GT-SUITE for cooling circuit & engine heat-balance Gamma · GT-SUITE for cooling circuit & engine heat"balance 25.11.2009 19 Deutz AG, Thermal&Fluid Engineering, TE -TT Hans -Carsten

Deutz AG, Thermal&Fluid Engineering, TE-TT

Hans-Carsten Göttsche-Götze

GT�SUITE for cooling circuit & engine heat�balanceHans-Carsten Göttsche-Götze

GT-SUITE for cooling circuit &

engine heat"balance225.11.2009



Deutz Applications for Diesel engines

AGRI PowerConstruction machines

Generator sets Automotive





Engine spec with key components from customer





Use of GT Suite MP

Cooling system development

Customer data to Deutz

Engine spec

Vehicle package

Operation limits

Deutz Cooling Team

Heat rejection, Cooler

size, coolant flow

Thermostat setting

System configuration

Cooling components

Diameters, Roughness

Maps of pump, hx, Fan

Thermostat valve curve

Pressure losses

Data to Customer

Heat Rejection

Coolant flow

Charge Air flow





Development structure

Hx temperature difference

Required coolant flow

First engine heat balance

First model w/o hxw/o pump map

pressure level, losses, flow distribution

Experience





Engine coolant circuit

Thermostat

p

p

p

p

p

Measurement required p flow

∆p

∆p

∆p

∆p

∆p

flow

flow

flow

∆p

p

EGR

Oil

Radiator

Measure requirements for coolant system calculation

Known ∆p, flow











Pump map and more detailed model

CFD calculations

testing resultsInteraction with testing

Experience





CFD of difficult geometries

Result: pressure resistance





Example: full circuit w/o heat exchangers

Result: pump performance

coolant flow distribution

Engine block

Oil

EGR

Pump

Thermostat











Pump map and more detailed model

CFD calculations


Experience

Circuit with HX: Oil, EGR, coolant, CACEngine test results

Confirmation of heat rejection and system performance





Heat Balance Schematic

OilQ Coolant

Fuel

Exhaust

after Turbine

Radiation

Convection

EGR

Power

Q CACFriction

Convection

Coolant





Heat balance calc for full circuit

Principle:

Q_fuel = Power + Q_Exhaust + Q_Coolant + Q_CAC + Q_amb= BSFC x Power x Fuel Heat/3600000

Q_Exhaust = f( heat cap Exh, mass flow, Temperature after Turbine )

Q_CAC = f( heat cap Air, mass flow, Temperature after compressor )

Q_amb ~ 4%Q_fuel

Q_Coolant = Q_Engine + Q_oil + Q_EGR

Q_EGR = f( heat cap Exh_EGR, mass flow, Temp diff over EGR cooler)

EGR mass flow = f( EGR rate, air mass flow )

Q_Oil = f( heat cap, mass flow, Temp diff over oil cooler)





Measure requirements for heat balance

Measurement required Τ flow

RA

D

EG

R

CAC

Τ

flowΤ

BSFC

Τ

T oil sumpΤ

flow

Condition with and w/o EGR

Vol eff 0 Vol eff





Calculation of heat rejection with GT controls

6 value maps out of

measures

4 condition values

out of case setup

Result out:

Q_Coolant

Q_CAC

EGR rate

Maped Values XYZ points





Map generation with XYZ points

Example: charge air flow over speed and BMEP

23.00

20.00

15.00

10.00

1.80

5.00

1100 1250 1500 1750 2000 2200





Full cycle with heat exchangers

Result: Coolant flow

Temperature distribution

System behavior

Oil cicuit, EGR flow, CAC flow, Cooling Air flow





Full cycle with heat exchangersDetail: Oil module





Full cycle with heat exchangersDetail: Cooling pack

Air side of water circuit

Cooling air

Charge air

Coolant









First system w/o hxw/o map pump


Pump map and more detailed circuit

CFD calculations


Experience

Circuit with HX: Oil, EGR, coolant, CACEngine test results

Confirmation of heat rejection and system performance

Circuit with couplingGT Power calculation More detailed heat distribution to oil





Split coupling with GT Power: model 4cyl-2V

Block HeadOilReading Cool AirCoolant CA EGR Control





Result of coupling with GT Power





Use of GT Suite MP

Cooling system deveopment

Customer data to Deutz

Engine spec

Vehicle package

Operation limits

Deutz Cooling

Heat rejection

Hx size, ATB, coolant flow

Thermostat setting

System configuration

Cooling components

Diameters, Roughness

Maps of pump, hx, Fan

Thermostat valve curve

Pressure losses

Data to Customer

Heat Rejection

Coolant flow

Charge Air flow



Vielen Dank

GT-SUITE for cooling circuit & engine heat-balance Gamma · GT-SUITE for cooling circuit & engine heat"balance 25.11.2009 19 Deutz AG, Thermal&Fluid Engineering, TE -TT Hans -Carsten

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