vehicle design - part 1
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University Transilvania of Braov,
Laboratory of Fluid Power and Sonics
Professor Horia Abaitancei, PhD, [email protected],
Overview on
ResearchProjects
Summer 2011
idea
simulationexperiment
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Institute ProDD Department D02 2/40University Transilvania of Brasov
Overview on contents
Overall vision
Simulation / Research possibilities
Examples of research projects
ICE
Fluid power
Vehicle testing
Agricultural systems
Conclusions
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Institute ProDD Department D02 3/30University Transilvania of Brasov
Development vision
Methods:
CAE :CAD CFD FEA MBA - MPA
Experimental system analysisfluid power measurmentsnoise and vibration measurementsengine performance and emissions
Neuro fuzzy system identification
Dynamical system theory
Research activities:
fundamental research demonstration models applied / industry research
Systems:
Vehicle propulsion systems
engine gas exchange systemsinjection systemvalve train systems
hydraulic & sonic propulsionenergy recoveryfree piston engine
Concept car
Working devicesrecovering energy for lifting systemshydraulic log lifting systempumping devicesbicycle
Energy systemspumping system for heat pumpsstreet energy recovery system
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Overview on Research Facilities
Software
CAD: CATIA V5CFD: FluentHydraulics: DSH+MBA: LMS Virtual.Lab; MSC AdamsMSA: LMS Amesim; MSC Easy 5FEA: LMS Virtual.Lab; MSC Patran /
Nastran
Special AVL Partnership:
Boost 1D engine CFDHydsim fluid powerFire 3D CFDExcite MB / FEACruise vehicle dynamics
Testing facilities
Engine test rig HoribaEmission control system AVL
Fuel properties testing rig
Mobile Hydraulic pressure and
flow measurement system
Vehicle vibrations and dynamicstesting equipment
Concept car
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Overview on research projects and partners
fundamental research
ICE gas exchange systems
ICE pressure wave analysis of ice injection systems
Fluid Power Systems
power transmission using waves in liquids
hydraulic systems dynamical phenomena
NVH vibration system identification
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Overview on industry research projects and partners
Support / joint research industry projects:
identification and optimisation of pressure waves of the injection system
pressure wave supercharger CFD analysis
dynamical analysis of valve train
gas exchange system optimization
friction analysis
vibration analysis mobile hydraulic hammer
Institute ProDD Department D02 6/40University Transilvania of Brasov
USA
RO
DE
DE
DE
RO
DE/RO
DE/RO
partnerships under
construction
BE/RO
RO
AT
USA/RO
http://www.renault-technologie-roumanie.com/http://www.autoliv.com/wps/wcm/connect/autoliv/Homehttp://www.ecomotors.com/http://www.renault-technologie-roumanie.com/ -
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EXAMPLES OF Internal Combustion EnginesAPPLICATIONS
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Institute ProDD Department D02 8/40University Transilvania of Brasov
Pressure Wave Supercharger
The TC model
The PWS model
Boost pressure
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Pressure(bar)
800 1000 1200 1400 1600 1800 2000 2200
Engine speed(rpm)
Pressure MeasuringPoint 1(bar)
Torque
300
320
340
360
380
400
420
Torque(N.m
)
800 1000 1200 1400 1600 1800 2000 2200
Engine speed(rpm)
Torque TC (N.m)
Torque PWSC (N.m)
Goal: replacing turbocharger with pressure wavesupercharger for low speed torque and dynamicresponse improvement
Ideal engine chargingpressure for goaltorque curve
Goal torque curve
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Institute ProDD Department D02
PWS Process Simulation 1D simulation influence of cell length
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Air Low Pressure
0.093
0.0935
0.094
0.0945
0.095
0.0955
0.096
0.0965
Pressure(MPa
)
0 90 180 270 360 450 540 630 720
CRANKANGLE(deg)
93mm(MPa)
110mm(MPa)
150mm(MPa)
Air High Pressure
0.112
0.114
0.116
0.118
0.12
0.122
0.124
0.126
0.128
0.13
0.132
Pressure(MPa)
0 90 180 270 360 450 540 630 720
CRANKANGLE(de )
93mm(MPa)
110mm(MPa)
150mm(MPa)
Burned Gases Low Pressure
0.1025
0.103
0.1035
0.104
0.1045
0.105
0.1055
Pressure(MPa)
0 90 180 270 360 450 540 630 720
CRANKANGLE(deg)
93mm(MPa)
110mm(MPa)
150mm(MPa)
Burned Gases High Pressure
0.11
0.12
0.13
0.14
0.15
0.16
0.17
Press
ure(MPa)
0 90 180 270 360 450 540 630 720
CRANKANGLE(deg)
93mm(MPa)
110mm(MPa)
150mm(MPa)
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Institute ProDD Department D02
PWS Process Simulation 1D simulation influence of cell length
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Institute ProDD Department D02
PWS Process Simulation mechanical analysis
University Transilvania of Brasov
Normal modes analysis
1st normal frequency:
540 Hz
Thermal analysis:
Maximum displacement0,48 mm / 700 K
Structural analysis:at 15000 rev/min
Maximum stress:108 MPa
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Institute ProDD Department D02 12/40University Transilvania of Brasov
Acoustical supercahrging
Goal: acoustical engine supercharging
Research steps:
1D geometry identification for maximumpressure wave amplitude depending on enginespeed3D CAD integrated on given engine geometry
Results: pressure wave amplitude,CAD Model
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Institute ProDD Department D02 13/40University Transilvania of Brasov
Combustion chamber flow analysis
Goal: identification of ICE cylinder flow fordifferent inlet geometries to improve cylinder
turbulence
Research steps:CAD generationDefinition of different inlet system shapes3D CFD dynamic analysis
Results: diagonal positioning for maximum flow
coefficient and turbulence generation
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Institute ProDD Department D02 14/40University Transilvania of Brasov
Injection process analysis
Goal: identification of injectionprocess and spray development
Research steps:Constant volume chamber fast
image recording3D spray simulation (Fire)
Results:model calibrationinfluence of injection pressureon spray development
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Exhaust system analysis
Goal: Coupled mechanical and CFD (1D, 3D analysis)Analysis of identification of injection process and spray development
Research steps:Normal modes analysis for different geometry1D thermodynamic analysis of engine and exhaust pipe system; pressure wave amplitude identification for differentgeometries
Results:Optimized geometry for mechanical and exhaust pressure wave amplitudes
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-1
0
1
2
3
-180-160-140-120-100 -80 -60 -40 -20 0 20 40 60 80 100 120 140 160 180
Experiment vs Simulation difference [%]
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Dynamic flow process analysis ICE injection system
Goal: pressure wave ICE injection systems
Research steps:Injection system model design fordifferent geometries;
Model calibrationIdentification of optimum geometry forminimum pressure wave amplitudes
Results:geometry of the injection system
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Institute ProDD Department D02 17/40University Transilvania of Brasov
Bio-fuels combustion research
Goal: identification of optimum combustionchamber shape using biofuels
Research steps:
Combustion chamber shape definitionFuel definitionSpray simulation (Fire)
Results:fuel distribution, emissions
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Engine valve train analysis tappet rotation
Goal: valve train valve assembly rotation
Research steps:Multi body (Virtual Lab) simulation
Results:Influence of geometry parameters ontappet rotation
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Institute ProDD Department D02 19/40University Transilvania of Brasov
Homogeneous Mixture in Compression Ignition Engine
Gasoline HCCI engine with
camphasers (gas trappingmethod)
HCCI engine modelAVL Boost
HCCI operating parameters cylinderprerssure, valve lifts, injection timing)
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Engine friction analysis
Goal: ICE friction analysis
Research steps:thermodynamic model, engine kinematics modeljournal bearingmodel
Results:Crank angle dependent minimum oil film thicknessCrank angle dependent friction power loss
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FEA mechanical / thermal / normal modes
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EXAMPLES OF FLUID POWER APPLICATIONS
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Example of integrated project conception solution development vehicle integration
Goal:
integrated model; pressurewave engine coupled withhydrostatic transmissionintegrated on a vehicle
Research steps:Pressure wave engine definitionRunning resistance definitionCFD / FEA analysis
Fluid power actuation scheme
Results:CAD modelDigital mock-upCFD/FEA
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Institute ProDD Department D02 24/40University Transilvania of Brasov
Timber lifting system
Goal:Hydraulic / mechanical design of a timber lifting system
Research steps:
Multy
domain analysis : planar mechanical / fluid power analysis
Results: system forces, mechanical, fluid power, control parameters
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Timber lifting system - continued
CAD Model
MB Analysis
ll
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mechanical parameters
control parametersfluid flowparameters
Timber lifting system
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Timber lifting system - continued
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A hydraulic propulsion, + engine running conditionsB brake energy recovery + 40%C shock absorber energy recovery + 8%
Institute ProDD Department D02 27/40University Transilvania of Brasov
Hydraulic Hybrid propulsion system
Goal:
Development of simulation andexperimental demonstrationvehicle with series hydraulichybrid propulsion systemintegrating shock and brakeenergy recovery
Research steps:Simulation model (Amesim)
Experimental model
Results:Overall efficiency evaluationSimulation modelConcept vehicle
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Engine speedEmissions
Consumption
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Hydraulic hybrid propulsion system - performances
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1st price
Youth Innovation Fair 2007
organised by the Romanian YouthMinistry
Institute ProDD Department D02 29/40University Transilvania of Brasov
Shock absorber energy recoveryGoal:Principle demonstration ofshock absorber energyrecovery
Research steps:Simulation model (Amesim)Test rigTest vehicle
Results:Oscillation computation &measurement
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Institute ProDD Department D02 30/40University Transilvania of Brasov
Fluid power optimisation vision
Fluid power
energy source
Transmission linePressure wave
based transmission
Sonic system
Free pistonsolution
Hydraulicactuators Sonic motors and
cylinders
Thermodynamic efficiency ()Mechanical
power loss
simple system
power loss simple system
Recovery systemsbrakes, shock
absorber, liftingsystems
overall efficiency
advantages
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Free piston solution
Conventional coupling of ICEwith hydraulic pump
sine function for piston movement,friction losses;
free shape of compression function+ efficiency;
simple variable engine displacement+ consumption;+ emissions.
compact+ lower mass
Institute ProDD Department D02 31/40University Transilvania of Brasov
Free piston solution for efficient fluid power energygeneration project start - up
Goal:Principle demonstration and performanceevaluation
Research steps:
Simulation model (1D multy domain, CFD,FEA),Test rig model;Vehicle application
Results:to be evaluated end spring 2012
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Institute ProDD Department D02 32/40University Transilvania of Brasov
Sonic propulsion system based on pressure wavespropagated in liquids - principle demonstration
Goal:Principle demonstration as vehicle propulsion systemand fluid power actuation system
Research steps:
Concept, optimum system structure developmentInfluences on liquid pressure waves identificationSimulation model (1D multy-physics< CFD; FEA)Test rig model, Concept car
Results:Ongoing testing: efficiency evaluation
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EXAMPLES OF INTEGRATED VEHICLEAPPLICATIONS
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Running cycle comparison of alternative propulsion systemsusing propulsion system model with driver and test cycle models (Amesim)
Fuel economy EPA Highway [mg/s]Conventional propulsionAutomatic driveSeries electric hybrid
V h l d & b l
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Vehicle dynamics & vibration analysis
active suspension main parts
Goal:Vehicle active control suspensiontesting
Research steps:Oscillation measurement fordifferent running conditions
Results:Data for multy physics modelcalibration
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EXAMPLES OF AGRICULTURAL SYSTEMS
APPLICATIONS
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J i t f l i l d ith FEA f i lt l
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Institute ProDD Department D02 37/40University Transilvania of Brasov
Joint force analysis coupled with FEA of agriculturalworking devices
D i l i f di d i d t ti d
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Institute ProDD Department D02 38/40University Transilvania of Brasov
Dynamic analysis of seeding devices and traction andworking devices
Seeding device sub -
system kinematics anddynamics
System
assemblyidentification
Integrated device forsoil treatment andsapling seeding
Goal:
Agricultural equipment development
Research steps:Modeling of system dynamics
Results:Concepts and experimental, testedsolutions
C l i
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Conclusions
joint participation at
student / engineeringdesign / innovationcompetitions:e.g. mini baja
Joint participationat research
projects
Development ofcontinuous education
centre
Research projects withsubventions from theRomanian State
Bachelor, Master,PhD thesis with
subjects fromindustry
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