Development of Tools to Automatethe Analysis of Turbo-MachineryTom Lincoln / Jaideep BangalCooper Standard / Altair Engine...
Executive Summary• Cooper Standard (CS) Corporate Overview• History of CFD at Cooper Standard• Cooper Standard adoption of...
About Cooper Standard                                        Headquarters:                 Novi, MI                       ...
History                                                                  2012                                             ...
Strategic Footprint                            Key                             Headquarters                             Sa...
Global Customers          RENAULT             HYUNDAI
Breadth of Product & Segments
Thermal Management – Key Capabilities                                        Heating and cooling                          ...
Technology                                                  Global Six Sigma Award Best•   Automotive News PACE Award     ...
Cooper Standard’s History With Pumps• Cooper Standard identified a market for electrically driven coolant  pumps.• Develop...
Early CFD Analyses – August 2005• Combination Tet and Hex  cells• Uniform mesh size• Significant time to set-up  manually
CFD Analyses – June 2010•    ~5M cells ranged from 0.2 mm to 2 mm•    Manual set-up required a full day and 6-     10 hour...
Early CFD - Challenges• Results were good but   •   Model set-up would take 8+ hours   •   Each flow point would take 4 – ...
AcuSolve Process Automation    Import CAD /       •   Process intelligence            1      HM mesh                      ...
Cooper Standard Pump Analysis•   Goal: Predict pump performance,    Flow Curve•   Reduce Setup and Solution time•   Enable...
AcuSolve’s Rotating Machinery Process                • First run                • Very fast setup and solution            ...
AcuSolve’s Rotating Machinery Process• Refined Mesh• Analysis converged in 9th iteration• AcuSolve results matched test re...
AcuSolve ResultsContours of Static Pressure   Contours of Velocity
AcuSolve Results                        Velocity Profile                                           Pressure Distribution –...
AcuSolve Results                            Contours of Pressure on                            Planes Cut Through a PumpCo...
AcuSolve Results Pressure Distribution   Velocity Profile
AcuSolve Results Pressure Distribution   Velocity Profile
AcuSolve’s Rotating Machinery Process• 1-hour setup• Automeshing ensures optimized mesh near critical flow/impeller  featu...
Additional Collaboration - Thermal Analysis –Pump• Cooper Standard engaged Altair in a consulting project to set-up the  i...
Additional Collaboration - Thermal Analysis -Pump  IR Camera Image                            AcuSolve Thermal Analysis re...
AcuSolve Results
Thank You
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Development of Tools to Streamline the Analysis of Turbo-Machinery - Cooper Standard

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Cooper Standard partnered with Altair to create a tool in AcuSolve to speed the set-up of centrifugal pump CFD analyses. This tool steps the Engineer through the selection of the components to the pump and then automatically identifies and meshes the surfaces in the model.

This presentation will detail how the AcuSolve move has been a huge success with Cooper Standard.

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Development of Tools to Streamline the Analysis of Turbo-Machinery - Cooper Standard

  1. 1. Development of Tools to Automatethe Analysis of Turbo-MachineryTom Lincoln / Jaideep BangalCooper Standard / Altair Engineering, Inc.
  2. 2. Executive Summary• Cooper Standard (CS) Corporate Overview• History of CFD at Cooper Standard• Cooper Standard adoption of AcuSolve for enhanced CFD efficiencies and accuracy• Additional AcuSolve Applications at Cooper Standard
  3. 3. About Cooper Standard Headquarters: Novi, MI Established: 1960 Employees: 21,500+ Our Mission Locations: 70+ in 19 CountriesProvide outstanding service, support 2010 Top 100 Global Suppliers: Rank 62 and innovative solutions to our 2010 Top 100 North American Suppliers: Rank 35customers benefiting all stakeholders of Cooper Standard. 2011 Sales: $2.85 B
  4. 4. History 2012 2011 2010 2007 2007 2006 2005 20041960 1999 2000
  5. 5. Strategic Footprint Key Headquarters Sales / Administration Technical Center Manufacturing Manufacturing / Technical Center North America Europe Asia Pacific South AmericaJoint Ventures CountriesCooper-Standard Saiyang Wuhu 94% /6% Australia Czech Republic Japan RomaniaCooper-Standard NISCO 40% / 60% Belgium France Korea Thailand Brazil Germany Mexico United KingdomCooper Hubei Jingda 37% / 63% Canada India Netherlands United StatesMetzeler India 74% / 26% China Italy PolandCooper Hasco China 47.5% / 47.5% / 5%Guyoung Tech Korea 20% / 80%Cooper Standard France 51% / 49% 2012 - Located in 19 CountriesNishikawa Tachaplalert Cooper Limited 20% / 80% 2004 - Located in 14 Countries
  6. 6. Global Customers RENAULT HYUNDAI
  7. 7. Breadth of Product & Segments
  8. 8. Thermal Management – Key Capabilities Heating and cooling management systems for hybrids, electric vehicles and internal combustion engines Electromechanical Devices Thermal Devices Thermal Integration
  9. 9. Technology Global Six Sigma Award Best• Automotive News PACE Award Achievement of Design for Six Sigma Honorable Mention • Coolant Water Valve • Electric Water Valve Assembly • Thermoplastic Rear Door Glass Over 500 Patents Globally • Daylight Opening Modules Seal Assembly • Engineered Stretched Plastics • Metal to Plastic Fluid Connection with • Occupant Detection Systems Overmolded Anti-Rotation Retainer • Low Fuel Permeation Nylon Tubing • Day Light Opening (DLO) System • Quick Connect Fluid Couplings• Society of Plastics Engineers • Core process methods Most Innovative Use of Plastic: Finalist • Electric Water Valve Assembly • Transmission Thermal Valve Assy • Electric Brushless Pump cooperstandard
  10. 10. Cooper Standard’s History With Pumps• Cooper Standard identified a market for electrically driven coolant pumps.• Development began in 2005, CFD was used from the start.• Cooper Standard offers pumps to replace the vehicle main water pump and auxiliary supplemental flow.• Wattages range from <20 W to 1 kW.
  11. 11. Early CFD Analyses – August 2005• Combination Tet and Hex cells• Uniform mesh size• Significant time to set-up manually
  12. 12. CFD Analyses – June 2010• ~5M cells ranged from 0.2 mm to 2 mm• Manual set-up required a full day and 6- 10 hours to converge each flow point Comparison Between Measured Data and CFD Prediction 1.20 1.00 Pressure Gain 0.80 0.60 Measured 0.40 Pressure Gain Predicted 0.20 Pressure Gain 0.00 5000 7000 9000 11000 13000 Flow Rate
  13. 13. Early CFD - Challenges• Results were good but • Model set-up would take 8+ hours • Each flow point would take 4 – 10 hours to converge • 6 flow points for one pump = 40+ hours • Meshing was manual and required expertise to generate a good mesh
  14. 14. AcuSolve Process Automation Import CAD / • Process intelligence 1 HM mesh • Fast setup: 4 steps Define• Solids • Auto meshing• Stationary Fluid• Rotational Volume • Angular velocity • Auto solving strategy • Rotation axis 2 • Auto Time steps calculation Boundary • Setup multiple flow points Conditions and run it batch mode Inlet / Outlet 10 3 minutes Automeshing Setup time Auto time step 4 calculations SOLVE
  15. 15. Cooper Standard Pump Analysis• Goal: Predict pump performance, Flow Curve• Reduce Setup and Solution time• Enable CSA Engineering team to analyze designs early Pump – Meshed Model Meshed Impeller
  16. 16. AcuSolve’s Rotating Machinery Process • First run • Very fast setup and solution • Helped understand process and setup before adding more details • Setup Time: 1 hour from receipt of CAD impeller • Solution Time: 12 flow points – 10 hours 1.200 Test… 1.000 First RunPressure Gain 0.800 0.600 0.400 Boundary Layer = 1.4 mm Mesh Size 7 mm 0.200 0.000 0.000 0.200 0.400 0.600 0.800 1.000 1.200 Flow 16
  17. 17. AcuSolve’s Rotating Machinery Process• Refined Mesh• Analysis converged in 9th iteration• AcuSolve results matched test results• Setup Time: Unchanged• Solution Time: 12 flow points-24 hours 1.200 1.000 Pressure Gain 0.800 0.600 Test Pressure Gain Final Converged Run Boundary Layer = 0.1 mm 0.400 Mesh Size 2 mm (on Impeller) 0.200 0.000 0.000 0.200 0.400 0.600 0.800 1.000 1.200 Flow 17
  18. 18. AcuSolve ResultsContours of Static Pressure Contours of Velocity
  19. 19. AcuSolve Results Velocity Profile Pressure Distribution – fluid volumePressure Distribution
  20. 20. AcuSolve Results Contours of Pressure on Planes Cut Through a PumpContours of Velocity onPlanes Cut Through a Pump
  21. 21. AcuSolve Results Pressure Distribution Velocity Profile
  22. 22. AcuSolve Results Pressure Distribution Velocity Profile
  23. 23. AcuSolve’s Rotating Machinery Process• 1-hour setup• Automeshing ensures optimized mesh near critical flow/impeller features• Accurate results• Standardized inputs built into the tool• 5 flow points can be run in 10 hours on a 4 core laptop• The tool is being rolled out to the Product Engineers to handle increased demand 23
  24. 24. Additional Collaboration - Thermal Analysis –Pump• Cooper Standard engaged Altair in a consulting project to set-up the initial AcuSolve models• Altair transferred knowledge to Cooper Standard for future product development 3D CAD Model Simplified FEA 3D Model
  25. 25. Additional Collaboration - Thermal Analysis -Pump IR Camera Image AcuSolve Thermal Analysis results AcuSolve predicted high temperature component locations and were later confirmed by IR camera
  26. 26. AcuSolve Results
  27. 27. Thank You
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