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Advanced Engine Thermal Management


         Sudhi Uppuluri
      Principal Investigator,
            CSEG, LLC
Computational Sciences Experts Group
We don’t sell software. We bring our modeling expertise
           and make your CAE ...
CSEG Services



1. Calibrate:                  2. Integrate:
                               We integrate various
We build...
The Speaker


Sudhi Uppuluri, Principal Investigator

Sudhi has over 14 years of experience in the
simulation industry. He...
Topics


a) Engine thermal management challenges

b) Traditional cooling system – Key
   considerations

c) HEV, EV specif...
Why is Engine Thermal Management
            important?

• Cold Engine = Bad
  Fuel Economy                               ...
Challenges for Engine Thermal
           Management
                     Tighter packaging!

                    Right s...
Challenges – Simulating Engine
         Thermal systems

    Requires           Responsibility fragmented
 expertise acros...
key considerations in modeling a
Lets look at
  transient Engine Thermal model
Steady State Flow Model – Starting
               point


                              Geometry and
  Fairly Straightforw...
Key issue #1: Model necessary
thermal interactions between sub-
             systems
         Requires integration of all ...
Key Issue #2: Get Heat additions
               correct

Combustion heat = Energy from Fuel &Air mixture – Exhaust Energy ...
Key issue #2a: Get heat losses
            correct




                                              Heat Loss to
        ...
Where the heat goes during warm-
               up




SAE 2000-01-0299
Warm-Up of a D.I. Diesel Engine: Experiment and Mo...
Key issue #3: Modeling Thermal
           inertia right


Thermal inertia
option 1 –                                      ...
Key issue #3: Modeling Thermal
              inertia right


• Thermal
  inertia option
  2 – Capturing every
  heat trans...
Key issue #3: Modeling Thermal
              inertia right


• Thermal
  inertia option
  3 – Capturing every
  heat trans...
Where the heat goes during warm-
               up




  Reference: SAE paper 931153, Shayler et al.
Key Factors in warm-up

                         Heat distribution and loss




 Thermal Inertia
Key Issue #5: Include a dynamic
       coolant Thermostat




                    • Include dynamic model
                ...
HEV, EV specific challenges




                          •   Li-ion battery cooling is
                          •   more...
HEV Additions – front-end cooling
                       pack




                                                        ...
Improving fuel economy


                                                   5

Accurate
                                  ...
Thermo-Fluid System Analysis
                   Roadmap
                                                                  ...
Topics covered


a) Engine thermal management challenges

b) Traditional cooling system – Key
   considerations

c) HEV, E...
FURTHER     Sudhi Uppuluri has over 14 years of
             experience in the simulation industry. He


DISCUSSION
      ...
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Advanced Engine Thermal Management – Key Considerations Slide 1 Advanced Engine Thermal Management – Key Considerations Slide 2 Advanced Engine Thermal Management – Key Considerations Slide 3 Advanced Engine Thermal Management – Key Considerations Slide 4 Advanced Engine Thermal Management – Key Considerations Slide 5 Advanced Engine Thermal Management – Key Considerations Slide 6 Advanced Engine Thermal Management – Key Considerations Slide 7 Advanced Engine Thermal Management – Key Considerations Slide 8 Advanced Engine Thermal Management – Key Considerations Slide 9 Advanced Engine Thermal Management – Key Considerations Slide 10 Advanced Engine Thermal Management – Key Considerations Slide 11 Advanced Engine Thermal Management – Key Considerations Slide 12 Advanced Engine Thermal Management – Key Considerations Slide 13 Advanced Engine Thermal Management – Key Considerations Slide 14 Advanced Engine Thermal Management – Key Considerations Slide 15 Advanced Engine Thermal Management – Key Considerations Slide 16 Advanced Engine Thermal Management – Key Considerations Slide 17 Advanced Engine Thermal Management – Key Considerations Slide 18 Advanced Engine Thermal Management – Key Considerations Slide 19 Advanced Engine Thermal Management – Key Considerations Slide 20 Advanced Engine Thermal Management – Key Considerations Slide 21 Advanced Engine Thermal Management – Key Considerations Slide 22 Advanced Engine Thermal Management – Key Considerations Slide 23 Advanced Engine Thermal Management – Key Considerations Slide 24 Advanced Engine Thermal Management – Key Considerations Slide 25 Advanced Engine Thermal Management – Key Considerations Slide 26
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Advanced Engine Thermal Management – Key Considerations

  1. 1. Advanced Engine Thermal Management Sudhi Uppuluri Principal Investigator, CSEG, LLC
  2. 2. Computational Sciences Experts Group We don’t sell software. We bring our modeling expertise and make your CAE software do advanced stuff. The stuff you bought the software to do to begin with.
  3. 3. CSEG Services 1. Calibrate: 2. Integrate: We integrate various We build accurate simulation tools for a simulation models and specific problem to calibrate them with test reduce error and data improve accuracy 4. Optimize: 3. Interface: We build optimization We build simplified tools or integrate with interfaces for complex existing ones to models to enable faster optimize key variables and wider use of in the system simulation models
  4. 4. The Speaker Sudhi Uppuluri, Principal Investigator Sudhi has over 14 years of experience in the simulation industry. He worked as a consulting engineer and sales manager at Flowmaster USA for 8 years where he worked on various advanced fluid system modeling in Automotive and Aerospace fields. He has various technical publications on related subjects in SAE and AIAA journals. He holds a Masters in Aerospace Engineering from the University of Illinois at Urbana-Champaign and a Certificate in Strategy and Innovation from the MIT Sloan School of business. Email: Sudhi.Uppuluri@cseg.us Full Profile on Linked in: Sudhindra Uppuluri
  5. 5. Topics a) Engine thermal management challenges b) Traditional cooling system – Key considerations c) HEV, EV specific challenges d) Bigger picture e) Roadmap
  6. 6. Why is Engine Thermal Management important? • Cold Engine = Bad Fuel Economy Frictional losses reduce – Incomplete as engine combustion warms up – Increased thermal losses through the combustion chamber walls – Increased friction losses with the increase of the lubricant oil viscosity. Referemce: 2000-01-0299 Warm-Up of a D.I. Diesel Engine: Experiment and Modeling L. Jarrier and J. C. Champoussin Ecole Centrale de LYON R. Yu Renault D.R. D. Gentile University of Versailles
  7. 7. Challenges for Engine Thermal Management  Tighter packaging!  Right size component.  Fuel economy sensitive to temperatures! Engines are getting smaller More components need cooling Not enough heat Electric components for satisfactory (Battery, inverter etc.) heater core need to be cooled performance. Overheating and fires! Cabin comfort is compromised!
  8. 8. Challenges – Simulating Engine Thermal systems Requires Responsibility fragmented expertise across across the organization multiple subjects Why Engine Model is Thermal data Management hungry Modeling is Experimental hard! procedures are Data not for validating Majority of readily designs, not data is available models steady- state
  9. 9. key considerations in modeling a Lets look at transient Engine Thermal model
  10. 10. Steady State Flow Model – Starting point Geometry and Fairly Straightforward – Based on component supplier data
  11. 11. Key issue #1: Model necessary thermal interactions between sub- systems Requires integration of all key thermal fluid systems – Cooling, AC, Engine Oil, Transmission Oil, Front-End cooling pack
  12. 12. Key Issue #2: Get Heat additions correct Combustion heat = Energy from Fuel &Air mixture – Exhaust Energy – Work (indicated Po +Qcomb +QFric Frictional heat = Indicated Power –Pumping Work
  13. 13. Key issue #2a: Get heat losses correct Heat Loss to the ambient (Conduction + Natural convection Heat absorbed + Forced by the mass convection) Heat Loss to the Coolant Heat Loss to the Oil
  14. 14. Where the heat goes during warm- up SAE 2000-01-0299 Warm-Up of a D.I. Diesel Engine: Experiment and Modeling L. Jarrier and J. C. Champoussin Ecole Centrale de LYON R. Yu Renault D.R. D. Gentile University of Versailles
  15. 15. Key issue #3: Modeling Thermal inertia right Thermal inertia option 1 – Cylinder head Capturing minimum number of masses to predict warm-up Coolant Circuit Include the correct Upper block volume of fluid. (Thermal inertia of the Lower block fluid) Engine Oil Circuit Sump
  16. 16. Key issue #3: Modeling Thermal inertia right • Thermal inertia option 2 – Capturing every heat transfer path (more components = more data required) Reference: SAE paper 910302, Kaplan and Heywood.
  17. 17. Key issue #3: Modeling Thermal inertia right • Thermal inertia option 3 – Capturing every heat transfer path (more components = more data required) Reference: SAE paper 960073, Bohac, Baker and Assanis.
  18. 18. Where the heat goes during warm- up Reference: SAE paper 931153, Shayler et al.
  19. 19. Key Factors in warm-up Heat distribution and loss Thermal Inertia
  20. 20. Key Issue #5: Include a dynamic coolant Thermostat • Include dynamic model – Lift vs temperature (supplier data, left) – Test data (below) – Dynamic mechanical model
  21. 21. HEV, EV specific challenges • Li-ion battery cooling is • more than just an additional isolated • cooling task. It requires • complex thermal management and • careful analysis • Reference: Behr Technical Press Day 2009; http://www.behr.de/internet/behrmm.nsf/lupgraphics/Behr_ Thermomanagement_TPT09_E.pdf/$file/Behr_Thermomanage ment_TPT09_E.pdf
  22. 22. HEV Additions – front-end cooling pack Segmented heat exchanger analysis to enable higher fidelity cooling pack analysis • Reference: Behr Technical Press Day 2009; http://www.behr.de/internet/behrmm.nsf/lupgraphics/Behr_ Thermomanagement_TPT09_E.pdf/$file/Behr_Thermomanage ment_TPT09_E.pdf
  23. 23. Improving fuel economy 5 Accurate standard model 4.5 with coldstart friction engine numerical model with coldstart friction transmission with coldstart friction eng&trans 4 of Engine Thermal fuel consumption [kg/s] Management 3.5  Predictive fuel 3 economy and Engine 2.5 thermal model 2  Evaluate a wide 1.5 array of solutions to 1 improve fuel economy and added HEV cooling 0.5 challenges 0 0 50 100 150 200 250 300 t [s] For 600s simulation, starting from 40degC: standard model 0.4347 kg with coldstart friction engine 0.4557 kg +4.8% with coldstart friction transmission 0.4543 kg +4.5% with coldstart friction engine & transm. 0.4799 kg +10.4%
  24. 24. Thermo-Fluid System Analysis Roadmap Deliver • Fuel economy benefits with effective thermal management strategy • Predictive analytical capability reducing prototype costs Collaborate Value • Provide trade-off across multiple systems (cooling, Lubrication, AC, transmission, front-end cooling pack) • Value-added partnership with customers and suppliers Analysis basics in place. Are we here? Troubleshoot and Optimize • Transient behavior of system providing insight into delivering a robust design • Optimization of system variables Ensure accurate system operation • Flow balancing to ensure all components have adequate flow • Evaluate individual component performance Functionality
  25. 25. Topics covered a) Engine thermal management challenges b) Traditional cooling system – Key considerations c) HEV, EV specific challenges d) Bigger picture e) Roadmap
  26. 26. FURTHER Sudhi Uppuluri has over 14 years of experience in the simulation industry. He DISCUSSION worked as a consulting engineer and sales manager at Flowmaster USA for 8 years .He has various technical publications on related subjects in SAE and AIAA journals. He holds a Masters in Aerospace Engineering from the University of Illinois at Urbana-Champaign and a Certificate in Strategy and Innovation from the MIT Sloan School of business. Contact: Sudhi Uppuluri Principal Investigator Sudhi.uppuluri@cseg.us (781) 640 2329 www.cseg.us
  • AmolPawale

    Mar. 1, 2016
  • ssuserac15be

    Dec. 10, 2015

Key considerations and roadmap for advanced engine thermal management simulation: Technical Webinar discussion.

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