Simulation of a Hydraulic Cam Phaser Motion with 6-DOF morphing and - - PowerPoint PPT Presentation

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Simulation of a Hydraulic Cam Phaser Motion with 6-DOF morphing and - - PowerPoint PPT Presentation

Jan 04, 2023 259 likes •536 views

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

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SLIDE 1

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

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SLIDE 2

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

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 2

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SLIDE 3
  • 1. Introduction

Design and Function of a Hydraulic Cam Phaser Tasks for the CFD Simulation with STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 3

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SLIDE 4

Design and Function of a Hydraulic Cam Phaser

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 4

  • 1. Introduction

Outlet Inlet

Cylinder head of a 4-cylinder gasoline engine with two cam phasers Cam phaser inlet

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SLIDE 5

Design and Function of the Hydraulic Cam Phaser

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 5

  • 1. Introduction

Position valve with piston Camshaft Sprocket Electro- magnetic valve actuator Vane piston Lock pin

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SLIDE 6

Design and Function of the Hydraulic Cam Phaser

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 6

  • 1. Introduction

Position valve with piston Camshaft Sprocket Electro- magnetic valve actuator Vane piston Lock pin

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SLIDE 7

Tasks for the CFD Simulation with -CCM+

  • 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
  • il 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

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  • 1. Introduction
Time [s]
  • 50
  • 40
  • 30
  • 20
  • 10
10 PhaseAngle Inlet R [[deg]] 25 50 75 100 TV NW2 [%] Measurement Time01 [sec]
  • 50
  • 40
  • 30
  • 20
  • 10
10 Calculated PhaseAngle Inlet R [deg]
  • 1.5
  • 1
  • 0.5
0.5 1 1.5 2 Spool Lift:ZV_P-AdvCh-1 [mm] 1D Simulation Phasing Inlet right T=90 degC n=1000 rpm p=1,8 bar(rel.)

500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 Crank speed [rpm]

  • 10

10 20 30 40 50 60 70 80 90 100 110 120 Temperature [°C]

Phasing speed [deg/s]
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SLIDE 8
  • 2. CFD Simulation of the Cam

Phaser

Design of the Simulation Model in STAR-CCM+ Java Macro for Controlling the Simulation

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 8

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SLIDE 9

Design of the Simulation Model in STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 9

  • 2. CFD Simulation of the Cam Phaser

Cylinder Head Cam Phaser

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SLIDE 10

Design of the Simulation Model in STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 10

  • 2. CFD Simulation of the Cam Phaser

Cam Shaft Bearing with Groove Cam Phaser Chamber

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SLIDE 11

Design of the Simulation Model in STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 11

  • 2. CFD Simulation of the Cam Phaser

Stagnation Inlet Pressure Outlet

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SLIDE 12

Design of the Simulation Model in STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 12

  • 2. CFD Simulation of the Cam Phaser

Fixed Regions Motion Specification: Stationary Region CamShaft Motion Specification: Rotation

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SLIDE 13

Design of the Simulation Model in STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 13

  • 2. CFD Simulation of the Cam Phaser

Region Chamber Motion Specification: DFBI Morphing

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SLIDE 14

Design of the Simulation Model in STAR-CCM+

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 14

  • 2. CFD Simulation of the Cam Phaser

Region LockPin Motion Specification: DFBI Morphing Interface: Overset Mesh

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SLIDE 15

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 15

Lock Pin Background / Overset Mesh

Design of the Simulation Model in STAR-CCM+ Volume Mesh

  • 2. CFD Simulation of the Cam Phaser
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SLIDE 16

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 16

Design of the Simulation Model in Star-CCM+ Volume Mesh

  • 2. CFD Simulation of the Cam Phaser
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SLIDE 17

Java Macro for Controlling the Simulation

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 17

  • 2. CFD Simulation of the Cam Phaser

Start

Current Time Step= … ? Move Piston Mesh Pipeline Current Time Step= … ? Move Piston Mesh Pipeline Current MinCell Quality <= … ? Mesh Pipeline CurrAngle < MaxAngle?

Run

CurrentAngleRever se=CurrAngle TimeStepForward =CurrentTimeStep true false true true true false false false End of Forward Movement Start Reverse Movement

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SLIDE 18
  • 3. Selected Results

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SLIDE 19

Flow Speed Value at Selected Intersecting Planes

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  • 3. Selected Results
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SLIDE 20

Flow Speed Value at Selected Intersecting Planes

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 20

  • 3. Selected Results
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SLIDE 21

Pressure Distribution During Adjustment

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 21

  • 3. Selected Results
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SLIDE 22

Pressure Distribution During Adjustment

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 22

  • 3. Selected Results
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SLIDE 23

Comparative Presentation of the Phasing Angle

  • ver Time for Different Design Variants

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 23

  • 3. Selected Results
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SLIDE 24
  • 4. Summary

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 24

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SLIDE 25

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.

2014-03-17_Presentation_Daimler-Berlin | Daimler AG Berlin Plant | 03/17/2014 25

  • 4. Summary
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SLIDE 26

Thank you for your attention! Special thanks to the Nürnberg Support-Team!

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