The Virtual Climatic Wind Tunnel project STAR CCM+, London, 22 - - PowerPoint PPT Presentation

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The Virtual Climatic Wind Tunnel project STAR CCM+, London, 22 - - PowerPoint PPT Presentation

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The Virtual Climatic Wind Tunnel project STAR CCM+, London, 22 March 2010 Author: J. Arbiol, E. Aramburu Content Overview of IDIADA Overview of VCWT project UH thermal simulation State of the art Benchmark The VCWT methodology

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The “Virtual Climatic Wind Tunnel” project

STAR CCM+, London, 22 March 2010 Author: J. Arbiol, E. Aramburu

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Content

Overview of IDIADA UH thermal simulation The VCWT methodology

State of the art Benchmark Automatic surface meshing Automatic volume mesh Examples Design Modules Set-up STARCCM+ & Radtherm coupling Correlation Input (Command / Organisation / Set-up) Output Code VCWT exe

Overview of VCWT project

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Development partner to the automotive industry

Product development projects 850 engineers in 15 countries world-wide Automotive services

  • Testing facilities
  • Proving ground
  • Engineering

Concept Finding & Benchmarking Styling & Feasibility Package & Surfacing Product Engineering Design (CAD) Product Engineering

  • Simul. (CAE)

Development Test Validation Homologation Preparation

Overview of IDIADA

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IDIADA is developing the “Virtual Climatic Wind Tunnel” project to calculate the under-hood temperatures. Thanks to the VCWT, IDIADA will calculate the cooling system temperatures and the UH parts temperatures for gradients, Vmax and extended idle tests. The VCWT must be fast, robust and accurate. The VCWT project is a 2 year project (2007 & 2008) and it is funded by IDIADA and the Catalan Government

Overview of the VCWT project Main Characteristics

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SLIDE 5

A software benchmark for all of the next modules has been carried out: Geometry clean-up Surface meshing Volume mesh CFD simulation Thermal simulation Results analysis (HTML) Currently, the chosen software is: ANSA, STARCCM+ & RADTHERM

The VCWT methodology Modules

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Executable vcwt26 /users/kk/work data_100.inp 1 0 data_1.txt 0 1000 Working folder Mesh file Scale factor Number of prism layer Data file

(inlet velocity, fan rotation,…)

Type of simulation Number of iterations

The VCWT methodology. VCWT script: inputs Command

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SLIDE 7

Surface clean-up & organisation

Data translation & surface meshing, holes’ closure & wrappings.

428 BND_FAN1_Mrf1Body_RAD-0_INTERFACE_T2_SideMrf1 429 BND_FAN1_Mrf1Body_RAD-0_INTERFACE_T4_InletMrf1 433 BND_FAN1_Mrf1Body_RAD-0_INTERFACE_T4_OutletMrf1 500 BND_FAN1_Mrf1Body_RAD-0_WALL_T3_Fan1 430 BND_FAN2_Mrf2Body_RAD-0_INTERFACE_T2_SideMrf2 431 BND_FAN2_Mrf2Body_RAD-0_INTERFACE_T4_InletMrf2 432 BND_FAN2_Mrf2Body_RAD-0_INTERFACE_T4_OutletMrf2 501 BND_FAN2_Mrf2Body_RAD-0_WALL_T3_Fan2 416 BND_HXCON1_HxConBody_RAD-0_INTERFACE_T4_InletCondensador 417 BND_HXCON1_HxConBody_RAD-0_INTERFACE_T4_OutletCondensador 418 BND_HXCON1_HxConBody_RAD-0_WALL_T5_LateralesCondensador 421 BND_HXINT1_HxInterIzqBody_RAD-0_INTERFACE_T4_InletIntercoolerIzq 420 BND_HXINT1_HxInterIzqBody_RAD-0_INTERFACE_T4_OutletIntercoolerIzq 419 BND_HXINT1_HxInterIzqBody_RAD-0_WALL_T5_LateralesIntercoolerIzq 424 BND_HXINT2_HxInterDerBody_RAD-0_INTERFACE_T4_InletIntercoolerDer 423 BND_HXINT2_HxInterDerBody_RAD-0_INTERFACE_T4_OutletIntercoolerDer 422 BND_HXINT2_HxInterDerBody_RAD-0_WALL_T5_LateralesIntercoolerDer 427 BND_HXRAD1_HxRadBody_RAD-0_INTERFACE_T4_InletRadiador 426 BND_HXRAD1_HxRadBody_RAD-0_INTERFACE_T4_OutletRadiador 425 BND_HXRAD1_HxRadBody_RAD-0_WALL_T5_LateralesRadiador 111 BND_UH_Body_RAD-0_WALL_T10_BodyP5 108 BND_UH_Body_RAD-0_WALL_T16_BodyP2 110 BND_UH_Body_RAD-0_WALL_T20_BodyP4 109 BND_UH_Body_RAD-0_WALL_T25_BodyP3 42 BND_UH_Body_RAD-0_WALL_T30_BodyP1 428 BND_FAN1_Mrf1Body_RAD-0_INTERFACE_T2_SideMrf1 429 BND_FAN1_Mrf1Body_RAD-0_INTERFACE_T4_InletMrf1 433 BND_FAN1_Mrf1Body_RAD-0_INTERFACE_T4_OutletMrf1 500 BND_FAN1_Mrf1Body_RAD-0_WALL_T3_Fan1 430 BND_FAN2_Mrf2Body_RAD-0_INTERFACE_T2_SideMrf2 431 BND_FAN2_Mrf2Body_RAD-0_INTERFACE_T4_InletMrf2 432 BND_FAN2_Mrf2Body_RAD-0_INTERFACE_T4_OutletMrf2 501 BND_FAN2_Mrf2Body_RAD-0_WALL_T3_Fan2 416 BND_HXCON1_HxConBody_RAD-0_INTERFACE_T4_InletCondensador 417 BND_HXCON1_HxConBody_RAD-0_INTERFACE_T4_OutletCondensador 418 BND_HXCON1_HxConBody_RAD-0_WALL_T5_LateralesCondensador 421 BND_HXINT1_HxInterIzqBody_RAD-0_INTERFACE_T4_InletIntercoolerIzq 420 BND_HXINT1_HxInterIzqBody_RAD-0_INTERFACE_T4_OutletIntercoolerIzq 419 BND_HXINT1_HxInterIzqBody_RAD-0_WALL_T5_LateralesIntercoolerIzq 424 BND_HXINT2_HxInterDerBody_RAD-0_INTERFACE_T4_InletIntercoolerDer 423 BND_HXINT2_HxInterDerBody_RAD-0_INTERFACE_T4_OutletIntercoolerDer 422 BND_HXINT2_HxInterDerBody_RAD-0_WALL_T5_LateralesIntercoolerDer 427 BND_HXRAD1_HxRadBody_RAD-0_INTERFACE_T4_InletRadiador 426 BND_HXRAD1_HxRadBody_RAD-0_INTERFACE_T4_OutletRadiador 425 BND_HXRAD1_HxRadBody_RAD-0_WALL_T5_LateralesRadiador 111 BND_UH_Body_RAD-0_WALL_T10_BodyP5 108 BND_UH_Body_RAD-0_WALL_T16_BodyP2 110 BND_UH_Body_RAD-0_WALL_T20_BodyP4 109 BND_UH_Body_RAD-0_WALL_T25_BodyP3 42 BND_UH_Body_RAD-0_WALL_T30_BodyP1

Model organisation

The VCWT methodology. VCWT script: input

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SLIDE 8

Type of simulation Number of Set-ups Specific Bocos:

  • Inlet,
  • Outlet,
  • floor,
  • wheels,
  • fans,
  • porosities,
  • heat exchange,
  • etc..

MODEL: :BENCHMARK THERMAL CALCULATION: TYPE: :2: SETUPS: :1:

  • VRS_INT:

:-1200,-1200,-320:2000,1200,1500: SIZE_VR_INT: :22: VRS_EXT: :-2500,-1400,-320:4000,1400,2200: SIZE_VR_EXT: :100:

  • VINUH:

:31.1: TINUH: :300: KINUH: :0.001: EINUH: :0.001: AFBODY: :2: TOUTUH: :300: KOUTUH: :0.001: EOUTUH: :0.001: VIMUH: :-3: TIMUH: :300: KIMUH: :0.001: EIMUH: :0.001: VSF: :31.1,0,0: VSN: :31.1,0,0:

  • OR_D:

: 9.8,-801,26.4: WR_D: :-100:

  • OW_FAN1:

:-478.8,-184.75,251: V3_FAN1: :10.75,-0.0047,-0.45: WF_FAN1: :400:

  • V1_HXRAD1:

:17.970,0,-0.942: V2_HXRAD1: : 0,1,0: R1_HXRAD1: :150: R2_HXRAD1: :600: V1W_HXRAD1: :0,0,1: V2W_HXRAD1: :1,0,0: VIN_INHXRAD1: :1.16: TIN_INHXRAD1: :355: TOUT_OUTHXRAD1: :300: QT_HXRAD1: :21800: TITULO_HXRAD1: :MassFlowRateAire Q: PTS_HXRAD1: :4: P1_HXRAD1: :1.207 59840: P2_HXRAD1: :1.810 77430: P3_HXRAD1: :2.414 90880: P4_HXRAD1: :3.017 101660: MFH_HXRAD1: :2: TIH_HXRAD1: :363: CPH_HXRAD1: :4180: TIC_HXRAD1: :293: CPC_HXRAD1: :1024: DC_HXRAD1: :1.1:

  • Set-up (BOCO file)

The VCWT methodology. VCWT script: input

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SETUP_2 SETUP_n Hardcopies HTML

. . .

WORKING FOLDER SETUP_1 POST Hardcopies HTML POST Hardcopies HTML POST PARAM_1 PARAM_2 PARAM_n

The VCWT methodology. VCWT script: output

VCWT_run.sh

Log file

simulation simulation simulation

VCWT Outputs

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#Script for CFD models with VCWT echo “VCWT calculations" #Mesh session with the geometric param: PARAM_100 echo “Doing the mesh: PARAM_100" vcwt_MESH_PARAM_100.java . . #Mesh calculation session: PARAM_100 with setup: 1 . . echo “Doing mesh: PARAM_100 with setup: 1" starccm+ -np 4 -batch vcwt_MESH_PARAM_100_SETUP_1.java data_100_SETUP_1_iniOK_rough_3mm_03.sim . . echo "Post-processing the mesh: PARAM_100 with setup: 1" starccm+ -batch vcwt_MESH_PARAM_100_SETUP_1_POST.java data_100_SETUP_1_iniCOLD_FINAL.sim echo echo echo “Calculation is done “

VCWT_run.sh

Code The VCWT methodology. VCWT script: output

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WRAP REMESH VOLUM ANSA

The VCWT methodology. Modules Automatic surface meshing

Automatic element size assignation Automatic clean-up loop

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The VCWT methodology. Modules ROBUSTNESS 95% Probability

  • f running a simulation

Automatic volume mesh

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Exchangers

The needed regions for each type of simulation are: Cold flow means that there is not energy. In this model only the fluid equations (momentum, mass and turbulence) will be

  • calculated. Applications: exterior aerodynamics, air conditioned systems, defrost.

With the Hot flow dual it is possible to run different types of coupled simulations in a single model (with energy). Applications: underhood.

Dual model

UH region Hx region INHx region OUTHx region External flow simulation Internal flow simulation Hx region Hx are linked to both simulations. The released heat in the circuit’s water will be the same that the released in the air of the UH region.

The VCWT methodology. Modules

INHXRAD1 OUTHXRAD1 HXRAD1

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  • V1_HXRAD1: :1,0,0:

V2_HXRAD1: :0,1,0: R1_HXRAD1: :123.9: R2_HXRAD1: :519.4: VIN_INHXRAD1: :1.46: TIN_INHXRAD1: :293: TOUT_OUTHXRAD1: :368: V1W_HXRAD1: :0,0,1: V2W_HXRAD1: :1,0,0: QT_HXRAD1: :40833: TITULO_HXRAD1: :MassFlowRateAire Q PTS_HXRAD1: :9: P1_HXRAD1: :0.39 26571.1: P2_HXRAD1: :0.65 40833.1: P3_HXRAD1: :1.04 57733.1: P4_HXRAD1: :1.3 66204.1: P5_HXRAD1: :1.82 78958.1: P6_HXRAD1: :2.21 87271.1: P7_HXRAD1: :2.6 94263.1: P8_HXRAD1: :2.99 100241.1: P9_HXRAD1: :3.38 105514.1: MFH_HXRAD1: :2.12: TIH_HXRAD1: :368: CPH_HXRAD1: :3271: TIC_HXRAD1: :293: CPC_HXRAD1: :1024: DC_HXRAD1: :1.2:

  • WR_T:

:78.1:

  • OW_FAN1: :-633.,139.,278:

V3_FAN1: :103,-3.9,0: WF_FAN1: :1300:

  • V1_HXINT1:

:1,0,0: V2_HXINT1: :0,1,0: R1_HXINT1: :-0.185: R2_HXINT1: :735.27: V1W_HXINT1: :0,0,1: V2W_HXINT1: :1,0,0: VIN_INHXINT1: :15.4: TIN_INHXINT1: :417: QT_HXINT1: :7600: TITULO_HXINT1: :MassFlowRateAire Q PTS_HXINT1: :4: P1_HXINT1: :1. 3000: P2_HXINT1: :1.284 5000: P3_HXINT1: :1.71 8000: P4_HXINT1: :1.8 10000: MFH_HXINT1: :0.104: TIH_HXINT1: :423: CPH_HXINT1: :1012: TIC_HXINT1: :293: CPC_HXINT1: :1012: DC_HXINT1: :1.20:

  • The VCWT methodology. Set-up

Model set-up from set-up file definition

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STARCCM+ to Radtherm

Starccm+ Radtherm

Near Wall fluid Temperature

Images by Courtesy of PSA

Wall temperature

Radtherm to STARCCM+

H coefficient

daten2tcd prof2xy Simulation Simulation Starccm+ Radtherm

The VCWT methodology. Starccm+ & Radtherm coupling CFD – Thermal loop

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Target: Simulation turn around time < 3 weeks

CFD SIMULATION:

  • 1. Surface clean-up (ANSA): 2 day
  • 2. Surface organization (ANSA): 2 day
  • 3. CFD set-up (BOCO file): 1 day
  • 4. Volume mesh (STARCCM+): 10 hours (computer time)
  • 5. Troubleshooting: 1 day
  • 6. CFD Simulation: 16 Hours

Total: 1,5 weeks

Process automation

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Radtherm SIMULATION:

  • 1. Surface remesh (ANSA): 1 day
  • 2. Radtherm set-up: 1 day
  • 3. Radtherm Simulation: 8 Hours

Total: 0,5 weeks Coupled simulation (5 iterations): STARCCM+ & Radtherm: 2 days Post-process STARCCM+ & Radtherm: 1 week

Total turn-around time 3 weeks. Process automation

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Testing:

  • Climatic Wind tunnel tests
  • Proving ground tests

The VCWT methodology. Correlation

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Underhood thermal management; correlation

T meas. T Sim.

26,2º C 23,5 º C

T Meas. T Sim.

67,7 º C 64,7 º C

T Meas. T Sim.

82,1 º C 84,6 º C

Wall temperature Wall temperature Air temperature

Images by Courtesy of PSA

The VCWT methodology. Correlation

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Temperature was measured in 26 different locations during test

Temperatures of underhood test The VCWT methodology. Correlation

1.7 1.6

  • 7.9

2.1

  • 19.4

5.2 5 5

  • 4.4

5.3

  • 0.9

4.5 8.6 0.8

  • 11.4

0.8

  • 1

0.3

  • 2
  • 0.1 0.9
  • 5.8
  • 1
  • 1.3

3.7

  • 3.1

47-batery 48-batery_2 49-batery_fr 51-alternador 52-alternator 53-alternaror 58-mount 59-belt_left 60-firewall 61-steering 62-brake_pipe 63-brake 66-oxigen 68-fuel_tank 71-hs_manifold 72-hs_manifold 73-muffler_heat_shield 75-Underhood ambient front right 76-Underhood ambient front left 77-Underhood ambient back right 78-Underhood ambient back left 83-motor 84-hs-catalyst 86-shroud 82-ECU 31-39 Rad back

  • 200
  • 150
  • 100
  • 50

50 TEST SIMULATION INCREMENT

Temperature Temperature

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Conclusions:

The VCWT: fully automated process for CFD thermal under-hood simulations Automated coupled process of STARCCM+ & Radtherm Robustness Correlated process (wind tunnel and proving ground)

The VCWT methodology

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Thank you very much for your kind attention