Thermal Management Using LMS Imagine.

Lab AMESim

Review of Automotive Air-Conditioning 2008

David ALMER – Thermal Management
 Content

ƒ Introduction / context of use of LMS Imagine.Lab AMESim for Thermal

management
ƒ Simulating the performances of a CO2 AC system
ƒ Integration of the AC system in its global thermal environment
ƒ Complete Vehicle Thermal Management Systems: purpose
ƒ Interest of use of such VTM models
ƒ Conclusions

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 Introduction

ƒ Automotive Industry Main Challenges

ƒ Improve thermal subsystems performances to:

• Optimize engine performances
• Reduce fuel consumption and pollutant emissions
• Optimize passenger comfort

ƒ Intensive use of 1D simulation platforms to:

ƒ Simulate the performances of independent thermal subsystems

ƒ Test / Anticipate new technologies, control laws
ƒ Model and simulate thermal subsystems interactions (under hood and
cabin)
ƒ Reduce costs

Æ Multi-Domain 1D simulation platform required

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 Thermal management collaborative design matrix

ƒ From accurate thermal subsystems models to thermal Management Analysis

Æ Need for a 1D systems network simulation platform

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 LMS Imagine.Lab for AC systems analysis

SOLUTION OVERVIEW
ƒ From validated and documented component libraries
ƒ Transient and steady-state analysis
ƒ Prediction of pressures, temperatures, flow rates …
ƒ Geometrical Heat Exchanger Characterization
ƒ Prediction and optimization of component performance, loop COP
ƒ Drive cycle analysis

KEY BENEFITS
ƒ Ensure sufficient performance of the loop to provide optimal
comfort to the passenger whatever the operating conditions,
ƒ Size components (HEX, compressor, TXV, …)
ƒ Optimize mass of refrigerant in the loop
ƒ Evaluate new architectures (multi-evaporator, heat pumps)
ƒ Evaluate performance of loop using alternative fluids
ƒ Evaluate Performance of heat recovery systems (Rankine cycles)

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Purpose:

ƒ Refrigerant replacement is needed (heating prevention)

ƒ CO2 (R744) is one of expected alternative refrigerants
ƒ Effect on component design (higher pressures, supercritical conditions,
additional components integration)
ƒ Use of simulation to shorten the development cycles
ƒ Study Cabin Cool down and influence of components on the cabin cool
down
ƒ Study deterioration of components on AC system performance

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ The system to be modeled:

Gas cooler
Internal heat exchanger

evaporator

expansion valve

compressor
accumulator

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Subsystem modeling and simulation:

Gas cooler

compressor

IHX accumulator
Carbon Dioxide: Pressure - Enthalpy Diagram

1 000

240 oC
t = 0 oC

180

280
200

220
120

160

260
100

140
80
40

60
-20
-40

20
3
0 00
90 kg/m

00
00 r= r=8 70 0 r = 60
0

12
10 =
r= 50
0

50
sity

r=
50 r= De n

11

00
10 r = 40
0

r=

11
r=

r=
0
r = 30
3
0 kg/m

0
0 kJ/kg, oC
r = 20

-2.00

-1 .70

-- 1.6

0
-1.90

0
s = -2.20

-1.80

-.9
0
0

.30
r = 150

-1 .5

.0

0
-2.10

-1 .4
EXP

-.8
-1 .1

-1
0
-1

-1 .2
100 r = 100

0
-.7
Entropy = -2.3
r = 75
Pressure, Bar

0
-.6
r = 50
-. 50
r = 35

evaporator -.4
0
r = 25
= 20 kg/m
3

Melting Line
-.3
0 De nsity
r =15
0 r = 10
10 -.2
0
-.1 r=8

0
=
r=6

s
Triple Point (5.18 bar, -56.558 oC)

220
160

180

200
-40 oC

100

120

140
40
60
20

80
-20
0
Sublimation Line
1
Enthalpy, kJ/kg
-500 -400 -300 -200 -100 0 100 200

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Other results:

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Simulation of Cabin Cool Down

Æ Need to study AC system in interaction with cabin:

Compressor
Gas Cooler
Internal Heat Exchanger

Cabin
Expansion Valve
Evaporator

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Simulation of Cabin Cool Down

Cabin details:
-Internal and external
convection
- Wall thermal solid capacities
- Solar heat flux
- Radiation with ambient
- internal temperature and
humidity calculation

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Example of simulation / experiment validation

Æ Expansion valve type and cabin cool down performance

Cabin cool down Experiment

Amb. Temp. 40degC
60
Expansion valve
Air Temperature (degC)

EXP/V---1
50
EXP/V---2
40km/hr 100km/hr IDL EXP/V---1
40 1 EXP/V---2
Evaporator in 1
30 2 2
1
20
Evaporator out 1
10 2
2
0
0 1000 2000 3000 4000 5000
Time (sec)

Æ Good agreement between simulation an experiments

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ Example of simulation / experiment validation

Æ Deterioration of gas cooler performance (durability test) Æ component level

Gas Coole r
mark:experiment
line:AMESim
12
10
new

he at flow kw
8
deterioration
6
4
2
0
0 2 4 6
air ve loc ity m/ se c

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 LMS Imagine.Lab: application to the modeling of a R744 AC system

ƒ The results provided by the 1D simulation tool for the modeling of AC systems enables:

ƒ To analyze the behavior and performance of components (ex: influence of HEX

geometries on their heat transfer performances)
ƒ To analyze the behavior and performance of the complete loop (system level
analysis) on single operating points or specific drive cycles
ƒ To analyze the behavior of the AC system in connection with a 1D cabin model
(system network analysis)
ƒ To analyze the effect of components degradation on AC system performance and
passenger comfort.

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 Integration of Sub-systems in LMS_Imagine.Lab

ƒ Recall of the main challenges:

ƒ Ensure engine reliability
ƒ Cope with higher and higher efficiency engines
ƒ Go on reducing fuel consumption and pollutant emissions while:
9 Keeping maximum engine performance
9 Ensuring maximum passenger comfort
ƒ Reduce number of prototypes

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 What is Vehicle Thermal Management ?

ƒ Vehicle Thermal Management is

ƒ The study and optimization of all energy flows

ƒ under the hood and
ƒ within the cabin
ƒ Contributing directly or indirectly to
ƒ the emissions of pollutant,
ƒ the consumption of fuel,
ƒ the engine performance
ƒ the passenger comfort

9 Mechanical energy
9 Thermal and thermal fluids energies
9 Electrical energy

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 Subsystems found in a complete VTM model

This is not an exhaustive list:

ƒ Simplified Lubrication system

ƒ Vehicle Cooling system
ƒ Simplified Engine Thermal model
ƒ Air-conditioning system
ƒ Front End Heat Exchanger stack
ƒ HVAC module (from outside air, to the cabin, through heat exchangers)
ƒ Cabin model
ƒ Drive forward model (Driver, engine, clutch, transmission, vehicle)
ƒ Exhaust line model for thermal and post-treatment analysis
ƒ Electrical auxiliaries with battery and alternator

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 How to build Vehicle Thermal Management models ?

ƒ To develop a Vehicle Thermal Management model 3 steps are required

ƒ DATA ACQUISITION
• In order to provide all necessary data for a VTM model,
divisions of the same company have to exchange its expertise
and its database.

ƒ TEST MEASURES
• A roller bench test is required to get measures used to validate
the final model.

ƒ MODELLING
• Divisions of the company model their specific subsystems and
finally work together for the complete model.

Î Importance of a single platform to exchange and

connect models for interaction analysis

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 Example of Complete Vehicle Thermal Management model (Part I)

Model upper part

CAB AC

HVAC
Control

Research & Development Engine Thermal Model

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(oil/Coolant/metal/air)
 Example of Complete Vehicle Thermal Management model (Part II)

Model lower part

Research & Development

Electric
Auxiliaries
model
Vehicle model

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 Cabin cool down: European Cycle – Different scenarii

European cycle
Ambient = 29 °C

10- No AC

11- 100% air

recycling

12- 20% air

recycling

Research & Development

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 Results: NEDC AC - 5

Fuel consumption [g]

NEDC / 29°C diff
Case 10 705 -
Case 11 768 8.9%
Case 12 782 10.8%

Research & Development

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 1D VTM simulation: wide range of analysis possibilities

Illustration of the use and accuracy of a 1D multi-domain platform for:

ƒ AC Component Analysis
ƒ AC Subsystem Analysis
ƒ AC / Cabin Subsystems interaction Analysis
ƒ Vehicle Thermal Management System Analysis:

Æ Heat management strategies simulator (engine warm-up optimization

through specific strategies (storage tank, heat recovery from exhaust, split
cooling …))
Æ Fuel consumption simulator (influence of each component/subsystem
(thermal, mechanical, electrical) on fuel consumption (additional heaters,
AC, electric devices)),
Æ Optimization of energy flow for best compromise between engine
performance, fuel consumption and pollutant emissions, passenger
comfort

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 Thanks for your attention

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