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Overview – Features and Applications
About us…
25.01.2011 2Gregor Breuer
Magna International
SEATING EXTERIORS
CLOSURES
VISION SYSTEMS
ROOF SYSTEMS
BODY & CHASSISPOWERTRAIN
ELECTRONICS
VEHICLE ENG
CONTRACT MFG
FUEL SYSTEMS
Our Company
Author: W. Dantendorfer 3
Engineering Center in St. Valentin
• Complete Vehicle Engineering
• Technology & Software Development
• Vehicle Testing
The KULI Team
4
Software Developers and Software Users exist under one umbrella!
Software Development
Thomas Naderhirn
Sales
Rolf Salomon
Services
Christian Rathberger
07.08.2017R. Salomon
Energy & Fluid Simulation
Christian Rathberger
Software Methods
Christoph Stroh
What is KULI?
5
Powertrain Cooling Air Conditioning
• Temperatures
• Pressures
• Mass flow
• Heat flow
• Other Energy flows
Consideration of all Thermodynamic Key Values
Thermal Management Software
6
Windows Desktop Software for the 1D-Simulation of the Vehicle Thermal Energy Management
Thermal Management Software
Gregor Breuer 725.01.2011
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
8
Typical Applications
9
Typical Applications – Top Tank Temperature
10
• 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 Applications – Concept Studies
• Compare direct and indirect charge air cooling
11
conventional CAC
water-cooled CAC
low temperature
radiator
297 mm
259 mm
Typical Applications – Minimize Package Size
• Reduce heat exchanger sizes according to performance limits
12
400 mm
300 mm
Typical Application – Transient Simulation
• Warm up and cool down investigations
13
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
14
Applications – A/C system use for battery conditioning
15
Complete vehicle thermal management
A/C system use for battery conditioning
Heat pump
Air Condition (electric driven)
Latent Heat Storage System
…
Chiller
Battery
Radiator
Typical Application – Energy Management
16
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
18
Why KULI?
19
Why Thermal Energy Management?
20
Engine power increasing
Inlet area decreasing (design)
New technologies (e.g. hybrid)
More components / auxiliaries
Legislative Standards
Em
issio
ns
Fuel C
on
sum
ption
Com
fort
Dura
bility
Costs
Why use Computer Simulation?
System Comprehension
• Understand complex component interactions easily
• Effects of single measures can be within measurement accuracy
Concept Studies
• Fast analysis and solutions: “Rapid Prototyping”
• Save time and cost (test bench, prototypes)
Support Test Bench
• Improve test quality through plausibility checks
• Reduce hardware test loops
System Optimization
• Quickly find measures for improvement
• Find control strategies for auxiliaries
• Computation only possibility of optimum validation
Minor Model Update
• Easy handling of engine upgrades
• Component replacements: compare different suppliers
21R. Salomon07.08.2017
Why use KULI? – Low Hardware Demands
22
• Works on anylaptop
Desktop Application
• Steady state results within seconds
Quick Simulation
R. Salomon07.08.2017
Why to use KULI? – Realistic Results at Low Effort
23
Component &
Function
Toolbars
Project
Organization
Analysis
Progress Info
3D Air
Network View
2D Fluid
Network View
Learn to use within 2 days of Training
From Engineers for Engineers
Specialized: Automotive Industry
Modular StructureFlexible Software: simple & complex
Why use KULI? – Tailored to Customer Needs
R. Salomon07.08.2017
– Global Footprint
32
Passenger Cars – Trucks – Construction/Farm Machines – Trains… | OEMs – Suppliers – Researchers
INDIA
SOUTH AMERICA
CHINA
SOUTH KOREA
JAPAN
NORTH AMERICAEASTERN + WESTERN EUROPE
Enterex America
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
33
Why use KULI? – Best Software Support
• Expertise through product overview
• Expertise through product insight
• Expertise through product practice
Support is given by all members of
the KULI Team
• Working to YOUR advantageFriendly and
personal
• usually within 24 hoursQuick response
• Paid services for quick and reliable solutions
Facility to “enhanced”
support
34
Software
Development
Sales Services
Software
Methods
KULI Team
R. Salomon07.08.2017
Who should use KULI?
35
Who should use KULI?
36
Engineers concerned with Thermal Management
(not restricted to Automotive Industry)
OEMs Suppliers ResearchersEngineering Service
Companies
Design-Engineers CAE-Engineers Test-Engineers
R. Salomon07.08.2017
How to get started?
37
Concept Development
Product Specification
Virtual Model
Product Design
1. Prototypes / Mules
E K PT1 P PPAP Disp SOPPT2 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
38R. Salomon07.08.2017
Concept Simulation Prototyping Funct. Testing Vehicle Testing
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
39
SUPPLIER
OEM
R. Salomon07.08.2017
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
40R. Salomon07.08.2017
How to use KULI – KULI lab Output
41
Variant Comparison
User-defined 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
R. Salomon07.08.2017
Where to buy KULI?
25.01.2011 42Gregor Breuer
– Global Contact
43
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
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
SOUTH AMERICA
Youngwook KIM
Magna International Japan Inc.
Yaesu Center Building 5F
1-6-6 Yaesu, Chuo-ku,
Tokyo 103-0028, Japan
Phone: +81 3 3548 0310
JAPAN
Terra CAI
Magna International China
801-813, Tower A, Eton Place
69 Dongfang Road, Pudong,
Shanghai PRC 200120
Phone: +86 21 6165 1649
CHINA
Rolf SALOMON
Magna Powertrain
Engineering Center GmbH & CoKG
Steyrer Strasse 32
4300 St. Valentin, Austria
Phone: +43 7435 501 2382
EASTERN + WESTERN EUROPE
Jin SEOK
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
SOUTH KOREA
Rajeev GOPALAKRISHNAN
MAXrad SOFTware (India) Pvt Ltd
'SHUBAM'#35,6th Cross,
Nanjappa Garden, Babusapalaya
Bangalore 560043
Phone: +91 8049144149
INDIA
Date: D R A F T / Author: Name © Advanced Engineering / Disclosure or duplication without consent is prohibited 44
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