exhaust line simulations using star-ccm+ and...
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![Page 1: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/1.jpg)
Exhaust line simulations using Star-CCM+ and automation
Yohann Perrot
22-March-2010
![Page 2: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/2.jpg)
2Propertyof Faurecia -Duplication prohibited
Agenda
� Faurecia Emissions Control Technologies
� Exhaust line components
� Some correlations and investigations
� Enhancements
� Automation
![Page 3: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/3.jpg)
3Propertyof Faurecia -Duplication prohibited
Agenda
� Faurecia Emissions Control Technologies
� Exhaust line components
� Some correlations and investigations
� Enhancements
� Automation
![Page 4: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/4.jpg)
4Propertyof Faurecia -Duplication prohibited
Emission limits – LDV Diesel
Europe
NOx
[g/km]
USA
0.2 0.3 0.4 0.50.1
JP 2005
JP 2002
JP 2009
PM [g/km]
0.02
0.03
0.04
0.01
0.05
NOx
[g/km] 0.4 0.3 0.2 0.10.5
Japan
Tier 2 / Phase In (2004)
Tier II Bin 8 (2004)
Tier II Bin 5 (2009)
EU 3 (2000)
EU 4 (2005)EU 5(2009)
EU 6(2014)
PM [g/km]
0.04
0.03
0.02
0.05
0.01
![Page 5: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/5.jpg)
5Propertyof Faurecia -Duplication prohibited
AMELI & AMELI & GTGT--PowerPowerTail pipe noiseTail pipe noise
FLOWMASTERFLOWMASTERBack pressure
AMELI & GTAMELI & GT--PowerPowerTL, EBP predictionTL, EBP prediction
Full validated exhaust
CustomerSpecif.Sheet
Vehicle LevelVehicle LevelVehicle LevelVehicle Level
System LevelSystem LevelSystem LevelSystem Level
Subsystem LevelSubsystem LevelSubsystem LevelSubsystem Level
Component Component Component Component LevelLevelLevelLevel
CFD/GTCFD/GTCFD/GTCFD/GT----PowerPowerPowerPower1D/3D coupling
FIREFIREDPF, SCR simulations
StarStar--CCM+CCM+Flow distributionFlow distribution
StarStar--CCM+, FIRECCM+, FIREHeat TransferHeat Transfer
SIMCPSIMCPCatalysts & DPF BackpressureCatalysts & DPF Backpressure
Development process
![Page 6: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/6.jpg)
6Propertyof Faurecia -Duplication prohibited
�When Faurecia develops a new product or an innovation, a corresponding CFD & FEA procedure must be created
� CAD templates have to developed and then deployed for each current and new product
� Communication between CAE software must be ensured automatically
� Thanks to this approach, among their activities, CAE experts will � Spend more time in analyzing the results than meshing or debugging
� Assist and help in defining where and what to measure during experimental tests
� Contribute in building the design know-how/guideline of their local customers
� Inform regularly the CAE coordinator of the future needs expressed by the customers and give update of their requirements
� Star tools participate to that vision
Global CAE vision
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7Propertyof Faurecia -Duplication prohibited
Agenda
� Faurecia Emissions Control Technologies
� Exhaust line components
� Some correlations and investigations
� Enhancements
� Automation
![Page 8: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/8.jpg)
8Propertyof Faurecia -Duplication prohibited
Overview of exhaust activity
Cold EndAcoustic
Hot EndEmission control
Structural integrityDurability
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9Propertyof Faurecia -Duplication prohibited
Manifold & Turbo
Heat exchanger, EHRS
Fuel Vapo
3W catalyst,
DOC, DPF
SCR
Injector Vein, Mixers
LP EGR,
backpressure
valves
Muffler
3WV
Exhaust line components
![Page 10: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/10.jpg)
10Propertyof Faurecia -Duplication prohibited
Agenda
� Faurecia Emissions Control Technologies
� Exhaust line components
� Some correlations and investigations
� Enhancements
� Automation
![Page 11: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/11.jpg)
11Propertyof Faurecia -Duplication prohibited
PPPPmeasmeasmeasmeas....= 463mbar= 463mbar= 463mbar= 463mbarPPPPStarStarStarStar----CCM+CCM+CCM+CCM+= 466mbar= 466mbar= 466mbar= 466mbar
TTTTmeasmeasmeasmeas....= 740= 740= 740= 740°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= = = = 827827827827°°°°CCCC(lack engine block cooling)(lack engine block cooling)(lack engine block cooling)(lack engine block cooling)
PPPPmeasmeasmeasmeas....= 469mbar= 469mbar= 469mbar= 469mbarPPPPStarStarStarStar----CCM+CCM+CCM+CCM+= 467mbar= 467mbar= 467mbar= 467mbar
TTTTmeasmeasmeasmeas....= 750= 750= 750= 750°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= = = = 840840840840°°°°CCCC(Presence of radiator not taken into (Presence of radiator not taken into (Presence of radiator not taken into (Presence of radiator not taken into account)account)account)account)
TTTTmeasmeasmeasmeas....= 663= 663= 663= 663°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 677= 677= 677= 677°°°°CCCC(Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken into account)into account)into account)into account)
TTTTmeasmeasmeasmeas....= 816= 816= 816= 816°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 800= 800= 800= 800°°°°CCCC
TTTTmeasmeasmeasmeas....= 802= 802= 802= 802°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 820= 820= 820= 820°°°°CCCC
PPPPmeasmeasmeasmeas....= 380mbar= 380mbar= 380mbar= 380mbarPPPPStarStarStarStar----CCM+CCM+CCM+CCM+= 377 mbar= 377 mbar= 377 mbar= 377 mbar
TTTTmeasmeasmeasmeas....= 737= 737= 737= 737°°°°CCCCTTTTStarStarStarStar----CCM+CCM+CCM+CCM+= 730= 730= 730= 730°°°°CCCC(Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken (Presence of radiator not taken into account)into account)into account)into account)
Some correlations…
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12Propertyof Faurecia -Duplication prohibited
Catalytic converter simulations
Some correlations…
Hot wire anemometry measurements
EOPEngine
���� 419 kg/h @ 560°C
Corresponding EOPFlow bench
(Reynolds analogy)
���� 207 kg/h @ 20°C
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13Propertyof Faurecia -Duplication prohibited
EHRS simulation – 810 kg/h @ 830°C – Bypass way
Some correlations…
Tmeas. = 585°C
TStar-CCM+ = 602°C
Tmeas. = 398°C
TStar-CCM+ = 384°CTmeas. = 198°C
TStar-CCM+ = 216°C
Tmeas. = 598°C
TStar-CCM+ = 614°C
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14Propertyof Faurecia -Duplication prohibited
Transient manifold simulation (following the firing order)
Some investigations…
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15Propertyof Faurecia -Duplication prohibited
Velocity uniformity index vs. time
0.910.910.910.91
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16Propertyof Faurecia -Duplication prohibited
Full cold-end simulation (PSA EP6DTS)
Toward full exhaust line simulations…
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17Propertyof Faurecia -Duplication prohibited
Agenda
� Faurecia Emissions Control Technologies
� Exhaust line components
� Some correlations and investigations
� Enhancements
� Automation
![Page 18: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/18.jpg)
18Propertyof Faurecia -Duplication prohibited
Enhancements
� Heat transfer simulation
� Purpose: To take into account the whole heat transfer (conduction, convection and radiation) without simulating the solid
� Heat exchanger simulation
� Basics in thermomechanics for fast & complete optimization (relative comparisons)
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19Propertyof Faurecia -Duplication prohibited
Agenda
� Faurecia Emissions Control Technologies
� Exhaust line components
� Some correlations and investigations
� Enhancements
� Automation
![Page 20: Exhaust line simulations using Star-CCM+ and automationmdx2.plm.automation.siemens.com/sites/default/files/... · 2018-05-06 · Exhaust line simulations using Star-CCM+ and automation](https://reader030.vdocuments.site/reader030/viewer/2022040101/5f2a82c5f248cb1cad6fc84e/html5/thumbnails/20.jpg)
20Propertyof Faurecia -Duplication prohibited
Faurecia Emissions Control Technologies
� Simulation gain (ex: Catalyst-DPF fluid dynamics simulation):
� Pre-processing: 50%
� Running: 25%
� Post-processing: 10%
� Example…
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21Propertyof Faurecia -Duplication prohibited
Thank you for your attention