Excel Sheet,…
Compare with System
Measurement Data
Interpret Results,
Reporting
25.01.2011 41 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
How to use KULI? – KULI lab Output
Variant Comparison
Userdefined Units
Data Filter Various Graphics
Temperature levels and
Pressure Drops
Heat Turn-over and Efficiency of
Package
Detailed Conditions and
amounts of Cooling Air
Optimized Parameters
depending on Targets
25.01.2011 42 Gregor Breuer
© ECS / Disclosure or duplication without consent is prohibited
Where to get KULI?
Where to get
KULI?
25.01.2011 43 Gregor Breuer
Disclosure or duplication without consent is prohibited
– Global Contact
Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers
Albert TUERTSCHER
AT engineering LLC
1891 Denver West Ct. #1432
Golden, CO 80401-0924
Phone: +1 734 276 5516
NORTH AMERICA
Leandro GARBIN
VirtualCAE
Servicos de Sistemas Ltda.
Rua Tiradentes 160 - Sala 22
São Caetano do Sul,
São Paulo (CEP 09541-220 )
Phone: +55 11 4229-1349
SOUTH AMERICA
Yoshiyuki MOTOYANAGI
Magna International Japan Inc.
Yaesu Center Building 5F
1-6-6 Yaesu, Chuo-ku,
Tokyo 103-0028, Japan
Phone: +81 3 3548 0310
JAPAN
Terra CAI
Magna International China
801-813, Tower A, Eton Place
69 Dongfang Road, Pudong,
Shanghai PRC 200120
Phone: +86 21 6165 1649
CHINA
Yogesh RAHANE
Tata Autocomp Systems Ltd.
Sr. No. 280 Village Mann,
Tal Mulshi, Hinjewadi Phase –II,
Pune 411 057 Pune
Phone: +91 20 6675 5496
INDIA
Rolf SALOMON
Magna Powertrain
Engineering Center GmbH & CoKG
Steyrer Strasse 32
4300 St. Valentin, Austria
Phone: +43 7435 501 2382
EASTERN + WESTERN EUROPE
25.01.2011 44 Gregor Breuer
Jong-Kwan PARK
TAE SUNG S&E Inc.
Seoulforest Kolon Digital Tower II 10F
Seongsu-dong2-ga, Seongdong-gu,
133-120, Seoul, KOREA
Phone: +82 2 3431 2442
SOUTH KOREA
© ECS / Disclosure or duplication without consent is prohibited
Contact & Summary
• Quasi 1-dimensional Analysis of the Air Flow
• Consideration of Pressure Drops and Overlapping
• Tool for Developing, Analyzing and Testing Engineers
Characteristics
• Measurements of Components from Suppliers
• Temperature Measurements of Vehicle if available
• Demanded Dimensions and Positions of Components
• Coolant Flow Rates and its Heat Amount
• Operating Points of Vehicle and Boundary Conditions
Input
• Heat Turn-over and Efficiency of Cooling Packages
• Temperature Levels
• Detailed Conditions and Amounts of Cooling Air
Output
• Comfortable Handling
• Quick Analysis and Solutions
• High Flexibility
• Save Time and Cost
Benefits
22.10.2014 45 Gregor Breuer
Albert TUERTSCHER
AT engineering LLC
1891 Denver West Ct. #1432
Golden, CO 80401-0924
Phone: +1 734 276 5516
Leandro GARBIN
VirtualCAE
Servicos de Sistemas Ltda.
Rua Tiradentes 160 - Sala 22
São Caetano do Sul,
São Paulo (CEP 09541-220 )
Phone: +55 11 4229-1349
Yoshiyuki MOTOYANAGI
Magna International Japan Inc.
Yaesu Center Building 5F
1-6-6 Yaesu, Chuo-ku,
Tokyo 103-0028, Japan
Phone: +81 3 3548 0310
Terra CAI
Magna International China
801-813, Tower A, Eton Place
69 Dongfang Road, Pudong,
Shanghai PRC 200120
Phone: +86 21 6165 1649
Yogesh RAHANE
Tata Autocomp Systems Ltd.
Sr. No. 280 Village Mann,
Tal Mulshi, Hinjewadi Phase –II,
Pune 411 057 Pune
Phone: +91 20 6675 5496
Jong-Kwan PARK
TAE SUNG S&E Inc.
Seoulforest Kolon Digital Tower II 10F
Seongsu-dong2-ga, Seongdong-gu,
133-120, Seoul, KOREA
Phone: +82 2 3431 2442
Roland MAYR
Magna Powertrain
Engineering Center GmbH & Co KG
Steyrer Strasse 32
4300 St. Valentin, Austria
Phone: +43 7435 501 2383
Rolf SALOMON
Magna Powertrain
Engineering Center GmbH & CoKG
Steyrer Strasse 32
4300 St. Valentin, Austria
Phone: +43 7435 501 2382