Detailed Engine Thermal Model for Vehicle Energy. Management Simulations. GT-User Conference 2011, 24.10.2011, Frankfurt/Main. Dr. M. Weinrich, R.
Detailed Engine Thermal Model for Vehicle Energy Management Simulations
GT-User Conference 2011, 24.10.2011, Frankfurt/Main Dr. M. Weinrich, R. Rossmann, Daimler AG Dr. M. Grill, A. Tonev, M. Sossio, FKFS /
Agenda Project goals Test Bench Heat Balance Measurements Friction at low temperatures Operating points and model validation Hydraulic and thermal modeling Results Integration in vehicle environment Summary and Outlook
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Goals Measurements
Model Calibration & Engine Simulation
real world test bench environment
virtual world test bench environment
Extended Heat Balance
Benefits:
Reduction of measurement points and duration
Further conclusions for
non-measured operating points
Effect of minor changes in hardware
Effect of application changes
Future development: Use of a simplified model (fast running model) in vehicle simulation
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
Vehicle Simulation
virtual world vehicle enironment Folie 3
Test Bench – Heat Balance (2) Measured parameter for outer heat balance
(1) Test bench environment with conditioning Measurement technique used for outer heat balance as a standard process
rotational speed, torque, different fluid temperatures and pressures
Cooling of coolant, oil and intake air with external conditioning
Power Exhaust gas heat Coolant heat
Measurements extended with full pressure indication
Oil heat Intercooler heat
…
pcylinder
Twater_in coolant conditioning
T2 1
2
3
(3) Measured parameter for inner heat balance Cylinder pressure
intercooler
Twater_out
oil conditioning
T3 Toil_in
Toil_out
4
5
6
Low pressure indication ECU data: injection etc.
Tcylinder
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Friction test bench Friction Test bench Measurement are necessary to develop a friction model Operating range from -20°C to 100°C Correlation for oil sump temperature to friction points Pcrankcase
Tsurface pintake cyl2
Twater_in Tsurface cylinder head Toil_pan
Mfriction torque
Tmain_bearing_4 Tmain_bearing_2
Twater_out
Toil_sump Toil galery poil galery
Tsurface
pintake cyl5
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Operating points for model calibration and validation 2. Measurement of friciton drag measurements
BMEP [bar]
1. Measurements of 18 stationary operating Points
engine speed [rpm]
T_water_out T_water_in
temperature [°C]
temperature [°C]
3. Engine warm up measurements
Necessary measurements 1. Stationary points (fired) for validation of detailed engine model and heat distribution (heat balance) 2. Stationary points (motored) at different temperatures for friction model 3. Transient warm up for over all calibration of thermal net and complete model
time [s] GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Hydraulic model of the coolant circuit 1. Discretisation
2. Export using GEM3D
3. Structuring
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Stationary Points - Simulation vs. Measurement Radiation, oil- and coolant enthalpy Radiation Q_oil (T_oil 130°C) Q_coolant (T_water 105°C)
S
M
S
M
S
M
S
M
S
M
S = Simulation M = Measurement GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Engine Model in Test Bench Environment
Combustion & gas dynamics
Coupling
Simple ECU model
Water circuit
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
Oil circuit & thermal masses
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Integration into full vehicle simulation environment Full Vehicle simulation: slow with coupled detailed gas dynamic and combustion model Coupling of engine and vehicle circuits Investigations for engine heating up and thermal comfort for passengers
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Example for Vehicle Simulation - NEDC
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Example for Vehicle Simulation - Cabin Heating Up
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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Summary and Outlook Summary Measurement of inner and outer heat balance (high and low pressure indication) Modeling of a detailed gas exchange and a predictive combustion model Use of GEM3D for creation of the hydraulic network Additional friction investigations at low temperatures and extended friction model Manual generation of the thermal network Benefits: Calculation of not measured operating points Different level of detail for model depending on investigation focus Investigation of changes in combustion and minor hardware changes Outlook Focus on gasoline engine Simple FE structure model for thermal network Fast Running Model of the detailed gas exchange and combustion model Integration of detailed ECU
GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS
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