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Daimler AG
Full Vehicle Thermal Management (VTM)
Seite 2 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
The Role of Simulation at Change Full Vehicle Thermal Management - - PowerPoint PPT Presentation
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
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Daimler AG
- ca. 400 000 cells
- 3 weeks of computation time
- 9 months for meshing
- Role of simulation: nice to have
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 3
First Generation of Simulation Model for Underhood (1990)
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Daimler AG
- 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
Second Generation of Simulation Model for Underhood
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 4
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Daimler AG
Latest Generation of Simulation Model for VTM
Seite 5 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
- 120 Mio cells (Hexahedral mesh)
- 40 Mio cells (Polyhedral mesh)
- Role of simulation: fully accepted
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Daimler AG
- Vehicle components
- Exhaust system
- Heat exchange package
- engine
- Dynamic load cases
Reproduction of the time depend temperature behavior of all thermal relevant components
Latest Generation of VTM Physical Modeling
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 6
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Daimler AG Seite 7 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
Load case vmax Load case up hill drive Load Cases - vmax, up hill drive, etc.
Full VTM Process Testing
Simulation - which boundary conditions ?
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Daimler AG
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Safety of Prediction Flexibility Efficiency
General Requirements on Full VTM Simulation
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 8
Omission of Vehicle Hardware Substitution by Simulation Shortening and Modifications of Development Process “Mass Production of VTM Simulation”
10 20 30 40 50 60 70
Duration of a CFD Simulation [days]
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Daimler AG
Continuous Improvement Process for VTM Simulation
Source: M. Disch (upcoming Ph.D thesis, FKFS)
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 9 Dissertation Dr. Weidmann „Engine Soak“
- Dissertation Mario Disch
Simulation Transient Driving Up hill Dissertation Frau Michel „Transient Load Cases TAG E/E“ Dissertation Frau Urban „Water Separation“ Dissertation Herr Enriquez-Geppert „Modeling Full Exhaust System“
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Dissertation Frau Pulz „Modeling Full Engine/Transmission“
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Daimler AG Seite 10 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
Generic Digital Prototype Process
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Daimler AG Seite 11 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
Full Vehicle Thermal Management Process
Evaluation Component Temperatures Digital E-Vehicle Evaluation Global Concept Digital Phase 1 Evaluation Local Concept Digital Phase 2 Digital B-Vehicle
E-Vehicle- Testing B-Vehicle- Validation
Start of Project SoP Optimization Component Temperatures
Digital Assessment Digital and Physical Assessment Tandem of simulation engineer and testing engineer is responsible for VTM
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Daimler AG
VTM Co-Simulation
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Thermal Convection Thermal Conduction Thermal Radiation
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
- Change from pure CFD
engineer towards VTM engineer
- Increase of the complexity
- f simulation
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Daimler AG
Costs of VTM
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 13
Flow Mesh Generation Solid Mesh Generation Analysis Analysis Result Preparation Result Preparation
CoSim
CAD data preparation Result Assessment
License costs Engineer service costs ? Engineer service costs ? Reducing the number of physical prototypes increases costs for digital prototypes
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Daimler AG
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Efficient Full VTM Simulation Process
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 14
Pre-Processing
Tools used: TIG** , STAR-CCM+
- Need for Automation
- Investment in Software
CAD-Preparation
Tool used: Model Manager**
- Need for Automation
- Investment in Software
**Customized Software Tools for Daimler
Processing
Tools used: Event Manager,** STAR-CCM+
- Need for Automation
- Investment in Software
Post Processing
Tools used: Post Tools,** STAR-CCM+
- Need for Automation
- Investment in Software
2 4 6 8 10 12 14 Vehicle 1 Vehicle 2 Vehicle 3 Vehicle 4 Number of Referenz Vehicles per DPT Loop 1000 2000 3000 4000 5000 6000 7000 8000 2008 2009 2010 2011 2012 Number of Components per Vehicle
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Daimler AG 15
Imprinting of adjacent Component Parts by means of LFE Tools
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 15
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Daimler AG
Full VTM Post Processing
Seite 16 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
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Daimler AG
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
Seite 17 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
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Daimler AG
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
Seite 18 The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
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