Vehicle Design - Part 1

8/3/2019 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

Institute ProDD Department D02 1/40University Transilvania of Brasov
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Overview on contents

Overall vision

Simulation / Research possibilities

Examples of research projects

ICE

Fluid power

Vehicle testing

Agricultural systems

Conclusions


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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


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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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

University Transilvania of Brasov 9/40

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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PWS Process Simulation 1D simulation influence of cell length

University Transilvania of Brasov 10/40


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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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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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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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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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-2

-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 [%]


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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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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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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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


Timber lifting system - continued


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A hydraulic propulsion, + engine running conditionsB brake energy recovery + 40%C shock absorber energy recovery + 8%


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


Hydraulic hybrid propulsion system - performances


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1st price

Youth Innovation Fair 2007

organised by the Romanian YouthMinistry


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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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


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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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


J i t f l i l d ith FEA f i lt l


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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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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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Vehicle Design - Part 1

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