Fluid Power System Simulation Hand in Hand

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Fluid Power System Simulation Hand in Hand

  1. 1. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 1FLUIDON at HTC 2013© 2013 FLUIDONCOMPETENCE IN FLUID POWER SYSTEMS SIMULATIONKOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEMEand AcuSolveFluid Power SystemSimulation Hand in HandDr. Heiko BaumFLUIDON GmbH2013 European Altair Technology Conference
  2. 2. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 2FLUIDON at HTC 2013© 2013 FLUIDONHyperGraphResult AnalysisMotionSolveMulti-Body co-simulationof mechatronicsystemsflexibility of componentsRADIOSSFinite Elementdata for stress analysisCAE supported design levelHyperStudyParameter OptimizationMeasurementsValidationvalidation levelHow The Presentation Fits into the CAE Development Process withUse of CFD for the pressure loss determination of complex flowchannel geometries and the integration of these pressure losses inthe 1D simulationoff-line coupling(data table export)AcuSolveCFD1D System Simulation
  3. 3. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 3FLUIDON at HTC 2013© 2013 FLUIDONContentMotivation1Application Example2Classic Modeling Method in 1D Simulation Programs such as3Use of Computational Fluid Dynamics (AcuSolve)4Summary5
  4. 4. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 4FLUIDON at HTC 2013© 2013 FLUIDONMotivation At present the energy optimization of production processes gains increasingly insignificance. The optimization of the machines but also the optimization of their operatingcycles provide a contribution to the desired energy savings. FLUIDON is involved in numerous engineering projects and research projects, that focuson the simulation of energy optimized processes. As a consequence for FLUIDON, the demanded quality and the level of detail for therequired 1D system simulation in rise continuously. If only the essential resistances of the system were modeled in the past, then the smallerresistances are taken into account nowadays, too. In this context the classic modeling method of the 1D system simulation is pushed to itsborders. The presentation will show how the combination of 1D system simulation with the CFDsimulation is capable of improving the simulation accuracy.
  5. 5. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 5FLUIDON at HTC 2013© 2013 FLUIDONQSLSumme1123QSL1QSL2WK5Dekompression1aGeschwindigkeitsregler1aNS250 NS130RNS130LQNS130L QNS130RQNS250VZRVZLRZRRZLHochtankHydPneuvPresseS3bVSBM2M1RM12RFSolldruckZPRH1Speicherblock1WRCE32SWRC160FG_WRC160SWRC100FG_WRC100VS3aNS100_WRC100 NS100_WRC160Vol1GaskolbenHydPneuSL2x-fachVS3S3aSG_FOutVA2SL1x-fachQ_TankklappeTankklappeBlende1QSVADiffusor2Diffusor1L1x|fachL3x|fachL2x|fachL4x|fachL9x|fachL10x|fachVA1S5PT1NG100S4PT1NG160xWRCE100xWRCE160S3S2H2SpQHuebeZaehler1XPresseS1VS8VS7VS6VS4 VS5Q_WRCE100Q_WRCE160WRCE100KWRCE160KVS2RSPVS0Q_SPQ_DBV_SPDBV_SPnPumpeSAntriebSSchmiedePumpenVS1Q_WRCE32VR5VR4VR2VR1RRPVR0Q_RPQ_DBV_RPDBV_RPnPumpeRAntriebRRueckzugPumpenZPRSSchmiedesteuerung1SMSMEER Korrektur_OTKorrektur_UTRueckzugSchmiedenxUTUTKxOTOTKSchmiedezylinder5Flaechen1Motivation: Reduction of Energy Losses in Heavy Equipment Valve BlocksPush-down type forging press with two columnsFluidtronic - A DesignEnvironment for FluidTechnical MechatronicalSystemsSource:Image Brochure ofRUPPEL HydraulikSüdstraße 231848 Bad Muender OT BakedeGermanyExample of a valve block drawing. Thepressure losses due to these flowchannels are currently neglected inmost 1D system simulations.Component oriented valveblock assembly in thesimulation modelSimulationModel
  6. 6. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 6FLUIDON at HTC 2013© 2013 FLUIDONMotivation: Reduction of Energy Losses in Production Duty-CyclesP_DV_6P_DV_5P_DV_4P_DV_3P_DV_2P_PumpeDemultiplexer3Node3Sub_Druckversorgung2Demux2Sub_Setzzylinder1Ventil24KEilgangKDU1KSolldruckKSolldruckNiederhalterK EilgangRueckKSolldruckVBKDU2KTZwPZwA2A A3A A1AA1ZA3ZA2ZNode2x_Niederhalterx_NietbolzenQ_NB2v_Niederhalterv_NietbolzenQ_NB1Q_NH1A1A3A2TPVentilblockKSolldruckKLeerlauf1KRichtungKEilgangSignal1PTVentilblockSignal2Signal3QTankKLeerlauf2QPumpeSub_Ventilblock2P_VentilblockDemultiplexer1P1P2P3P4P5P6P7P_NietbolzenP_NiederhalterSumme1+Summe2+Signal19P_Sum_DVIntegrierer1Integrierer2Integrierer3Integrierer4E_PumpeE_Sum_DVE_NiederhalterE_NietbolzenSumme3+Summe4+ Summe5+Signal25Signal26Integrierer5P_Sum_Ventilblock E_Sum_VentilblockSchlauchKP1x|fachP_SKP1SchlauchKP2x|fachP_SKP2SchlauchKP5x|fachP_SKP5SchlauchKP4x|fachP_SKP4SchlauchKP3x|fachP_SKP3Summe6+P_Sum_SKP3-5_1Summe7+Integrierer6P_Sum_SKP1-2 E_Sum_SKP1-2Integrierer7E_Sum_SKP3-5Summe8+Summe9+E_SetzzylinderE_VerlustSumme10+E_VerifR2aP_R2aSumme11+R3aP_R3aR1aP_R1aP_Sum_SKP3-5_2Summe12+P_Sum_SKP3-5R2a1P_R2a1TaP_TaSumme13+Signal50RIVSET® Gen2Self-pierce riveting in its new generation© Bollhoff Verbindungstechnik GmbHESEMO - development of self-monitoringenergy optimized assembly roboticsProject Funding:Simulation ModelComponent oriented valveblock assembly in thesimulation model
  7. 7. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 7FLUIDON at HTC 2013© 2013 FLUIDONMotivation: Improved Energy-Efficientcy of Vehicle Hydraulic SystemsBaum, H. ; Ulrich, H.:Digitale Simulation bei der Entwicklung fluidtechnischer Fahrzeugsysteme.Haus der Technik, Essen, 2003Project Partner:OptiELF - Optimization of energy efficiency at the power transmission ofvehicle hydraulic systems.Problem• Increasing fuel consumption due to energy losses at the multiple resistancesSectional view of a hydraulic steering lineStandard steel pipeFlexible fabric hoseTunerlineCompressionRestrictor
  8. 8. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 8FLUIDON at HTC 2013© 2013 FLUIDONContentMotivation1Application Example2Classic Modeling Method in 1D Simulation Programs such as3Use of Computational Fluid Dynamics (AcuSolve)4Summary5
  9. 9. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 9FLUIDON at HTC 2013© 2013 FLUIDONApplication Example: Power Steering Hose LineHose Design OverviewPumpSteering387 1224015596 3843 12019030angenommen115 620551644St-TunerPipe Section with Multiple Bends
  10. 10. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 10FLUIDON at HTC 2013© 2013 FLUIDONApplication Example: Power Steering Hose LinePressure Loss Measurement of the Section with Multiple BendsFlow DirectionPressure Sensor P1 Pressure Sensor P2Temperature SensorPressure Loss of the Pipe Segment with Multiple Bends
  11. 11. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 11FLUIDON at HTC 2013© 2013 FLUIDONContentMotivation1Application Example2Classic Modeling Method in 1D Simulation Programs such as3Use of Computational Fluid Dynamics (AcuSolve)4Summary5
  12. 12. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 12FLUIDON at HTC 2013© 2013 FLUIDONPipe section of the OptiELF powersteering line with multiple pipe bendsPressure-Loss Calculation of Pipes with Multiple BendsClassical Method in 1D System SimulationQ, pInQ, pOutSimplified pipe section with multiplepipe-bends to explain the "classicalmethod"Other Examples of pipes with multiple bends
  13. 13. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 13FLUIDON at HTC 2013© 2013 FLUIDONPressure-Loss Calculation of Pipes with Multiple BendsClassical Method in 1D System Simulation 2R v2dLpDpR,1DpR,2DpR,3DpR,4Pipe Segments 22vpFPipe BElbowsDpF,1DpF,2DpF,3ElbowsPipeSegmentsPipeVOutIn ppppp Q, pInQ, pOut
  14. 14. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 14FLUIDON at HTC 2013© 2013 FLUIDONPressure-Loss Calculation of Pipes with Multiple BendsClassical Method in 1D System SimulationQ = 18 L/minn = 104 mm2/s = 858 kg/m3Re = 476D = 7,7 mm L = 369 mmBend 1 u. 2: R = 12 mm, d = 50°Bend 3: R = 12 mm, d = 20°Calculation methodep in barOriginal[1] [2] [3] [4] [5] [6]1,34 1,66 1,20 1,21 1,28 1,33[1] to [6] represent different literature sources to calculate the pressure loss coefficient .
  15. 15. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 15FLUIDON at HTC 2013© 2013 FLUIDONPressure-Loss Calculation of Pipes with Multiple BendsClassical Method in 1D System SimulationQ, pIn Q, pOutWeaknesses of theclassical method are: Loss coefficients  for form pieces result fromdifferent sources with and without attention ofthe Reynolds number. Loss coefficients  are not available for all formpiece geometries. Order and geometric orientation of theindividual elements are not taken into account. The inlet flow and outlet flow in the individualtest for the determination of the loss coefficientis different from the real application.ElbowsPipeSegmentsPipeVOutIn ppppp More information can be found in:„Einsatz von CFD zur Bestimmung von Druckverlustenin laminar durchströmt gebogenen Rohrelementenfür die 1D-Simulation„Key-Note Speach at FLUIDON Conference 2012Prof. Axel FaßbenderLaboratory for Vehicle HydraulicInstitute for Vehicle Technology – FH Köln
  16. 16. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 16FLUIDON at HTC 2013© 2013 FLUIDONContentMotivation1Application Example2Classic Modeling Method in 1D Simulation Programs such as3Use of Computational Fluid Dynamics (AcuSolve)4Summary5
  17. 17. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 17FLUIDON at HTC 2013© 2013 FLUIDONCFD Model Set-up in AcuSolveHyperStudyParameter Optimizationoff-line coupling(data table export)1D System SimulationMain geometry data:d = 8 mmL = 480 mmBend 1: R = 20 mm, d = 61°Bend 2: R = 20 mm, d = 77°Bend 3: R = 20 mm, d = 53°Bend 4: R = 20 mm, d = 59°Bend 5: R = 20 mm, d = 66°Bend 6: R = 20 mm, d = 90°Step 1:Model Set-up of thebending pipe segmentin AcuSolveAcuSolveCFD
  18. 18. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 18FLUIDON at HTC 2013© 2013 FLUIDONoff-line coupling(data table export)AcuSolveCFDAutomated Simulation with HyperStudy1D System SimulationStep 2:Automated simulation ofthe pressure loss atcharacteristic operationpointsTemperature form-10 °C to 80 °Cin 10 °C stepsFlow form1 l/min to 12 l/minin 1 l/min stepsAltogether 120 designpointsHyperStudyParameter Optimization
  19. 19. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 19FLUIDON at HTC 2013© 2013 FLUIDONPressure Loss Table inHyperStudyParameter Optimizationoff-line coupling(data table export)AcuSolveCFD1D System SimulationStep 3:Post processing of theCFD results and importas pressure loss lookuptable into .Pressure losses are flowand temperaturedependent.
  20. 20. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 20FLUIDON at HTC 2013© 2013 FLUIDONRepresentation of the Pressure Loss Ratios in the 1D SimulationIn the final pipe model the fluidinertia and the pressure lossesdue to a straight pipe arerepresented through .Pressure losses due to pipebends and secondary floweffects are covered throughCFD simulations.BendPressure LossSecondary PipePressure LossBendp222QAKBend Secondaryp222QAKSecundary OutIn pp OverallPressure Loss= + +Combined pressure Losses are derived from CFD results.pIn pOutBend 1Bend 2Bend 3Bend 4Bend 5Bend 6Primary PipePressure LossQrLstraight4.8Primaryp
  21. 21. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 21FLUIDON at HTC 2013© 2013 FLUIDONP2P1Simulation model of the entire power steering hose linePressure Loss Simulation of a Steering Hose LineP1P2387 1224015596 3843 12019030angenommen115 62051623555763Line segment overviewBendedPipeSection
  22. 22. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 22FLUIDON at HTC 2013© 2013 FLUIDONPressure Loss Simulation at T = 50 °CFlow [l/min]PressureLoss[bar]Measurement 50 °CImproved SimulationInitial Simulation
  23. 23. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 23FLUIDON at HTC 2013© 2013 FLUIDONContentMotivation1Application Example2Classic Modeling Method in 1D Simulation Programs such as3Use of Computational Fluid Dynamics (AcuSolve)4Summary5
  24. 24. This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbHSlide 24FLUIDON at HTC 2013© 2013 FLUIDONSummaryCFD simulations are an appropriate remedy to model minorpressure losses in a 1D system simulation.With and AcuSolve working hand in handa HyperWorks user has access to all necessary toolsfor such a workflow.Thank you for your attention

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