KULI Overview 20110720 BRG

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

„Comprehensive Software for Thermal Energy

Management Optimization“

© ECS / Disclosure or duplication without consent is prohibited

Who we are?

Who we are?

25.01.2011 3 Gregor Breuer


Who we are? – The Company

Gregor Breuer 4 08.12.2011

ECS – Engineering Center Steyr

• Complete Vehicle Engineering

• Technology & Software Development

• Vehicle Testing

Magna

Seating

Seating

Systems

Cosma

International

Body & Chassis

Systems

Magna Exteriors and Interiors

Exterior

Systems

Interior

Systems

Vision

Systems

Closure

Systems

Magna Mirrors &

Magna Closures

Powertrain &

Engineering

Electronic

Systems

Magna Powertrain Magna Steyr

Engineering

& Assembly

Roof

Systems

E-Car Systems

(J.V.)

Hybrid &

Electric

Vehicles

MAGNA International


ECS @ a Glance

Author: W. Dantendorfer 5 Oct. 2013

World leading engineering service provider focused on:

Innovation

System Engineering

Commercial Vehicle Engineering

Improved transport efficiency

Execution within a global network

Range of Services:

Commercial Vehicle Engineering

Powertrain Systems

Software & Simulation

Electronics & Electric

Testing Services

Low Volume Production

e-drive

IMG

HCU


Thermal- and Energy- Management

Author: Clemens Gamsjaeger Date: May 2013

Thermal Management HVAC Energy Management

• Simulation / Testing: - under hood flow - component temperatures - coolant/oil circuits - charge air circuits • Optimization of VTMS • Operating Strategies

• Product Specification

and Testing: - Fan/Cooler - Pumps (oil/coolant) - Entire Cooling Package - Thermostat / Valves • Vehicle testing: - chassis dynamometer - test track - on track

• Driving Performance

• Consumption

• CO2 – Optimization

• Energy Balance

• Operating Strategy

• Alternative Powertrains

• Aerodynamics:

- under hood

- circulation

- lift / drag

• AC Concepts

• AC Power

(Heating/Cooling)

• Comfort

• Deicing / Demisting

• HVAC Measurements

(test rig / road)

• Battery conditioning

• Operating strategy

• Component specification


Who we are? – The KULI Team


Department Energy & Fluid Simulation

Software Developers and Software Users exist under one umbrella!

Services

Dr. Christoph Stroh

Department Leader

E&F Simulation

Christian Rathberger

Sales

Rolf Salomon

Software

Thomas Naderhirn


What is KULI?

What is KULI?



Powertrain Cooling Air Conditioning

• Temperatures

• Pressures

• Mass flow

• Heat flow

• Other Energy flows

Consideration of all Thermodynamic Key Values

Thermal Management Software


Windows Desktop Software for the 1D-Simulation of the Vehicle Thermal Energy Management


Thermal Management Software


Component

& Function

Toolbars

Project

Organization

Analysis

Progress

Info

3D Air

Network

View

2D Fluid

Network

View

1-dimensional Fluid Network Analysis – Quasi 1-dimensional Air Flow Network Analysis


Energy Management Software

COM-Interface

Transient Conditions

Engine Model

E-mobility recuperation

Co-Simulation

CFD Analysis

Optimization

Cooling System

AC System


http://vallinsvit23/gallery2/main.php?g2_itemId=31390&g2_imageViewsIndex=2

© ECS / Disclosure or duplication without consent is prohibited Gregor Breuer 13 15.04.2011

Typical

Applications


• 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

Input

• Top tank temperature

• Air to boil

• Analysis of the operating points of the fans/coolers

Additional results:

• Parameter variation (fan speeds, volume flows,...)

on the above mentioned measurable variables

Results

Typical Application – Top Tank Temperature



Typical Application – Concept Studies

• Compare direct and indirect charge air cooling

conventional CAC

water-cooled CAC

low temperature

radiator



297 mm

259 mm

Typical Application – Minimize Package Size


• Reduce heat exchanger sizes

according to performance

limits

400 mm

300 mm


Typical Application – Transient Simulation

• Avoid oversizing of components due to steady state operating points


RPM_#ECU [1/min]

In

BMEP_#ECU [bar]

Out

RPM_#Amb [1/min]Out

BMEP_#Amb [bar]

Out

1.49

Out

2OutIn

OutIn

[Water]

Exit temperature OM

SP

RPM

Ambient pressure

Mean eff. pressure

Ambient temperature

Speed

In

SPEED_#ECU [km/h]In

SPEED_#Amb [km/h]Out

p_#Amb [hPa]Out

T_#Amb [°C]

Out

xOut

X1

X2

xOut

X1

X2

Out

In

CA

Out

In

CF

X3

X2

X1

Out

Out

In

Pressure

Temperature

Volume flow IM

Oil

In 2

In 1

Out In 2

In 1

Out

ECU

Pressure

SPEED

RPM

BMEP

Temperature

p_#Ambient

SPEEDcorrected

RPMcorrected

BMEPcorrected

Airpath

ThermostateCoolerCAC

Oil

Zusatzwasserkühler

Thermostat ByPass

Out 2

Out 1

In

KULI Engine Model

Thermal capacities

considered


Typical Application – Cool Down Simulation

• Find evaporator heat load

such that passenger cabin

cool down requirements

are met



Typical Application – Energy Management

Energy Management Simulation for a Hybrid Truck

Parallel Hybrid Vehicle

Driving Cycle (HUDDS) Heavy-Duty Urban Dynamometer Driving Schedule

Fuel Saving Potentials

Battery, Coolant Temperature



• Battery type (Li-Ion, NiMh,…)

• Internal resistance

= f(current, temperature, SOC)

• Open circuit voltage characteristic

= f(temperature, SOC)

• Heat source

= f(current, internal resistance)

• Cell cooling

• Thermal network

Application – Cell Temperature Optimization



Why to use KULI?

Why to use KULI?


© ECS / Disclosure or duplication without consent is prohibited Author:

Why Thermal Energy Management?

Engine power increasing

Inlet area decreasing (design)

New technologies (e.g. hybrid)

More components / auxiliaries

Legislative Standards

Em

issio

ns

Fu

el C

on

su

mp

tio

n

Co

mfo

rt

Du

rab

ility

Co

sts



Why to use Computer Simulation?

• Understand complex component interactions easily

• Effects of single measures can be within measurement accuracy

System Comprehension

• Fast analysis and solutions: “Rapid Prototyping”

• Save time and cost (test bench, prototypes) Concept Studies

• Improve test quality through plausibility checks

• Reduce hardware test loops Support Test Bench

• Quickly find measures for improvement

• Find control strategies for auxiliaries

• Computation only possibility of optimum validation

System Optimization

• Easy handling of engine upgrades

• Component replacements: compare different suppliers

Minor Model Update



Why to use KULI? – Low Hardware Demands

November 2010: KULI on iPad

• Works on any Laptop

Desktop Application

• Steady state results within seconds

Quick Simulation



Why to use KULI? – Realistic Results at Low Effort

Component

& Function

Toolbars

Project

Organization

Analysis

Progress

Info

3D Air

Network

View

2D Fluid

Network

View

Learn to use within 2 days of Training



Why to use KULI? – Tailored to Customer Needs

COM-

Interfa

ce

500

1000

1500

2000

0 200 400 600 800 1000 1200 1400 1600 1800

Time [s]

Transient

Conditions

Engine Model

Driving Cycles

Co-Simulation

CFD Analysis

Optimization

Cooling System

AC System

„From Engineers for Engineers“ Specialized: Automotive Industry

Modular Structure Flexible Software: simple & complex



Why to use KULI? – Multitude of Features

• Output Analysis

• Presentation Material for Management

Postprocessor

Uniform Component Library

• Water/Glycol, Oil, Exhaust, Refrigerant

Extendable Media Library

Unit Converter

• Optimization, Parameter Variation

Optimization Package

• Excel, Matlab, CFD codes,…

Software Interfaces



– Global Presence


Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers

INDIA

SOUTH AMERICA

CHINA

SOUTH KOREA

JAPAN

NORTH AMERICA

EASTERN + WESTERN EUROPE

Enterex America


Why to use KULI? – Best Software Support

• Expertise through product overview

• Expertise though product insight

• Expertise through product practice

Support is given by all members of the KULI Team

• Working to YOUR advantage

Friendly and personal

• usually within 24 hours

Quick response

• Paid services for quick and reliable solutions

Facility to “enhanced” support


[email protected]

Services

Department

E&F Simulation

Sales Software

KULI Team


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)

Why to use KULI?



Who to use KULI?

Who to use KULI?



Who to use KULI?

Engineers related to Thermal Management (not restricted to Automotive Industry)

OEMs Suppliers Researchers Engineering Service

Companies

Design-Engineers CAE-Engineers Test-Engineers


mailto:[email protected]?g2_itemId=16284&g2_imageViewsIndex=1


When to use KULI?

When to use KULI?



Concept Development

Product Specification

Virtual Model

Product Design

1. Prototypes / Mules

E K PT1 P PPAP Disp SOP PT2 B R@R

Simulation / DMU / Validation

2. Prototypes / Pre-Production

Program Management

Functional- / Fatigue- / Vehicle Testing

Key Milestones:

Product Definition Product Creation Industrialization

Product Validation

When to use KULI? - Product Development Process

Funct. Testing Vehicle Testing Simulation Concept Prototyping



How to use KULI?

How to use KULI?


© ECS / Disclosure or duplication without consent is prohibited Author:

How to use KULI? – Data Structure

Simulation Model

Component Data

• Dimensions

• Characteristics

Vehicle Data

• Design

• Engine

Simulation Conditions

• Ambient

• Operating Status

Boundaries & Targets

• Max. Dimensions

• Max. Top Hose Temperatures

SUPPLIER

OEM



How to use KULI? – Workflow

Component Setup

Input data (Geometry,

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, Vary

Parameters

Results

Get Output from

Postprocessor, Excel Sheet,…

Compare with System

Measurement Data

Interpret Results,

Reporting



How to use KULI? – KULI lab Output

Variant Comparison

Userdefined Units

Data Filter Various Graphics

Temperature levels and

Pressure Drops

Heat Turn-over and Efficiency of

Package

Detailed Conditions and

amounts of Cooling Air

Optimized Parameters

depending on Targets



Where to get KULI?

Where to get

KULI?


Disclosure or duplication without consent is prohibited

– Global Contact

Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers

Albert TUERTSCHER

AT engineering LLC

1891 Denver West Ct. #1432

Golden, CO 80401-0924

Phone: +1 734 276 5516

[email protected]

NORTH AMERICA

Leandro GARBIN

VirtualCAE

Servicos de Sistemas Ltda.

Rua Tiradentes 160 - Sala 22

São Caetano do Sul,

São Paulo (CEP 09541-220 )

Phone: +55 11 4229-1349

[email protected]

SOUTH AMERICA

Yoshiyuki MOTOYANAGI

Magna International Japan Inc.

Yaesu Center Building 5F

1-6-6 Yaesu, Chuo-ku,

Tokyo 103-0028, Japan

Phone: +81 3 3548 0310

[email protected]

JAPAN

Terra CAI

Magna International China

801-813, Tower A, Eton Place

69 Dongfang Road, Pudong,

Shanghai PRC 200120

Phone: +86 21 6165 1649

[email protected]

CHINA

Yogesh RAHANE

Tata Autocomp Systems Ltd.

Sr. No. 280 Village Mann,

Tal Mulshi, Hinjewadi Phase –II,

Pune 411 057 Pune

Phone: +91 20 6675 5496

[email protected]

INDIA

Rolf SALOMON

Magna Powertrain

Engineering Center GmbH & CoKG

Steyrer Strasse 32

4300 St. Valentin, Austria

Phone: +43 7435 501 2382

[email protected]

EASTERN + WESTERN EUROPE


Jong-Kwan PARK

TAE SUNG S&E Inc.

Seoulforest Kolon Digital Tower II 10F

Seongsu-dong2-ga, Seongdong-gu,

133-120, Seoul, KOREA

Phone: +82 2 3431 2442

[email protected]

SOUTH KOREA

mailto:[email protected]




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Contact & Summary

• Quasi 1-dimensional Analysis of the Air Flow

• Consideration of Pressure Drops and Overlapping

• Tool for Developing, Analyzing and Testing Engineers

Characteristics

• 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

Input

• Heat Turn-over and Efficiency of Cooling Packages

• Temperature Levels

• Detailed Conditions and Amounts of Cooling Air

Output

• Comfortable Handling

• Quick Analysis and Solutions

• High Flexibility

• Save Time and Cost

Benefits


Albert TUERTSCHER

AT engineering LLC

1891 Denver West Ct. #1432

Golden, CO 80401-0924

Phone: +1 734 276 5516

[email protected]

Leandro GARBIN

VirtualCAE

Servicos de Sistemas Ltda.

Rua Tiradentes 160 - Sala 22

São Caetano do Sul,

São Paulo (CEP 09541-220 )

Phone: +55 11 4229-1349

[email protected]

Yoshiyuki MOTOYANAGI

Magna International Japan Inc.

Yaesu Center Building 5F

1-6-6 Yaesu, Chuo-ku,

Tokyo 103-0028, Japan

Phone: +81 3 3548 0310

[email protected]

Terra CAI

Magna International China

801-813, Tower A, Eton Place

69 Dongfang Road, Pudong,

Shanghai PRC 200120

Phone: +86 21 6165 1649

[email protected]

Yogesh RAHANE

Tata Autocomp Systems Ltd.

Sr. No. 280 Village Mann,

Tal Mulshi, Hinjewadi Phase –II,

Pune 411 057 Pune

Phone: +91 20 6675 5496

[email protected]

Jong-Kwan PARK

TAE SUNG S&E Inc.

Seoulforest Kolon Digital Tower II 10F

Seongsu-dong2-ga, Seongdong-gu,

133-120, Seoul, KOREA

Phone: +82 2 3431 2442

[email protected]

Roland MAYR

Magna Powertrain

Engineering Center GmbH & Co KG

Steyrer Strasse 32


Phone: +43 7435 501 2383

[email protected]

Rolf SALOMON

Magna Powertrain

Engineering Center GmbH & CoKG

Steyrer Strasse 32


Phone: +43 7435 501 2382

[email protected]







Documents

KULI Overview 20110720 BRG