The Virtual Climatic Wind Tunnel project. STAR CCM+, London, 22 March 2010 Author: J. Arbiol, E. Aramburu

Transcription

1 The Virtual Climatic Wind Tunnel project STAR CCM+, London, 22 March 2010 Author: J. Arbiol, E. Aramburu

2 Content Overview of IDIADA Overview of VCWT project UH thermal simulation The VCWT methodology State of the art Benchmark Design Modules VCWT exe Automatic surface meshing Automatic volume mesh Examples Input (Command / Organisation / Set-up) Output Code Set-up STARCCM+ & Radtherm coupling Correlation

3 Overview of IDIADA 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

4 Overview of the VCWT project Main Characteristics 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

5 The VCWT methodology Modules 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

6 The VCWT methodology. VCWT script: inputs Command vcwt26 /users/kk/work data_100.inp 1 0 data_1.txt Executable Working folder Mesh file Scale factor Number of prism layer Data file (inlet velocity, fan rotation, ) Type of simulation Number of iterations

7 The VCWT methodology. VCWT script: input Surface clean-up & organisation Data translation & surface meshing, 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 holes closure & wrappings. Model organisation

8 The VCWT methodology. VCWT script: input Set-up (BOCO file) 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, ,251: V3_FAN1: :10.75, ,-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: : : P2_HXRAD1: : : P3_HXRAD1: : : P4_HXRAD1: : : MFH_HXRAD1: :2: TIH_HXRAD1: :363: CPH_HXRAD1: :4180: TIC_HXRAD1: :293: CPC_HXRAD1: :1024: DC_HXRAD1: :1.1: Type of simulation Number of Set-ups Specific Bocos: Inlet, Outlet, floor, wheels, fans, porosities, heat exchange, etc..

9 The VCWT methodology. VCWT script: output Outputs WORKING FOLDER VCWT VCWT_run.sh Log file PARAM_1 SETUP_1 simulation POST Hardcopies HTML PARAM_2 SETUP_2 simulation... PARAM_n POST SETUP_n Hardcopies HTML simulation POST Hardcopies HTML

10 The VCWT methodology. VCWT script: output Code VCWT_run.sh #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

11 The VCWT methodology. Modules Automatic surface meshing ANSA Automatic element size assignation WRAP Automatic clean-up loop VOLUM REMESH

12 The VCWT methodology. Modules Automatic volume mesh ROBUSTNESS 95% Probability of running a simulation

13 The VCWT methodology. Modules 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. External flow simulation Hx region UH region Internal flow simulation INHx region Hx region OUTHx region Dual model 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. INHXRAD1 HXRAD1 OUTHXRAD1

14 The VCWT methodology. Set-up Model set-up from set-up file definition OR_D: :6.54,-841.0,90.95: WR_D: :78.1: OR_T: :2714.0,-841.0,90.95: WR_T: :78.1: OW_FAN1: :-633.,139.,278: V3_FAN1: :103,-3.9,0: WF_FAN1: :1300: V1_HXRAD1: :1,0,0: V1_HXRAD1: :1,0,0: V2_HXRAD1: :0,1,0: V2_HXRAD1: :0,1,0: R1_HXRAD1: :123.9: R1_HXRAD1: :123.9: R2_HXRAD1: :519.4: 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: : : P2_HXRAD1: : : P3_HXRAD1: : : P4_HXRAD1: : : P5_HXRAD1: : : P6_HXRAD1: : : P7_HXRAD1: : : P8_HXRAD1: : : P9_HXRAD1: : : MFH_HXRAD1: :2.12: TIH_HXRAD1: :368: CPH_HXRAD1: :3271: TIC_HXRAD1: :293: CPC_HXRAD1: :1024: DC_HXRAD1: :1.2: 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: : : P2_HXINT1: : : P3_HXINT1: : : P4_HXINT1: : : MFH_HXINT1: :0.104: TIH_HXINT1: :423: CPH_HXINT1: :1012: TIC_HXINT1: :293: CPC_HXINT1: :1012: DC_HXINT1: :1.20:

15 The VCWT methodology. Starccm+ & Radtherm coupling Radtherm to STARCCM+ CFD Thermal loop Near Wall fluid Temperature H coefficient Starccm+ Simulation Starccm+ daten2tcd STARCCM+ to Radtherm prof2xy Wall temperature Simulation Radtherm Images by Courtesy of PSA Radtherm

16 Process automation 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

17 Process automation 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.

18 The VCWT methodology. Correlation Testing: Climatic Wind tunnel tests Proving ground tests

19 The VCWT methodology. Correlation Underhood thermal management; correlation T meas. T Sim. 26,2º C 23,5 º C Wall temperature T Meas. T Sim. 67,7 º C 64,7 º C Wall temperature T Meas. T Sim. 82,1 º C 84,6 º C Images by Courtesy of PSA Air temperature

20 The VCWT methodology. Correlation Temperature 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 Rad back Temperature Temperatures of underhood test Temperature was measured in 26 different locations during test TEST SIMULATION INCREMENT

21 The VCWT methodology 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)

22 Thank you very much for your kind attention