Modeling Mechanical System Interactions in Flowmaster Automotive Fuel Injection and Aircraft Hydraulics Actuation System Examples Sudhi Uppuluri Shayne Ziegler Arlie Nuetzel Computational Sciences Flowmaster USA Flowmaster USA Expert Group USA Call-in Number: 1-631-267-4890 Click “Global Call-in numbers for other regions Access Code: 958 533 404
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A smart approach to simulation Traditional approach CSEG approach• Evaluate which software to buy • CSEG does the analysis and provides with a trial license you with a simulation answers• Purchase software tool quickly(CSEG bring the right tools and manpower to the table)• Schedule and pay for training• Go through the learning curve of • Choose the right software once the the tool while building the model analysis is done (CSEG provides the• Spend ~2-3 yrs gaining models) competence and confidence on modeling with the new tool Very cost-effective Expensive approach Have simulation answers quickly (with Lost opportunity costs confidence in them) Simulation tool not effective during Meet your analysis deadlines the initial period Significantly shorten the learning Software training does not cover your curve application. Get calibrated model of your system built by experts immediately.
Our Approach• We focus on the problem, combining the right tools to provide accurate answers for your simulation challenge – not the tool any one company is selling. CSEG maintains licenses for best in class COTS tools providing instant technical capability expansion to your projects.System Tools CFD Tools• Flowmaster* • Ansys Fluent• Amesim • STAR-CD• Gamma Technologies OtherOptimization Tools • Matlab/Simulink• iSight* • Can integrate your• ModeFrontier in-house software with COTS
Gasoline Direct Injection• Simplified Example of electronically controlled gasoline direct injection system* Example layout from Wikipedia, retrieved Oct 2011
The system model Engine Control Unit (Simulink)Cylinder firing FuelTiming, Voltages consumption Integrate with engine control to evaluate and optimize fuel consumption Precise engine- management software to accurately tailor fuel-injection timing and duration
1D translation of the injector * Reference from Advanced Engine Technology, Heinz Heisler
Modeling Considerations (Mechanical) Coefficient of restitution to model needle bouncing
Modeling Considerations (Fluid) Pressure waves inside the passagesCombustionchamberpressure Cd Discharge Coefficient
Which variables should I really spend a lot of time getting right ? What about: supply pressure fluctuations? Coefficient of Discharge? Needle mass?
Parameter study• Sensitivity study of select input parameters performed using Isight by Simulia.• Isight linked with Flowmaster through MS Excel• Automated input generation, runs and results extraction
Parameter Study (an example) Shows effect of select variables on amount of fuel injected Extremely Important that we get the needle port area, Cd and fluctuations in the supply pressure accurately characterized. Variables such as Coefficient of Restitution, and fuel filter loss were not that important in this case. * Analysis using Isight by Simulia
Parameter Study (an example)Fluctuations in mass of fuel injected Fluctuations in input parameters * Analysis using Isight by Simulia
Calculating Cd• Discharge coefficient directly affects the fuel flow rate through the injector.• Cd is typically a function of injector port area.• Few ways of determining Cd – Literature indicates Cd range from 0.690.73 (references avbl) with some examples much higher. – CFD is a good way to determine the Cd for your particular injector (at varying port openings) (predictive) – Can back-calculate from available test data (non-predictive)
FURTHER Sudhi Uppuluri has over 14 years of experience in the simulation industry. HeDISCUSSION 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.email@example.com (781) 640 2329 www.cseg.us