Multiphysic modeling of Valeo Electrical cooling valve · PDF fileOctober 2014 S.Midrier...
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October 2014 S.Midrier Multiphysic modeling of Valeo Electrical cooling valve for robust engineering using GT-SUITE
Transcript of Multiphysic modeling of Valeo Electrical cooling valve · PDF fileOctober 2014 S.Midrier...
October 2014
S.Midrier
Multiphysic modeling of Valeo Electrical cooling valve for robust engineering using GT-SUITE
October 2014
Summary
Context
Valve description
Detailed modeling
Example of in-loop dimensioning
October 2014
Context : why create a complete model?
Predict performances without test data
Reducing time and cost compared to prototypes.
Analyzing behaviour in engine environment
Uses Robust engineering Pilotability study System study Quick dimensioning
Simulation tool identified : GT-SUITE
October 2014
Valve description
ThemisTM: THermal Management Intelligent System
Electrical multiway mechanical control valve of flow coolant repartition.
Valve gain: Zero flow warm-up Higher temperature regulation
Control strategy of the valve is defined by each customer function of its architecture
Valve challenges
Opening pressure
drop
Accurate flow
progressivity Response
time
Engine
Pump
Hea
ter
Cor
e
Auxiliary Water Pump
THEMISTM Valve
Fan
October 2014
DC-motor actuated
Electrical actuation
Worm gear system
Torque transmission
Rotary slide flow controlling
Valve description
October 2014
Fields to be modeledCoupled Multiphysic
Valve description
Fluids
Kinematic Thermal
Electrical
October 2014
Detailed modeling: fluid side
0,0000
0,1000
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0,5000
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0,7000
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0 10 20 30 40 50 60 70 80
Cd
Outlet opening [°]
Simulated Watergate Cd
Ø10.8
Ø15.35
Ø19.9
Ø24
Ø29
Fluidic behaviour building
Specific bends and pipes using GEM3D
Cd standard coefficients f (°) have been determined by D.O.E using CFD
Cross window function of angle
October 2014
Detailed modeling: electrical motor Thermal behaviour
Electrical behaviour
Thermal, Electrical
and mechanical modeling
function of transient
temperature evolution
Accuracy of: ± 6°C on coil temperature ±10% on thermal time constant ± 2% on torque, speed and current consumption
Model validity [-40°C;220°C]
October 2014
Detailed modeling: kinematic
Worm-gear kinematic input:
Distances
Helix angle
Pressure angle
Friction coefficients
Worm-gear kinematic output:
Velocities &Torques at each stage
Forces at each link
Friction losses
Dedicated connection developed by Gamma technology!
Accuracy of: ± 5% on current consumption/ torque and speed
Model validity [-40°C;140°C]
October 2014
Detailed modeling: Rotary slide
Friction calculation based on theory
∆P: calculated by fluidic model
µ: friction coefficient body/sealing ring
d: external diameter
Soutlet: surface of ways
Scontact: contact surface body/sealing ring
),,,,( contactoutlet SSdPftorqueFriction Σ∆= µ
Model validity [-40°C;140°C]
Link between fluidic model and kinematic model
October 2014
Detailed modeling: Rotary slide
Test validation ∆P Vs Torque of the model Model validity [-40°C;140°C]
Max torque and no load torque fit fine with the test!
Deviation with tests due to test pump characteristics unknown
Link between kinematic and fluids created and validated.
October 2014
Detailed modeling: complete model
DC-motor
Kinematic
Fluids
PRV Strong link from electrical command to flow repartition/permeability
Taking into account properties deviation function of temperature
Link missing: water heat transfer to valve body
October 2014
Example of in-loop dimensioning
Implementation of the valve into:
4 ways, including one permanent way
Pump max ∆P = 3.5bar
Pump max flow rate = 11m3/h
Electrical supply = 13.5V
Fluid temperature = 110°C
Valve could it be drivable in this environment?
October 2014
Example of in-loop dimensioning
Valve can follow the cycle with low current consumption @ max engine speed
Two validation tests at
max engine speed
Valve performances are compliant with engine environment
Valve can open in a good response time @ max engine speed
0-100% Response time @ Max pressure drop
Response time compliant with specification
Dc-motor thermal behaviour OK
October 2014
Example of in-loop dimensioning
Implementation of the valve into:
4 ways, including one permanent way
Pump max ∆P = 5.2bar
Pump max flow rate = 20m3/h
Electrical supply = 13.5V
Fluid temperature = 110°C
Valve could it be drivable in this environment?
October 2014
Example of in-loop dimensioning
Valve cannot fully open @ max engine speed
GT-SUITE can help us to improve smartly the kinematic valve performances
Two validation tests at
max engine speed
Valve can follow the cycle with low current consumption @ max engine speed
0-100% Response time @ Max pressure drop
Dc-motor thermal behaviour OK
October 2014
Example of in-loop dimensioning
Valve can open in a good response time @ max engine speed
Two validation tests at
max engine speed
Improvement of kinematic efficiency and boosting of DC-
motor performances
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Standard DC-motor/ Basic friction Boosted DC-motor/ Improved friction
Perc
enta
ge o
f tor
que
Available Torque
Friction link 8
Friction link 7
Friction link 6
Friction link 5
Friction link 4
Friction link 3
Friction link 2
Friction link 1
Valve can follow the cycle with low current consumption @ max engine speed
0-100% Response time @ Max pressure drop
Dc-motor thermal behaviour OK
Response time compliant with specification
October 2014
Conclusion
Valeo can share component models with customers
Component/environment interaction can be quickly and accurately determined
With standard plug&play component, dimensioning in early phases is faster an more accurate than standard development process
Further evolution are possible : aging study, cycle transient study (coupling with FRM models)…
