endo - coupling effects between fead and cranktrain systems · engine design optimization –endo...
TRANSCRIPT
D. BARBEAU 09/10/2017
Engine Design Optimization – ENDOCoupling effects between FEAD and Cranktrain systems
D. BARBEAU 09/10/2017
01 Introduction of ENDO project
02 Engine under investigation
03 Standalone subsystems models
04 Integrated models : Clutch +
Cranktrain + FEAD
05 Conclusion
Summary
01Introduction to ENDO project
D. BARBEAU 09/10/2017 4
Renault simulation tools : before ENDO situation
TOOL 5
TOOL 1
TOOL 3TOOL 4
TOOL 2
TOOL 6Results exchanges
01 Introduction on ENDO project
All standalone models
D. BARBEAU 09/10/2017 5
ENDO Project
Potential couplings
ENDO : GT-SUITEResults exchanges
01 Introduction on ENDO project
Standalone models + integrated models
D. BARBEAU 09/10/2017 6
ENDO : what is expected ?
▌ Replacement of current software by one unique software : GT-SUITE
4 In-House software, 2 commercial software
▌ Extended possibilities : Flexibility
Model new technical definitions that were not possible in In-House tools
▌ Commercial software :
Easier training
Strong maintenance
Possibility to find experienced users
01 Introduction on ENDO project
▌ Perform Design of Experiments (DOE) and optimization in the same Graphical Interface :
Core Competencies teams on Unique Subsystem Model
Simulation specialist on Integrated Models
▌ Model couplings effects between different subsystems
D. BARBEAU 09/10/2017 7
ENDO : what is expected ?
▌ Replacement of current software by one unique software : GT-SUITE
4 In-House software, 2 commercial software
▌ Extended possibilities : Flexibility
Model new technical definitions that were not possible in In-House tools
▌ Commercial software :
Easier training
Strong maintenance
Possibility to find experienced users
01 Introduction on ENDO project
▌ Perform Design of Experiments (DOE) and optimization in the same Graphical Interface :
Core Competencies teams on Unique Subsystem Model
Simulation specialist on Integrated Models
▌ Model couplings effects between different subsystems
D. BARBEAU 09/10/2017 8
Examples of different integrated models built during ENDO project01 Introduction on ENDO project
Timing Drive + Valvetrain
FEAD + Cranktrain + DMF
Cranktrain + DMF
FEAD + Timing Drive + Valvetrain
+ Cranktrain + DMF
And more…
02Engine under investigation
D. BARBEAU 09/10/2017 10
‘Stiff’ belt + Fixed tensioner
pulley (w/o OWC)
One Engine : 3 different configurations 02 Engine under investigation
‘Soft’ belt + OWC ‘Soft’ belt + no OWC
Engine displacement 1598 cc
Cylinder bore / Stroke 78 x 83.6 mm
Max Torque / Power 156 Nm / 84 kW
Transmission 2WD – MT
Crankshaft pulley Simple Torsional Vibration Damper (TVD)
DMF No
FEAD 3 different configurations
Seen on vehicle measurements : impact of Front End Accessory Drive (FEAD) configuration on Flywheel accelerations
Engine Specifications
OWC : One Way Clutch
1 2 3
D. BARBEAU 09/10/2017 11
Simulation models before ENDO project
Results exchanges
All standalone models
02 Engine under investigation
CRANKTRAIN
1
CLUTCH
2 3
FEAD
D. BARBEAU 09/10/2017 12
Simulation models after ENDO project02 Engine under investigation
CRANKTRAINCLUTCH FEAD
1. model subsystems independentlyTARGETS :
D. BARBEAU 09/10/2017 13
Simulation models after ENDO project
Integrated model : all solved together
02 Engine under investigation
2. model interactions between subsystems
CLUTCH + CRANKTRAIN + FEAD
1. model subsystems independentlyTARGETS :
03Standalone subsystems models
D. BARBEAU 09/10/2017 15
Cranktrain standalone model03 Standalone subsystems models
▌ Frequency domain model (previous standard) replaced by time domain
model
▌ Boundary conditions : combustion pressures
Results used as input data for
standalone models of FEAD and clutch
D. BARBEAU 09/10/2017 16
Clutch friction standalone model03 Standalone subsystems models
Pulsating torques rebuilt using main engine
orders and mean torque calculated with
standalone « Cranktrain » model
▌ Boundary conditions : only main engine orders calculated with standalone
« Cranktrain model » : 2, 4, 6 and 8 for a 4 cylinders engine
▌ Model that can be easily used with input data coming from measurements
D. BARBEAU 09/10/2017 17
FEAD standalone model : « Stiff » belt, no OWC, fixed tensioner03 Standalone subsystems models
Cyclic angle deviations as a function of crank
angle on TVD ring calculated with standalone
« Cranktrain » model
▌ Boundary conditions : cyclic angle deviations calculated with standalone
« Cranktrain model »
▌ Model that can be used with input data coming from measurements
D. BARBEAU 09/10/2017 18
FEAD standalone model : « Soft » belt, OWC03 Standalone subsystems models
Cyclic angle deviations as a function of crank
angle on TVD ring calculated with standalone
« Cranktrain » model
One Way Clutch▌ Almost identical configuration to the previous model except :
• Modeling of a One Way Clutch on the Alternator ;
• Removal of the tensioner pulley ;
• Belt properties (~stiffness /3) and pre-tension adjusted to carry
accessory loads.
04Integrated models : Clutch + Cranktrain + FEAD
D. BARBEAU 09/10/2017 20
Integrated model building workflow04 Integrated models : Clutch + Cranktrain + FEAD
D. BARBEAU 09/10/2017 21
Impact of FEAD on flywheel accelerations : simulation vs measurements04 Integrated models : Clutch + Cranktrain + FEAD
Simulation : Flywheel acceleration : order 2
• Important improvement offered by GT-SUITE : ability to run integrated models.
• Impact of FEAD technical definition on flywheel accelerations correctly modeled (trends
and levels).
• Strong improvements of flywheel acceleration results compared to previous methodology
Stiff Belt + fixed tensioner
pulley (w/o OWC)
Soft belt + OWC
Soft belt w/o OWC
Cranktrain standalone
Engine Measurements : Flywheel acceleration : order 2Engine Measurements vs Simulation
D. BARBEAU 09/10/2017 22
Difference of behaviour explanation04 Integrated models : Clutch + Cranktrain + FEAD
▌ Presence of a One way clutch decreases the
resonance energy of FEAD
▌ With OWC, Increase of Alternator load :
• Reduces the effectiveness of the OWC
• Increases alternator visible inertia
• Decreases FEAD system resonnance frequency ▌ Increase of belt stiffness increases resonance
frequency of FEAD
ALT loadBelt stiff.OWC
D. BARBEAU 09/10/2017 23
Impact of FEAD on Cranktrain results04 Integrated models : Clutch + Cranktrain + FEAD
Impact of FEAD definition :
• Up to 40% reduction on Flywheel
acceleration on Order 2 at low engine
speed
• Up to 25% reduction on Flywheel
maximum input torque at low engine
speed
• Up to 200% increase on TVD hub
torques amplitudes at low engine
speed
Integrated vs standalone models :
• Integrated simulations provide earlier
evaluation of key system interactions
Mean value difference due to
accessories loads (CA and ALT)
-40 %
+20 %
D. BARBEAU 09/10/2017 24
Impact of FEAD on Clutch – Gearbox results04 Integrated models : Clutch + Cranktrain + FEAD
Mean value difference due to
accessories loads (CA and ALT)
Impact of FEAD definition :
• Impact of FEAD definition seen on
Flywheel passed on Transmission input
• Up to 30% reduction/increase on
Transmission input acceleration on
Order 2 depending on FEAD definition
• No significative impact on torques
amplitudes seen by the transmission
input
Integrated vs standalone models :
• Integrated simulations provide earlier
evaluation of key system interactions
Image of Rattle noise
+/-30 %
+5 %
+20 %
D. BARBEAU 09/10/2017 25
Impact of integration on FEAD results04 Integrated models : Clutch + Cranktrain + FEAD
Integrated vs standalone models :
• Not the main point of interest for
this specific case
Impact of integration :
• Slight differences for ‘stiff’ belt
definition
• Almost no difference for ‘Soft’ belt
definition
Boundary conditions of
FEAD system
05Conclusion
D. BARBEAU 09/10/2017 27
Conclusion05 Conclusion
▌ GT-SUITE, Software adopted for ENDO project fulfill our expectations :
• Ensure the previous simulation activities continue
• Results satisfying : are validated relative to measurements and/or previous tools
• Integration capabilities allowing for earlier evaluation of key system interactions
• Modeling flexibility : can keep pace with engine complexity
▌ One unique simulation platform makes data transfer between standalone models easier
D. BARBEAU 09/10/2017 28
Acknowledgements05 Conclusion
▌ Special thanks to the ENDO project contributers :
• Renault :
o Pascal Pancrace, Ciprian Manole, Iulian Carciog
o Subcontractor for Renault :
o Maxime Ruello, Florian Louis
o Gamma Technologies :
o Greg Fialek, Neehar Kulkarni, Rubin Cholera, Andrew Lee, Pete Nguyen
D. BARBEAU 09/10/2017 29
Thanks