Development of Tools to Automate the Analysis of Turbo-MachineryTom Lincoln / Jaideep BangalTom Lincoln / Jaideep Bangal

Cooper Standard / Altair Engineering, Inc.

Executive Summary

• Cooper Standard (CS) Corporate Overview

• History of CFD at Cooper Standard

• Cooper Standard adoption of AcuSolve for enhanced C FD efficiencies

and accuracy

• Additional AcuSolve Applications at Cooper Standard

About Cooper Standard

Our Mission

Headquarters: Novi, MI

Established: 1960

Employees: 21,500+

Locations: 70+ in 19 Countries

Provide outstanding service, support

and innovative solutions to our

customers benefiting all stakeholders

of Cooper Standard.

2010 Top 100Global Suppliers: Rank 62

2010 Top 100 North American Suppliers: Rank 35

2011 Sales: $2.85 B

History

2011

2012

20052006

2007

2007

1960 1999 2000 2004

2010

Strategic Footprint

North America

Europe Asia Pacific

HeadquartersSales / AdministrationTechnical CenterManufacturingManufacturing / Technical Center

Key

South America

AustraliaBelgiumBrazilCanadaChina

JapanKoreaMexicoNetherlandsPoland

CountriesCzech RepublicFranceGermanyIndiaItaly

RomaniaThailandUnited KingdomUnited States

2012 - Located in 19 Countries2004 - Located in 14 Countries

Cooper-Standard Saiyang Wuhu 94% /6%Cooper-Standard NISCO 40% / 60%Cooper Hubei Jingda 37% / 63%Metzeler India 74% / 26%Cooper Hasco China 47.5% / 47.5% / 5%Guyoung Tech Korea 20% / 80%Cooper Standard France 51% / 49%Nishikawa Tachaplalert Cooper Limited 20% / 80%

Joint Ventures

Global Customers

RENAULT

HYUNDAI

Breadth of Product & Segments

Thermal Management – Key Capabilities

Heating and cooling management systems for

hybrids, electric vehicles and internal combustion engines

Electromechanical DevicesThermal DevicesThermal Integration

Technology

• Automotive News PACE Award

Honorable Mention• Electric Water Valve Assembly

• Thermoplastic Rear Door Glass

Seal Assembly

• Metal to Plastic Fluid Connection with

Overmolded Anti-Rotation Retainer

Global Six Sigma Award Best Achievement of Design for Six Sigma

• Coolant Water Valve

Over 500 Patents Globally• Daylight Opening Modules• Engineered Stretched Plastics• Occupant Detection Systems• Low Fuel Permeation Nylon TubingOvermolded Anti-Rotation Retainer

• Day Light Opening (DLO) System

• Society of Plastics Engineers

Most Innovative Use of Plastic: Finalist• Electric Water Valve Assembly

• Transmission Thermal Valve Assy

• Electric Brushless Pump

• Low Fuel Permeation Nylon Tubing• Quick Connect Fluid Couplings• Core process methods

cooperstandard

Cooper Standard’s History With Pumps

• Cooper Standard identified a market for electricall y driven coolant

pumps.

• Development began in 2005, CFD was used from the st art.

• Cooper Standard offers pumps to replace the vehicle main water pump

and auxiliary supplemental flow.

• Wattages range from <20 W to 1 kW.• Wattages range from <20 W to 1 kW.

Early CFD Analyses – August 2005

• Combination Tet and Hex cells

• Uniform mesh size• Significant time to set-up

manually

CFD Analyses – June 2010

• ~5M cells ranged from 0.2 mm to 2 mm • Manual set-up required a full day and 6-

10 hours to converge each flow point

0.00

0.20

0.40

0.60

0.80

1.00

1.20

5000 7000 9000 11000 13000

Pre

ssur

e G

ain

Flow Rate

Comparison Between Measured Data and CFD Prediction

Measured Pressure GainPredicted Pressure Gain

Early CFD - Challenges

• Results were good but• Model set-up would take 8+ hours

• Each flow point would take 4 – 10 hours to converge

• 6 flow points for one pump = 40+ hours

• Meshing was manual and required expertise to generate a good mesh

AcuSolve Process Automation

Import CAD / HM mesh

Define• Solids• Stationary Fluid• Rotational Volume

• Angular velocity• Rotation axis

• Process intelligence

• Fast setup: 4 steps• Auto meshing

• Auto solving strategy

• Auto Time steps calculation

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22

Boundary Conditions

Inlet / Outlet

Automeshing

Auto time step calculations

SOLVE

10 minutes

Setup time

• Auto Time steps calculation

• Setup multiple flow points and run it batch mode

44

33

Cooper Standard Pump Analysis

• Goal: Predict pump performance, Flow Curve

• Reduce Setup and Solution time

• Enable CSA Engineering team to analyze designs early

Meshed Impeller

Pump – Meshed Model

analyze designs early

AcuSolve’s Rotating Machinery Process

• First run

• Very fast setup and solution

• Helped understand process and setup before adding m ore details

• Setup Time: 1 hour from receipt of CAD impeller

• Solution Time: 12 flow points – 10 hours

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0.200

0.400

0.600

0.800

1.000

1.200

0.000 0.200 0.400 0.600 0.800 1.000 1.200

Test …First Run

16

Boundary Layer = 1.4 mmMesh Size 7 mm

Flow

Pre

ssur

e G

ain

AcuSolve’s Rotating Machinery Process

• Refined Mesh

• Analysis converged in 9 th iteration

• AcuSolve results matched test results

• Setup Time: Unchanged

• Solution Time: 12 flow points-24 hours1.200

17

Boundary Layer = 0.1 mmMesh Size 2 mm (on Impeller)

Flow

Pre

ssur

e G

ain

0.000

0.200

0.400

0.600

0.800

1.000

0.000 0.200 0.400 0.600 0.800 1.000 1.200

Test Pressure Gain

Final Converged Run

AcuSolve Results

Contours of Static Pressure Contours of Velocity

AcuSolve Results

Velocity Profile

Pressure Distribution

Velocity Profile

Pressure Distribution – fluid

volume

AcuSolve Results

Contours of Pressure on Planes Cut Through a Pump

Contours of Velocity on Planes Cut Through a Pump

AcuSolve Results

Pressure Distribution Velocity Profile

AcuSolve Results

Pressure Distribution Velocity Profile

AcuSolve’s Rotating Machinery Process

• 1-hour setup

• Automeshing ensures optimized mesh near critical flo w/impeller

features

• Accurate results

• Standardized inputs built into the tool

• 5 flow points can be run in 10 hours on a 4 core la ptop• 5 flow points can be run in 10 hours on a 4 core la ptop

• The tool is being rolled out to the Product Enginee rs to handle

increased demand

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Additional Collaboration - Thermal Analysis –Pump

• Cooper Standard engaged Altair in a consulting proj ect to set-up the

initial AcuSolve models

• Altair transferred knowledge to Cooper Standard for future product

development

3D CAD Model Simplified FEA 3D Model

Additional Collaboration - Thermal Analysis -Pump

IR Camera Image AcuSolve Thermal Analysis results

AcuSolve predicted high temperature component locations and were later confirmed by IR camera

AcuSolve Results

Thank You