Detailed Engine Thermal Model for Vehicle Energy Management ...

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Detailed Engine Thermal Model for Vehicle Energy. Management Simulations. GT-User Conference 2011, 24.10.2011, Frankfurt/Main. Dr. M. Weinrich, R.
Detailed Engine Thermal Model for Vehicle Energy Management Simulations

GT-User Conference 2011, 24.10.2011, Frankfurt/Main Dr. M. Weinrich, R. Rossmann, Daimler AG Dr. M. Grill, A. Tonev, M. Sossio, FKFS /

Agenda  Project goals  Test Bench  Heat Balance Measurements  Friction at low temperatures  Operating points and model validation  Hydraulic and thermal modeling  Results  Integration in vehicle environment  Summary and Outlook

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Goals Measurements

Model Calibration & Engine Simulation

real world test bench environment

virtual world test bench environment

Extended Heat Balance

Benefits: 

Reduction of measurement points and duration



Further conclusions for 

non-measured operating points



Effect of minor changes in hardware



Effect of application changes



Future development: Use of a simplified model (fast running model) in vehicle simulation

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

Vehicle Simulation

virtual world vehicle enironment Folie 3

Test Bench – Heat Balance (2) Measured parameter for outer heat balance

(1) Test bench environment with conditioning  Measurement technique used for outer heat balance as a standard process

 rotational speed, torque, different fluid temperatures and pressures

 Cooling of coolant, oil and intake air with external conditioning

Power Exhaust gas heat Coolant heat

 Measurements extended with full pressure indication

Oil heat Intercooler heat



pcylinder

Twater_in coolant conditioning

T2 1

2

3

(3) Measured parameter for inner heat balance  Cylinder pressure

intercooler

Twater_out

oil conditioning

T3 Toil_in

Toil_out

4

5

6

 Low pressure indication  ECU data: injection etc.

Tcylinder

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Friction test bench Friction Test bench  Measurement are necessary to develop a friction model  Operating range from -20°C to 100°C  Correlation for oil sump temperature to friction points Pcrankcase

Tsurface pintake cyl2

Twater_in Tsurface cylinder head Toil_pan

Mfriction torque

Tmain_bearing_4 Tmain_bearing_2

Twater_out

Toil_sump Toil galery poil galery

Tsurface

pintake cyl5

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Operating points for model calibration and validation 2. Measurement of friciton drag measurements

BMEP [bar]

1. Measurements of 18 stationary operating Points

engine speed [rpm]

T_water_out T_water_in

temperature [°C]

temperature [°C]

3. Engine warm up measurements

Necessary measurements 1. Stationary points (fired) for validation of detailed engine model and heat distribution (heat balance) 2. Stationary points (motored) at different temperatures for friction model 3. Transient warm up for over all calibration of thermal net and complete model

time [s] GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Hydraulic model of the coolant circuit 1. Discretisation

2. Export using GEM3D

3. Structuring

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Stationary Points - Simulation vs. Measurement Radiation, oil- and coolant enthalpy Radiation Q_oil (T_oil 130°C) Q_coolant (T_water 105°C)

S

M

S

M

S

M

S

M

S

M

S = Simulation M = Measurement GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Engine Model in Test Bench Environment

Combustion & gas dynamics

Coupling

Simple ECU model

Water circuit

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

Oil circuit & thermal masses

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Integration into full vehicle simulation environment  Full Vehicle simulation: slow with coupled detailed gas dynamic and combustion model  Coupling of engine and vehicle circuits  Investigations for engine heating up and thermal comfort for passengers

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Example for Vehicle Simulation - NEDC

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Example for Vehicle Simulation - Cabin Heating Up

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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Summary and Outlook Summary  Measurement of inner and outer heat balance (high and low pressure indication)  Modeling of a detailed gas exchange and a predictive combustion model  Use of GEM3D for creation of the hydraulic network  Additional friction investigations at low temperatures and extended friction model  Manual generation of the thermal network Benefits:  Calculation of not measured operating points  Different level of detail for model depending on investigation focus  Investigation of changes in combustion and minor hardware changes Outlook  Focus on gasoline engine  Simple FE structure model for thermal network  Fast Running Model of the detailed gas exchange and combustion model  Integration of detailed ECU

GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFS

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