Streamline Solutions - Elements Vehicle CAE Suite

643 views

Published on

The new ELEMENTS Vehicle CAE Suite is described, along with extensive validation information from the ARC wind tunnel.

Published in: Automotive
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
643
On SlideShare
0
From Embeds
0
Number of Embeds
49
Actions
Shares
0
Downloads
0
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Streamline Solutions - Elements Vehicle CAE Suite

  1. 1. STREAMLINE SOLUTIONS | ELEMENTSELEMENTS Software SuiteAutomotive CAE SolutionsAngus Lock, Head of AerodynamicsAuto Research Center, USAEmail: alock@arcindy.comWeb: http://elements.streamline-cae.com© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  2. 2. Presentation Agenda• Who are Streamline Solutions?• What is the motivation for anew automotive CAE tool?• What is our vision forELEMENTS?• Current status• Validation Matrix• Future developments• Conclusions© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  3. 3. Streamline Solutions | Who We AreAUTO RESEARCH CENTERAutomotive Engineering R&D, WindTunnel, 7-Post & Gearbox RigENGYSCFD Engineering, MDO, Open SourceSoftware Development, User SupportSTREAMLINE SOLUTIONSARC and ENGYS unique combination ofautomotive engineering resources andCAE software development expertiseJointVenture© 2013 STREAMLINE SOLUTIONS. All rights reserved.www.arcindy.com www.engys.com
  4. 4. Streamline Solutions | Auto Research Center© 2013 STREAMLINE SOLUTIONS. All rights reserved.Wind Tunnel TestingVehicle Dynamic TestingGearbox/Differential TestingVehicle Simulation SoftwareReverse EngineeringComputational Fluid DynamicsConsultancy & DesignModel BuildingTest Facility Design & BuildRapid Prototyping• Design andoperate testfacilities• Provideconsultancyservices with afocus onautomotiveapplications: Motorsport Passenger car Heavy truck Military• Tier 1 supplier tomajorautomotiveOEMs
  5. 5. Streamline Solutions | ENGYS• Provider of CAE products andservices• Focus on Open Source solutions• Solution platforms: CFD → OPENFOAM™ (developers since 1999) Optimisation → DAKOTA (users since 2009) GUI → HELYX (original product since 2012)• History: 2009 → founded in the UK 2010 – present → 5 offices worldwide 2012 → Joint Venture with ARC (ELEMENTS)• Strong growth (> 30% annual)© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  6. 6. Motivation for a new automotive CAE tool© 2013 STREAMLINE SOLUTIONS. All rights reserved.• Regulatory improvements to fleetaverage fuel economy in theUnited States: By 2017  18% By 2021  34% By 2025  61%• Traditional developmentprocess leads to potentialcommunications issuesbetween styling,engineering andmanagement• ELEMENTS aims toresolve these issues todeliver better solutions,fasterELEMENTSSTYLINGDEPARTMENTMANAGEMENTTEAMENGINEERINGDEPARTMENT ANALYZEVISUALIZEDESIGN
  7. 7. ELEMENTS | The Vision© 2013 STREAMLINE SOLUTIONS. All rights reserved.Open Source CFD engine based onOPENFOAM® Engys EditionModular program architecture for fastexpansion and developmentFirst-class user support and extensivewritten documentationEmbedded best practices for best-in-class vehicle design simulationAdvanced Graphical User Interface (GUI)for ease-of-useSoftware suite satisfying the needs ofstyling, engineering and management
  8. 8. ELEMENTS | The Vision© 2013 STREAMLINE SOLUTIONS. All rights reserved.All ELEMENTS combine to streamline the automotive development processPost-processingDesigned to simply present aerodynamicsensitivities and optimal vehicle shapesOpen Source KernelDelivers rapid turnaround time for largenumbers of parameters (>50)Theme SelectionAutomatically set-up shape optimisationwith minimal user interventionGeometry MorphingEasily morph A-class surfaces tooptimize vehicle shapeStyling InterfaceCreated for design staff with limited CAEexperienceELEMENTS | DESIGNPost-processingParallel batch processing of all runs, aswell as advanced interactive toolsOpen Source KernelDelivers best-in-class accuracy as wellas highly competitive turnaround timesDOE and OptimisationAdvanced case manager enables easyset-up of large MDO simulationsGeometry Creation & MorphingEasily generate new geometry andoptimize with advanced morphing toolsAnalysis InterfaceCreated for engineering staff with CAEexperienceELEMENTS | ANALYZEPost-processingResults presented in a way that easilyhighlights potential opportunities & risksCross PlatformSoftware will run on standard Windowslaptop for maximum accessibilityAnnotation ToolsEasily allow management to givefeedback to styling & engineering teamsPLM IntegrationDesigned to be integrated withincompanies’ existing PLM solutionPresentation InterfaceCreated for management team withlimited CAE experienceELEMENTS | VIZUALIZE
  9. 9. Current status of ELEMENTS | ANALYZE• External aerodynamics RANS and DES• Under-hood thermalmanagement• HVAC, cabin comfort• Aero-acoustics• Soiling, water management• Powertrain• In-cylinder flows• Automatic optimisationWith kind permission of: Helsinki MetropoliaUniversity of Applied Sciences, www.metropolia.fiRaceAbout Association, www.raceabout.fi© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  10. 10. Current status of ELEMENTS | ANALYZE© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  11. 11. ELEMENTS | Validation• Objective: Validate best-practices for external aerodynamics• Requirements: Wind tunnel measurements Range of vehicle shapes• Outcome: Automated process to evaluate aerodynamicperformance within a specified confidence intervalof error© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  12. 12. CFD Modelling | Wind Tunnel• Wind tunnel domain scaled based on vehicle dimensions• Tunnel length = 20x vehicle length for far-field simulation• Full moving ground plane, multi-belt, single belt, fixedground set-ups• Fully-turbulent flow (I and L fixed at inlet)© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  13. 13. CFD Modelling | Mesh Setup• Base mesh scaled by vehicle dimensions• Hex-split based mesh• Surface-based cell-spacing• Near-wall layers on vehicle geometry• Volumetric refinement boxes and buffer layer refinement• Stagnation and wake zone refinement tailored for each vehicle type• Contact patch refinement via cylindrical plinthWith kind permission of: Helsinki Metropolia University of Applied Sciences www.metropolia.fiRaceAbout Association www.raceabout.fi
  14. 14. CFD Modelling | Solver Setup• Transient DES formulation• Spalart-Allmaras model with wall functions• Robust first/second-order blending for advectionscheme based on CFL and near-wall distance• Run time is scaled by vehicle length and free-stream velocity• Multiple time-steps (coarse and fine)• Reduced overall memory usage• Improved scaling for parallel processors© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  15. 15. CFD Modelling | Post-Processing• Automated post-processing: Contour plots of U, p, tauw, Unw fields Isosurfaces of Ptot Averaged CD and CL, CpWith kind permission of:Helsinki Metropolia University of Applied Scienceswww.metropolia.fiRaceAbout Associationwww.raceabout.fi© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  16. 16. Validation Process | ARC Wind Tunnel• Max Wind Speed : 50 m/s• Max Road Speed: 50 m/s• Nozzle Size: 2.3 m x 2.1 m• Contraction Ratio: 4.8 : 1.0• Moving Belt Size: 3.4 m x 1.7 m• Boundary Layer Thickness: 1mm• Main Fan Motor Power: 320 kW• Primary BL Motor Power: 80 kW• Secondary BL Motor Power: 19 kW• Rolling Road Motor Power: 120 kWRapid prototyping, workshops &office spaceMoving ground, scale-model wind tunnelVehicle dynamics 7-post rig© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  17. 17. Validation Process | Aerodynamic Balance© 2013 STREAMLINE SOLUTIONS. All rights reserved.• Models are mounted in the tunnel by means of an overhead sting• The 6-component balance is contained within the model• Secondary balance for tractor-trailer
  18. 18. Validation Process | Vehicle Types• 100+ different vehicle types: Sedan Hatchback Estate SUV Sportscar Streamliner Nascar Indycar Light Duty Truck Heavy Duty Truck© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  19. 19. Validation Process | Parametric Changes• Fixed Ground• 5-belt Moving Ground• Single Belt MovingGround• Yaw Angle• Ride Height• Test Speed• Vehicle Modifications(e.g. Open or ClosedCooling, Spoiler on/off,Underbody Panels on/off)© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  20. 20. Validation Process | Instrumentation• 128 pressure channels to allow for evaluation of surface pressuresfrom around the model• Cooling mass-flow measurement by a grid of up to 14 vane typeanemometers© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  21. 21. Validation Process | Results© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  22. 22. Validation Process | Results© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  23. 23. ELEMENTS | Future Developments• Wheels and fans: sliding mesh for rotating objects• Hybrid convection schemes for RANS/LES• DES model improvements• Time step and schemes• Coupled solvers• Adjoint solver© 2013 STREAMLINE SOLUTIONS. All rights reserved.
  24. 24. ELEMENTS | Conclusions• In summary ELEMENTS has been shown to deliver: Minimal CAD cleanup requirement  Hours, not weeks Fully automatic meshing  Improved speed and quality Embedded best practices  Decades of experiencedistilled into GUI Significantly reduced solution times  Benchmarked againstPowerFLOW & other solvers Automated parallel post-processing  Customisable scriptgenerates images, videos Highly accurate transient solutions  Advanced DES solver Heavily validated results (>100 cases)  Only software company withown wind tunnel Average drag errors of 1.2%  Industry leading accuracy Integrated optimisation solution  MDO or adjoint solutions• Further improvements to come with rapid development cycle© 2013 STREAMLINE SOLUTIONS. All rights reserved. Minimal CAD cleanup requirement  Hours, not weeks Fully automatic meshing  Improved speed and quality Embedded best practices  Decades of experiencedistilled into GUI Significantly reduced solution times  Benchmarked againstPowerFLOW & other solvers Automated parallel post-processing  Customisable scriptgenerates images, videos Highly accurate transient solutions  Advanced DES solver Heavily validated results (>100 cases)  Only software company withown wind tunnel Average drag errors of 1.2%  Industry leading accuracy Integrated optimisation solution  MDO or adjoint solutions
  25. 25. ELEMENTS | Questions?© 2013 STREAMLINE SOLUTIONS. All rights reserved.Angus Lock, Head of AerodynamicsAuto Research Center, USAEmail: alock@arcindy.comWeb: http://elements.streamline-cae.com

×