The document summarizes Cooper Standard's adoption and use of AcuSolve software for computational fluid dynamics (CFD) analysis of turbo-machinery like pumps. It describes how AcuSolve automated the setup process, reduced analysis time from days to hours, and provided accurate results that matched test data. Cooper Standard engineers can now independently conduct early-stage design evaluations to improve product development efficiency.
Development of Tools to Streamline the Analysis of Turbo-Machinery - Cooper Standard
1. Development of Tools to Automate
the Analysis of Turbo-Machinery
Tom Lincoln / Jaideep Bangal
Cooper Standard / Altair Engineering, Inc.
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. About Cooper Standard
Headquarters: Novi, MI
Established: 1960
Employees: 21,500+
Our Mission Locations: 70+ in 19 Countries
Provide outstanding service, support 2010 Top 100
Global Suppliers: Rank 62
and innovative solutions to our
2010 Top 100
North American Suppliers: Rank 35
customers benefiting all stakeholders
of Cooper Standard.
2011 Sales: $2.85 B
5. Strategic Footprint
Key
Headquarters
Sales / Administration
Technical Center
Manufacturing
Manufacturing / Technical Center
North America
Europe Asia Pacific
South America
Joint Ventures Countries
Cooper-Standard Saiyang Wuhu 94% /6% Australia Czech Republic Japan Romania
Cooper-Standard NISCO 40% / 60% Belgium France Korea Thailand
Brazil Germany Mexico United Kingdom
Cooper Hubei Jingda 37% / 63% Canada India Netherlands United States
Metzeler India 74% / 26% China Italy Poland
Cooper Hasco China 47.5% / 47.5% / 5%
Guyoung Tech Korea 20% / 80%
Cooper Standard France 51% / 49% 2012 - Located in 19 Countries
Nishikawa Tachaplalert Cooper Limited 20% / 80% 2004 - Located in 14 Countries
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. 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. 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. Early CFD Analyses – August 2005
• Combination Tet and Hex
cells
• Uniform mesh size
• Significant time to set-up
manually
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. 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. 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. 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. 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 Run
Pressure 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. 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
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. 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. 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