Mentor Graphics recently released a research report titled "Designing a Complex Automotive Cooling System", which introduces an effective combination of the current conductors and the use of the one-dimensional CFD tool Flowmaster® and the three-dimensional tool FloEFD®. The solution, how to work for a complex car cooling system.
This article refers to the address: http://
The author of this article is John Isaac, Department of Conductor Mechanical Analysis
Foreword
In today's automotive sector, many systems and components require computational fluid dynamics (CFD) analysis during the design process to ensure optimum performance, reliability, cost, and time to market. These systems and components may be structural components, electronic components, or both. CFD analysis is one of the three major methods of system design. Combining “virtual prototyping†with CFD analysis early in the design process and throughout the design process provides an optimized system at a lower cost (less physical prototype) and allows the system to get to market faster.
A very representative example of a complex automotive system is the engine and lubricant cooling system. It is complicated because it includes not only the coolant delivery piping system, but also engine cooling jackets that actually cool the engine. Here's how the design process can progress and how CFD tools can be used to optimize this system.
Key tool selection
Suppose we work for a car company that is developing a new car model, but we want to use a reliable engine that has been proven for many years. We must design a new cooling system that will use the engine but require a new piping system for the engine and the cabin. I have two CFD analysis tools, one of which can be used to analyze a pipe system, which can be viewed as one-dimensional (meaning that the fluid flows in one direction in the coolant pipe). Another 3D tool analyzes complex fluid flow and heat exchange components. The system to be designed is obviously a combination of one-dimensional piping system and three-dimensional complex components. Which CFD tool should I use to analyze this system?
Simulation analysis One-dimensional tools are significantly faster than 3D tools, but they are not accurate enough to simulate complex water jackets. But if we only use the 3D CFD tool to analyze the whole system, we can get the exact result we need, but the simulation calculation time will be too long, so we can't realize the virtual experiment with several design methods. The best way is to integrate 1D and 3D tools and take advantage of both.
One-dimensional - three-dimensional CFD
Ming Conductor recently announced a solution that effectively combines and utilizes the one-dimensional CFD tool Flowmaster® and the three-dimensional tool FloEFD®. Figure 2 illustrates how this combined 1D and 3D solution works for this example of a car cooling system.
Combining one-dimensional and three-dimensional CFD to take advantage of both, making analysis both speed and accuracy
Initially, the cooling system designer defined a series of boundary conditions such as the pressure and flow rate through the water jacket. They determine these values ​​by knowing the common driving scenarios of the car to be designed and how they relate to the engine's maximum torque (RPM) and pump performance.
The engine/water jacket structural designer uses the FloEFD tool embedded in the MCAD system for detailed fluid flow and heat exchange analysis on the water jacket. She built a set of FloEFD analyses based on the range of boundary values ​​proposed by the system designer. This may require running 30, 40, or even more batch models through 3D analysis. The data generated by these runs is automatically fitted to a detailed feature map and now forms a complete water jacket model. The water jacket boundary conditions are entered in the model to generate the coolant (and engine) flow temperature.
The model is simply embedded in the Flowmaster tool-related database. Today, system designers can perform cooling analysis with the range of driving scenarios expected by the new car model. Design changes can be added to the cooling system to run the analysis. The water jacket model remains intact as it covers all possible operating environments.
The accuracy of the 3D simulation of complex components (water jackets) combined with the speed of one-dimensional cooling system analysis combines the best of both worlds into one system. With the speed of analysis, system designers can design a cooling system that operates at a small bandwidth with optimal performance, with a temperature range of 3-4 degrees Celsius. If the cooling system is operated above this optimum range, it can cause overheating and high warranty costs for the car manufacturer. Operating at temperatures below the optimal temperature range may result in excessive emissions and too little gasoline mileage.
The same method can be used for other automotive systems such as exhaust, fuel and cabin air conditioning. It can also be used for fuel supply and environmental control, chemical processing, energy and utilities in industries such as military/aviation.
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