Overview – Features and Applications

About us…

25.01.2011 Gregor Breuer 2

Our Company
Magna International

CLOSURES VEHICLE ENG

POWERTRAIN
SEATING EXTERIORS VISION SYSTEMS BODY & CHASSIS CONTRACT MFG
ELECTRONICS
ROOF SYSTEMS FUEL SYSTEMS

Engineering Center in St. Valentin

• Complete Vehicle Engineering

• Technology & Software Development
• Vehicle Testing

Author: W. Dantendorfer 3
 The KULI Team

Energy & Fluid Simulation

Christian Rathberger

Sales Services
Rolf Salomon Christian Rathberger

Software Development Software Methods

Thomas Naderhirn Christoph Stroh

Software Developers and Software Users exist under one umbrella!

07.08.2017
R. Salomon 4
What is KULI?

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Thermal Management Software

Powertrain Cooling Air Conditioning

Consideration of all
Thermodynamic Key Values
• Temperatures
• Pressures
• Mass flow
• Heat flow
• Other Energy flows

Windows Desktop Software for the 1D-Simulation of the Vehicle Thermal Energy Management

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Thermal Management Software

Component
& Function
Toolbars
2D Fluid
Network View

Project
Organization
3D Air
Network View

Analysis
Progress Info

1-dimensional Fluid Network Analysis – Quasi 1-dimensional Air Flow Network Analysis

25.01.2011 Gregor Breuer 7

Energy Management Software

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Typical Applications

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Typical Applications – Top Tank Temperature

Input

• 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

Results

• 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

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Typical Applications – Concept Studies
• Compare direct and indirect charge air cooling

low temperature
radiator

conventional CAC

water-cooled CAC
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Typical Applications – Minimize Package Size

• Reduce heat exchanger sizes according to performance limits

400 mm

300 mm

297 mm
259 mm

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Typical Application – Transient Simulation
• Warm up and cool down investigations
Zusatzwasserkühl er
In 2
In

Out

Out In 2
Cooler Thermostate
CA CAC
In 1

Out T hermostat ByPass

In 1
Airpath
[Water]
In
In Out
Out
RPM_#ECU [1/min]

Thermal CF
Exit temperature OM BMEP_#ECU [bar]
SPEED_#ECU [km/h]
In

In

Oil In

capacities Out
In

Out
ECU

BMEPcorrected
2
In Out
SP

considered X1

X2 Out
X1
x Out
Oil
Volume flow IM
Temperature
RPMcorrected
SPEEDcorrected
p_#Ambient
Speed
Ambient temperature
X2
Temperature Mean eff. pressure
X3
Pressure
BMEP_#Amb [bar] BMEP Ambient pressure
Out
RPM_#Amb [1/min] RPM RPM
Out 1
Out
SPEED_#Amb [km/h] SPEED In
Out
p_#Amb [hPa] Pressure
Out
Out Out 2
X2
T_#Amb [°C]
Out
Out
x X1
1.49

KULI Engine Model

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Typical Application – Cool Down Simulation

• Find evaporator heat load such

that passenger cabin cool down
requirements are met

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Applications – A/C system use for battery conditioning

Chiller

Complete vehicle thermal management

 A/C system use for battery conditioning

 Heat pump
Radiator  Air Condition (electric driven)
 Latent Heat Storage System
…

Battery

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Typical Application – Energy Management
Energy Management Simulation for a Hybrid Truck

Driving Cycle (HUDDS)

Heavy-Duty Urban Dynamometer Driving Schedule

Fuel Saving Potentials

Parallel Hybrid Vehicle

Battery, Coolant Temperature

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Application – Cell Temperature Optimization

• 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

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Why KULI?

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Why Thermal Energy Management?

Fuel Consumption

Engine power increasing

Emissions

Costs Inlet area decreasing (design)

Durability
Comfort
New technologies (e.g. hybrid)

More components / auxiliaries

Legislative Standards

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 Why use Computer Simulation?

System Concept Support Test System Minor Model

Comprehension Studies Bench Optimization Update

• Understand • Fast analysis • Improve test • Quickly find • Easy handling

complex and solutions: quality through measures for of engine
component “Rapid plausibility improvement upgrades
interactions Prototyping” checks
easily • Find control • Component
• Save time and • Reduce strategies for replacements:
• Effects of single cost (test hardware test auxiliaries compare
measures can bench, loops different
be within prototypes) • Computation suppliers
measurement only possibility
accuracy of optimum
validation

07.08.2017 R. Salomon 21
 Why use KULI? – Low Hardware Demands

Desktop • Works on any

Application laptop

Quick • Steady state results

Simulation within seconds

07.08.2017 R. Salomon 22
Why to use KULI? – Realistic Results at Low Effort

Component &
Function
Toolbars
2D Fluid
Network View

Project
Organization
3D Air
Network View
Analysis
Progress Info

Learn to use within 2 days of Training

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 Why use KULI? – Tailored to Customer Needs

From Engineers for Specialized:

Engineers Automotive Industry

Flexible Software: Modular Structure

simple & complex
07.08.2017 R. Salomon
 – Global Footprint
EASTERN + WESTERN EUROPE
NORTH AMERICA

Enterex America

JAPAN

CHINA

SOUTH KOREA

INDIA

SOUTH AMERICA

Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers

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Why to use KULI? – Multitude of Features
Postprocessor
• Output Analysis
• Presentation Material for Management

Uniform Component Library

Extendable Media Library

• Water/Glycol, Oil, Exhaust,
Refrigerant

Unit Converter

Optimization Package
• Optimization, Parameter Variation

Software Interfaces
• Excel, Matlab, CFD codes,…

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 Why use KULI? – Best Software Support

Support is given • Expertise through product overview Sales Services

by all members of • Expertise through product insight
the KULI Team • Expertise through product practice Software Software
Development Methods

Friendly and • Working to YOUR advantage

personal

Quick response • usually within 24 hours

Facility to
“enhanced” • Paid services for quick and reliable KULI Team
solutions
support kuli.support.mpt@magna.com
07.08.2017 R. Salomon 34
Who should use KULI?

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 Who should use KULI?

Engineers concerned with Thermal Management

(not restricted to Automotive Industry)
Engineering Service
OEMs Suppliers Researchers
Companies
Design-Engineers CAE-Engineers Test-Engineers

07.08.2017 R. Salomon 36
How to get started?

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 When to use KULI - Product Development Process

Key Milestones: E K PT1 P PT2 B PPAP R@R Disp SOP

Program Management

Product Specification
Concept Development Product Design
Virtual Model Simulation / DMU / Validation
1. Prototypes / Mules 2. Prototypes / Pre-Production
Functional- / Fatigue- / Vehicle Testing
Product Validation

Product Definition Product Creation Industrialization

Concept Simulation Prototyping Funct. Testing Vehicle Testing

07.08.2017 R. Salomon 38
 How to use KULI – Data Structure

Simulation
Vehicle Data
OEM Conditions
• Design
• Ambient
• Engine
• Operating Status

SUPPLIER

Component Boundaries &

Data Targets
Simulation • Max. Dimensions
• Dimensions
• Characteristics
Model • Max. Top Hose
Temperatures

07.08.2017 R. Salomon 39
 How to use KULI – Workflow

Component System
Simulation Results
Setup Setup

• Input data (Geometry,
Characteristic)
• Save in Component
Library
• Load components (from • Run Analysis • Get Output from
Library) Postprocessor, Excel
• Optimize, Vary
Sheet,…
• Define Media Properties Parameters
• Compare with System
• Position and Connect
Measurement Data
Components
• Interpret Results,
• Input Simulation
Reporting
Parameters

07.08.2017 R. Salomon 40
 How to use KULI – KULI lab Output

Temperature
levels and User-defined Units
Pressure Drops

Heat Turn-over
and Efficiency of
Package

Data Filter Various Graphics

Detailed
Conditions and
amounts of
Cooling Air

Optimized
Parameters
depending on
Targets

Variant Comparison
07.08.2017 R. Salomon 41
 Where to buy KULI?

25.01.2011 Gregor Breuer 42

 – Global Contact
EASTERN + WESTERN EUROPE JAPAN
Rolf SALOMON Youngwook KIM
NORTH AMERICA

Albert TUERTSCHER Magna Powertrain Magna International Japan Inc.

Engineering Center GmbH & CoKG Yaesu Center Building 5F
AT engineering LLC Steyrer Strasse 32 1-6-6 Yaesu, Chuo-ku,
1891 Denver West Ct. #1432 4300 St. Valentin, Austria Tokyo 103-0028, Japan
Golden, CO 80401-0924 Phone: +43 7435 501 2382 Phone: +81 3 3548 0310
rolf.salomon@magna.com youngwook.kim@magna.com
Phone: +1 734 276 5516
kuli.usa.ecs@magna.com
CHINA

Terra CAI

Magna International China

801-813, Tower A, Eton Place
69 Dongfang Road, Pudong,
Shanghai PRC 200120
Phone: +86 21 6165 1649
terra.cai@magna.com
SOUTH AMERICA
INDIA SOUTH KOREA
Leandro GARBIN
Rajeev GOPALAKRISHNAN Jin SEOK
VirtualCAE
Servicos de Sistemas Ltda. TAE SUNG S&E Inc.
MAXrad SOFTware (India) Pvt Ltd
Rua Tiradentes 160 - Sala 22 Seoulforest Kolon Digital Tower II 10F
'SHUBAM'#35,6th Cross,
São Caetano do Sul, Seongsu-dong2-ga, Seongdong-gu,
Nanjappa Garden, Babusapalaya
São Paulo (CEP 09541-220 ) 133-120, Seoul, KOREA
Bangalore 560043
Phone: +55 11 4229-1349 Phone: +82 2 3431 2442
Phone: +91 8049144149
vendas@virtualcae.com.br jseok@tsne.co.kr
rajeev@maxsoft-india.com

Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers

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Date: D R A F T / Author: Name © Advanced Engineering / Disclosure or duplication without consent is prohibited 44