Multiphysics Simulations of Flow Meters
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12/10/2016
Products Solutions Services
COMSOL CONFERENCE 2016 MUNICH
Dr. Vivek Kumar
Endress+Hauser Flowtec AG
Multiphysics Simulations of Flow Meters
Slide 1
12/10/2016
Outline of the Talk
Introduction Endress+Hauser
Flowtec AG
Role of Numerical Simulations
Selected COMSOL Simulation Projects
Coriolis flow meter
Ultrasonic flow meter
Design optimization
process
Conclusion
Multiphysics Simulations of Flow Meters
Slide 2
12/10/2016
Endress+Hauser Flowtec AG
• Established in 1977
• Flowtec 1600 and E+H group over 12000 employees
• Headquarters in Reinach, Switzerland
• Development and production of Coriolis, Vortex,
Ultrasonic, Electromagnetic and Thermal mass flow
instruments
Reinach
SuzhouAurangabad
Cernay Greenwood
Itatiba
Multiphysics Simulations of Flow Meters
Slide 3
12/10/2016
Unit Sales Development
1977 1985 1990 1992 1995 1998 2003 2005 2008 2010 2011 2012 2013
Continuous growth since 1977
Coriolis
UltrasonicThermal
Vortex
Electromagnetic
According to sales by end of
2013
Multiphysics Simulations of Flow Meters
Slide 4
12/10/2016
Product Portfolio Endress+Hauser Flowtec AG
Industrial flow meters
• Line size 1 mm to 2.4 m
• Broad application range
• Precision up to ±0.05%
Multiphysics Simulations of Flow Meters
Slide 5
12/10/2016
Our Goal and Vision
Concept
Multiphysics modelling
•Flow-structure, Flow-acoustics, Flow-magnetic field ..
Design exploration
•Sensitivity, optimization and robustness studies
Prototype
Flow
Thermal
Ultrasonic
(acoustics)
Coriolis
(structure)
MID
Maxwell
Vortex
Multiphysics Simulations of Flow Meters
• Multiphysics modeling
• Automated workflows
• Design optimization
Five measuring principles
Slide 6
12/10/2016
Our Model
• All three must be consolidated to design outstanding and innovative products
PeopleTraining,
support,
communities,
internal Wikis
SoftwareMethod
development,
evaluation,
Support
HardwareWorkstation,
servers, HPC
cluster and
Clouds
Numerical Simulations
Multiphysics Simulations of Flow Meters
Democratization of numerical simulations
Numerical simulations is not just the software
Slide 7
12/10/2016
Role of Simulations
Simulations
Quality Productivity Manpower Innovation
Multiphysics Simulations of Flow Meters
Slide 8
12/10/2016
Coriolis Flow Meter – Measuring Principle
fR ~
~ Qm
fRQ
m
https://www.youtube.com/watch?v=gxYniN5WQjI
Multiphysics Simulations of Flow Meters
Slide 9
• Direct mass flow measurement
• Additional measurements: density and
viscosity
12/10/2016
Flow Structural deformation Acoustics
Coriolis Flow Meter – 3D Multiphysics Simulation
Complete modeling of a Coriolis flow meter requires Multiphysics interaction
Multiphysics Simulations of Flow Meters
• Effects are around 0.1 to 1%
• Efficient and precise methods requiredChallenges:
Slide 10
12/10/2016
Coriolis Flow Meter – Frequency Domain Analysis
• FSI in frequency domain
• First implemented using weak form ( 2012 V4.3)
• Available as predefined physics interface (V4.4) Flow Field
Linearized Euler: vibro-acoustics in frequency domain
Linearized N-S: vibro-visco-acoustics in frequency domain
Meter response
Multiphysics Simulations of Flow Meters
Slide 11
12/10/2016
Coriolis Flow Meter – Frequency Response and Damping
• Effect of viscosity on the frequency could be corrected with the help of simulations
• Viscosity can be measured with information on damping and phase
• This effect could only be solved in COMSOL
1
10
100
1 000
208.6 208.7 208.8 208.9
Dis
pla
cem
en
t (m
m)
Frequency (Hz)
Amplitude
viscosity (Pa*s) = 0.001viscosity (Pa*s) = 0.05viscosity (Pa*s) = 0.2viscosity (Pa*s) = 0.7viscosity (Pa*s) = 1viscosity (Pa*s) = 2viscosity (Pa*s) = 5viscosity (Pa*s) = 10
0
20
40
60
80
100
120
140
160
180
208.6 208.7 208.8 208.9
Ph
ase(°
)
Frequency (Hz)
Phase
viscosity (Pa*s) =0.001viscosity (Pa*s) =0.05viscosity (Pa*s) = 0.2
viscosity (Pa*s) = 0.7
Multiphysics Simulations of Flow Meters
Slide 12
12/10/2016
Coriolis Flow Meter – Frequency Domain Methods
Meter sensing a flow effect
Frequency DomainSolver
Experiments
Me
ter
resp
on
se
Flow variation -->
Effects due to changes in flow conditions : time vs frequency domain
COMSOL offers frequency domain methods
• A unique feature of COMSOL in multiphysics
context
• Flow, acoustics and structure interaction
• much faster than time-domain methods
Multiphysics Simulations of Flow Meters
COMSOL
Experiments
Order of effect 10−3
Slide 13
12/10/2016
Flow Induced Noise: Time to Frequency Domain (Mixed method)
Transient flow and frequency domain acoustic analysis
Surface
Pressure FFT
Flow induced noise
sources
DES/LES Simulations
COMSOL
Vibroacoustics
Flow induced
noise around the
meter
Multiphysics Simulations of Flow Meters
Slide 14
12/10/2016
Ultrasonic Flow Meter
Multiphysics Simulations of Flow Meters
Slide 15
12/10/2016
Ultrasonic Flow Meter – Measuring Principle
• Based on time-of-flight (TOF) method
• t12=𝐿
𝑐+𝑢∗𝑐𝑜𝑠𝜃< t21=
𝐿
𝑐−𝑢∗𝑐𝑜𝑠𝜃because of flow velocity
L
u
Ultrasonic sensor
Ultrasonic
sensor
Sound
Path
1.
2.
θc: speed of sound
D
Ultrasonic wave is sent from 1. to 2. and from 2. to
1.
• Flow velocity: V =𝐷
sin(2𝜃)∙
Δt
𝑡21∙𝑡12
where Δt = t21 – t12
Multiphysics Simulations of Flow Meters
Slide 16
12/10/2016
Ultrasonic Flow Meter – 3D FEM Multiphysics Simulations
Challenges
small wave lengths
at least 6-8 mesh elements per
wavelength (2nd order)
100 Million mesh elements or DOFs
Large computing resources
especially RAM
Flow and Piezoelectric coupling with
acoustics
Multiphysics Simulations of Flow Meters
Slide 17
12/10/2016
Ultrasonic Flow Meter – Convected Wave Equation
Background flow using CFD
CWE: manually implemented in v5.2 using weak form
•Discontinuous Galerkin (DG) method
•4th order spatial and temporal discretization
•Explicit time marching scheme
New interface Convected Wave Equation, Time Explicit released in v5.2a
𝑝0, 𝑣0 and 𝜌0 are the background flow quantities
Multiphysics Simulations of Flow Meters
Slide 18
12/10/2016
Ultrasonic Flow Meter – COMSOL CWE Solution (v5.2)
Transmitter
Signal
Background
Flow (50m/s)
Receiver
50 Million DoFs
380k Elements
Multiphysics Simulations of Flow Meters
Slide 19
12/10/2016
Ultrasonic Flow Meter – COMSOL Solution Time of Flight
• TOFs from up- and downstream signals agree well with theoretical estimation
• For mesh resolution at 𝜆/1.5 – nearly no numerical dispersion observed
Theory
Multiphysics Simulations of Flow Meters
Slide 20
12/10/2016
Optimization
Multiphysics Simulations of Flow Meters
Slide 21
12/10/2016
Optimization in Product Development
COMSOL server (Live Link for MATLAB)
FEM parametrized model
MATLAB
COMSOL model as MATLAB script(APIs)
COMSOL server
optiSLang
Optimization Algorithm
Sending
Parameter to
MATLAB
Sending results
to optiSLang
MATLAB starts
COMSOL server
in background
COMSOL
Results
Multiphysics Simulations of Flow Meters
Slide 22
12/10/2016
Direct Link to COMSOL
• A direct link to COMSOL using JAVA APIs is developed
parameter
Multiphysics Simulations of Flow Meters
Slide 23
12/10/2016
Conclusion
COMSOL is indeed a true Multiphysics simulation program •Solution of thermal and flow problems in frequency and time domain
•coupling of flow with acoustics and structure
It helps to optimize our flow sensors
Allows us to address problems which otherwise were not possible to solve
COMSOL development speed is outstanding and takes care of our needs•Linearized Navier-Stokes in frequency domain
•CWE acoustic solver for coupling flow with acoustics
Multiphysics Simulations of Flow Meters
Slide 24
12/10/2016
Acknowledgments
• Coriolis and Ultrasonic teamsE+H Flowtec
• Mads J. Herring Jensen, Zoran Vidakovic
COMSOL Multiphysics
Multiphysics Simulations of Flow Meters
Slide 25
12/10/2016
Multiphysics Simulations of Flow Meters
Thank you!
Slide 26
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