the “virtual climatic wind tunnel” project · idiada is developing the “virtualclimatic wind...
TRANSCRIPT
The “Virtual Climatic Wind Tunnel” project
STAR CCM+, London, 22 March 2010
Author: J. Arbiol, E. Aramburu
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
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 EngineeringSimul. (CAE)
DevelopmentTest
Validation Homologation Preparation
Overview of IDIADA
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
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
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
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
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
SETUP_2
SETUP_n
Hardcopies
HTML
.
.
.
WORKING
FOLDER
SETUP_1
POST
Hardcopies
HTMLPOST
Hardcopies
HTMLPOST
PARAM_1
PARAM_2
PARAM_n
The VCWT methodology. VCWT script: output
VCWT_run.shLog file
simulation
simulation
simulation
VCWT
Outputs
#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
WRAP
REMESHVOLUM
ANSA
The VCWT methodology. Modules
Automatic surface meshing
Automatic
element size
assignation
Automatic
clean-up loop
The VCWT methodology. Modules
ROBUSTNESS
95% Probability
of running a simulation
Automatic volume mesh
ExchangersThe 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 modelUH region
Hx region
INHx region
OUTHx region
External flow simulation Internal flow simulation
Hx regionHx 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
-------------------------------------
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:
-------------------------------------
-------------------------------------
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:
V2_HXRAD1: :0,1,0:
R1_HXRAD1: :123.9:
R2_HXRAD1: :519.4:
-------------------------------------
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
STA
RC
CM
+ to
Ra
dth
erm
Starccm+
Radtherm
Near Wall fluid Temperature
Images by Courtesy of PSA
Wall temperature
Ra
dth
erm
to
STA
RC
CM
+
H coefficient
daten2tcd prof2xy
Simulation
Simulation
Starccm+
Radtherm
The VCWT methodology. Starccm+ & Radtherm coupling
CFD – Thermal loop
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
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
Testing:
• Climatic Wind tunnel tests
• Proving ground tests
The VCWT methodology. Correlation
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
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 8.60.8
-11.4
0.8
-1
0.3
-2
-0.1 0.9
-5.8-1 -1.3
3.7
-3.1
47
-ba
tery
48
-ba
tery
_2
49
-ba
tery
_fr
51
-alte
rna
do
r
52
-alte
rna
tor
53
-alte
rna
ror
58
-mo
un
t
59
-be
lt_
left
60
-fire
wa
ll
61
-ste
erin
g
62
-bra
ke
_p
ipe
63
-bra
ke
66
-oxig
en
68
-fu
el_
tan
k
71
-hs_
ma
nifo
ld
72
-hs_
ma
nifo
ld
73
-mu
ffle
r_h
ea
t_sh
ield
75
-Un
de
rho
od
am
bie
nt fr
on
t rig
ht
76
-Un
de
rho
od
am
bie
nt fr
on
t le
ft
77
-Un
de
rho
od
am
bie
nt b
ack r
igh
t
78
-Un
de
rho
od
am
bie
nt b
ack le
ft
83
-mo
tor
84
-hs-c
ata
lyst
86
-sh
rou
d
82
-EC
U
31
-39
Ra
d b
ack
-200
-150
-100
-50
0
50
TEST SIMULATION INCREMENT
Te
mp
era
ture
Te
mp
era
ture
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
Thank you very much for your kind attention