„Comprehensive Software for Thermal Energy Management Optimization“

www.ecs.steyr.com
© ECS / Disclosure or duplication without consent is prohibited

Who we are?

Who we are?
25.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 3

Who we are? – The Company
MAGNA International
Cosma International Magna Seating Magna Mirrors Magna Closures Magna Powertrain Magna Car Top Systems Magna Steyr Magna Electronics

Magna Exteriors & Interiors

Body & Chassis

Interior Systems

Exterior Systems

Seating Systems

Vision Systems

Closure Systems

Powertrain & Engineering

Roof Systems

Engineering & Assembly

Electronic Systems

ECS – Engineering Center Steyr • Complete Vehicle Engineering • Technology & Software Development • Vehicle Testing

25.01.2011

Gregor Breuer

© ECS / Disclosure or duplication without consent is prohibited

4

Christoph Stroh Software Developers and Software Users exist under one umbrella! 25.Who we are? – The KULI Team Department Energy & Fluid Simulation Department Leader E&F Simulation Christian Rathberger Sales Rolf Salomon Software Thomas Naderhirn Services Dr.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 5 .01.

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 6 .What is KULI? What is KULI? 25.01.

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 25.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 7 .

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 8 .01.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.

Energy Management Software Transient Conditions AC System Engine Model Cooling System Driving Cycles 2000 1500 1000 500 0 200 400 600 800 1000 1200 1400 1600 1800 Time [s] Optimization CFD Analysis 25.2011 Gregor Breuer CoSimulation COM-Interface © ECS / Disclosure or duplication without consent is prohibited 10 .01.

Typical Applications 15.04.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 11 .

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 13 .01. volume flows.) on the above mentioned measurable variables 25....Typical Application – 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.

01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 14 .Typical Application – Concept Studies • Compare direct and indirect charge air cooling low temperature radiator conventional CAC water-cooled CAC 25.

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 15 .07.Typical Application – Minimize Package Size • Reduce heat exchanger sizes according to performance limits 400 mm 300 mm 297 mm 259 mm 08.

07.Typical Application – Transient Simulation • Avoid oversizing of components due to steady state operating points Zusatzwasserkühler In 2 In Out Out In 1 In 2 Cooler Thermostate CA CAC Out In 1 Thermostat ByPass Airpath [Water] In In Out Out Thermal capacities considered X1 Out CF Exit temperature OM Oil ECU In Out Out In Out RPM_#ECU [1/min] In BMEP_#ECU [bar] In SPEED_#ECU [km/h] In BMEPcorrected RPMcorrected SPEEDcorrected p_#Ambient Temperature 2 X1 Oil x Out SP Speed Ambient temperature Mean eff.49 KULI Engine Model 08.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 16 . pressure Ambient pressure RPM In Out 1 Volume flow IM Temperature Pressure X2 X2 X3 BMEP_#Amb [bar] RPM_#Amb [1/min] SPEED_#Amb [km/h] p_#Amb [hPa] X2 BMEP Out Out RPM SPEED Out Pressure Out Out T_#Amb [°C] Out Out 2 Out x X1 1.

01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 17 .Typical Application – Cool Down Simulation • Find evaporator heat load such that passenger cabin cool down requirements are met 25.

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 19 .01.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 25.

SOC) Open circuit voltage characteristic = f(temperature. NiMh. internal resistance) Cell cooling Thermal network 25.01.…) Internal resistance = f(current. temperature.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 20 . SOC) Heat source = f(current.Application – Cell Temperature Optimization • • • • • • Battery type (Li-Ion.

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 21 .Why to use KULI? Why to use KULI? 25.01.

2011 Author: Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 22 .g.01.Why Thermal Energy Management? Fuel Consumption Emissions Engine power increasing Costs Durability Inlet area decreasing (design) New technologies (e. hybrid) More components / auxiliaries Legislative Standards Comfort 25.

01. prototypes) • Improve test quality through plausibility checks • Reduce hardware test loops • Quickly find measures for improvement • Find control strategies for auxiliaries • Computation only possibility of optimum validation • Easy handling of engine upgrades • Component replacements: compare different suppliers 25.Why to use Computer Simulation? System Comprehension Concept Studies Support Test Bench System Optimization Minor Model Update • Understand complex component interactions easily • Effects of single measures can be within measurement accuracy • Fast analysis and solutions: “Rapid Prototyping” • Save time and cost (test bench.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 24 .

2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 25 .Why to use KULI? – Low Hardware Demands Desktop Application • Works on any Laptop Quick Simulation • Steady state results within seconds November 2010: KULI on iPad 25.01.

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 25.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 26 .01.

01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 27 .Why to use KULI? – Tailored to Customer Needs „From Engineers for Engineers“ Transient Conditions AC System Engine Model Specialized: Automotive Industry Cooling System Driving Cycles 2000 1500 1000 500 0 200 400 600 800 1000 1200 1400 1600 1800 Time [s] Optimization CoSimulation CFD Analysis COMInterfa ce Modular Structure Flexible Software: simple & complex 25.

… 25.Why to use KULI? – Multitude of Features Postprocessor • Output Analysis • Presentation Material for Management Uniform Component Library Extendable Media Library • Water/Glycol. Exhaust.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 28 . Matlab. Refrigerant Unit Converter Optimization Package • Optimization. Oil.01. Parameter Variation Software Interfaces • Excel. CFD codes.

01.2011 Gregor Breuer Disclosure or duplication without consent is prohibited 29 .Why to use KULI? – Used by Global Customers NORTH AMERICA EASTERN + WESTERN EUROPE JAPAN Enterex America CHINA SOUTH KOREA INDIA SOUTH AMERICA Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers 25.

com 25.steyr.Why to use KULI? – Best Software Support KULI Team Support is given by all members of the KULI Team • Expertise through product overview • Expertise though product insight • Expertise through product practice Friendly and personal Department E&F Simulation Sales Software Services • Working to YOUR advantage Quick response • usually within 24 hours Facility to “enhanced” support • Paid services for quick and reliable solutions kuli_support@ecs.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 30 .

Why to use KULI? Low hardware demands • Desktop PC • Short analysis time Realistic results at low effort • Clear and brief GUI • Easy to learn: “fit in 2 days” • No “hidden” data Tailored to customer needs • “from Engineers for Engineers” • Specialized Software • Flexible Software • Modular structure Multitude of features • Uniform Component Library • Extendable Media Library • Postprocessor • Optimization Package • Software Interfaces Worldwide usage • KULI data available from majority of suppliers Best software support • Quick response • Expertise through practical use • Facility of “enhanced” support (simulation services) 25.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 31 .

01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 32 .Who to use KULI? Who to use KULI? 25.

Who to use KULI? Engineers related to Thermal Management (not restricted to Automotive Industry) OEMs Design-Engineers Suppliers Researchers Engineering Service Companies Test-Engineers CAE-Engineers 25.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 33 .01.

01.When to use KULI? When to use KULI? 25.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 34 .

Product Development Process Key Milestones: E K PT1 P PT2 B PPAP R@R Disp SOP Program Management Product Specification Concept Development Virtual Model Product Design Simulation / DMU / Validation 1.When to use KULI? ./ Vehicle Testing Product Validation Product Definition Product Creation Industrialization Concept Simulation Prototyping Funct. Testing Vehicle Testing 25. Prototypes / Mules 2. Prototypes / Pre-Production Functional./ Fatigue.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 35 .

How to use KULI? How to use KULI? 25.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 36 .

01. Top Hose Temperatures 25. Dimensions • Max.2011 Author: Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 37 .How to use KULI? – Data Structure OEM SUPPLIER Vehicle Data • Design • Engine Simulation Conditions • Ambient • Operating Status Component Data • Dimensions • Characteristics Boundaries & Targets Simulation Model • Max.

Vary Parameters Results Get Output from Postprocessor. Characteristic) Save in Component Library System Setup Load components (from Library) Define Media Properties Position and Connect Components Input Simulation Parameters Simulation Run Analysis Optimize. Reporting 25.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 38 . Excel Sheet.01.… Compare with System Measurement Data Interpret Results.How to use KULI? – Workflow Component Setup Input data (Geometry.

How to use KULI? – Postprocessor Output Temperature levels and Pressure Drops Heat Turn-over and Efficiency of Package Userdefined Units Data Filter Detailed Conditions and amounts of Cooling Air Optimized Parameters depending on Targets Various Graphics Variant Comparison 25.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 39 .01.

Where to get KULI? Where to get KULI? 25.01.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 40 .

Hinjewadi Phase –II. #1432 Golden. Austria Phone: +43 7435 501 2382 rolf. KOREA Phone: +82 2 3431 2442 jkpark@tsne. Sr. Pune 411 057 Pune Phone: +91 20 6675 5496 yogesh.salomon@ecs.usa@ecs. Tal Mulshi. CO 80401-0924 Phone: +1 734 276 5516 kuli. 133-120. Chuo-ku.cai@magnapowertrain.2011 Gregor Breuer Disclosure or duplication without consent is prohibited 41 .steyr.01.com CHINA Terra CAI Magna International China 801-813. No. 280 Village Mann. Seongdong-gu. Japan Phone: +81 3 3548 0310 teruegoto@magnaint. Yaesu Center Building 5F 1-6-6 Yaesu.jp Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers 25. Valentin.com. Rua Tiradentes 160 .kr Jong-Kwan PARK Terue GOTO Magna International Japan Inc.co. Seoul. São Paulo (CEP 09541-220 ) Phone: +55 11 4229-1349 vendas@virtualcae.com SOUTH KOREA INDIA Yogesh RAHANE SOUTH AMERICA Leandro GARBIN VirtualCAE Servicos de Sistemas Ltda. Eton Place 69 Dongfang Road. Tokyo 103-0028. Tower A.Sala 22 São Caetano do Sul. Seoulforest Kolon Digital Tower II 10F Seongsu-dong2-ga.com Rolf SALOMON Magna Powertrain Engineering Center GmbH & Co KG Steyrer Strasse 32 4300 St.br Tata Autocomp Systems Ltd.– Global Contact EASTERN + WESTERN EUROPE JAPAN NORTH AMERICA Albert TUERTSCHER AT engineering LLC 1891 Denver West Ct. Pudong.rahane@tacogroup.com TAE SUNG S&E Inc.co.steyr. Shanghai PRC 200120 Phone: +86 21 6165 1649 terra.

salomon@ecs.com Characteristics • Quasi 1-dimensional Analysis of the Air Flow • Consideration of Pressure Drops and Overlapping • Tool for Developing.2011 Gregor Breuer © ECS / Disclosure or duplication without consent is prohibited 42 . Austria Phone: +43 7435 501 2382 rolf.01.Summary Rolf SALOMON Magna Powertrain Engineering Center GmbH & Co KG Steyrer Strasse 32 4300 St.steyr. Valentin. Analyzing and Testing Engineers Input • Measurements of Components from Suppliers • Temperature Measurements of Vehicle if available • Demanded Dimensions and Positions of Components • Coolant Flow Rates and its Heat Amount • Operating Points of Vehicle and Boundary Conditions Output • Heat Turn-over and Efficiency of Cooling Packages • Temperature Levels • Detailed Conditions and Amounts of Cooling Air Benefits • • • • Comfortable Handling Quick Analysis and Solutions High Flexibility Save Time and Cost 25.