Single-cylinder to multi-cylinder engine performancesimulation frameworkCitation for published version (APA):Ariannazar, M. (2019). Single-cylinder to multi-cylinder engine performance simulation framework: a step towardmulti-cylinder engine performance prediction using single-cylinder engine experiments. Eindhoven: TechnischeUniversiteit Eindhoven.

Document status and date:Published: 23/10/2019

Document Version:Publisher’s PDF, also known as Version of Record (includes final page, issue and volume numbers)

Please check the document version of this publication:

• A submitted manuscript is the version of the article upon submission and before peer-review. There can beimportant differences between the submitted version and the official published version of record. Peopleinterested in the research are advised to contact the author for the final version of the publication, or visit theDOI to the publisher's website.• The final author version and the galley proof are versions of the publication after peer review.• The final published version features the final layout of the paper including the volume, issue and pagenumbers.Link to publication

General rightsCopyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright ownersand it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights.

• Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal.

If the publication is distributed under the terms of Article 25fa of the Dutch Copyright Act, indicated by the “Taverne” license above, pleasefollow below link for the End User Agreement:www.tue.nl/taverne

Take down policyIf you believe that this document breaches copyright please contact us at:openaccess@tue.nlproviding details and we will investigate your claim.

Download date: 10. Apr. 2020

/ Department of Mathematics and Computer Science / PDEng Automotive Systems Design

Where innovation starts

Mohammadsadegh Ariannazar

Single-Cylinder to Multi-Cylinder Engine Performance Simulation Framework:A Step Toward Multi-Cylinder Engine Performance Prediction Using Single-Cylinder Engine Experiments

Executive Summary

October 2019

Single-Cylinder to Multi-Cylinder Engine Performance Simulation Framework

A Step Toward Multi-Cylinder Engine Performance Prediction Using Single-Cylinder Engine Experiments

M. S. Ariannazar

October 2019

Eindhoven University of Technology Stan Ackermans Institute - Automotive/Mechatronic Systems Design

PDEng Report: 2019/076

Public Executive Summary

Partners

DAF Trucks N.V. Eindhoven University of Technology

Steering Group Ir. Jarno Strik , DAF Trucks N.V. Ir. Görkem Argalıoğlu, DAF Trucks N.V. dr. Bart Somers, TU Eindhoven dr. Peter Heuberger, TU Eindhoven prof. dr. Henk Nijmeijer, TU Eindhoven

Date October 2019

Composition of the Thesis Evaluation Committee: Chair: Dr. Ir. Bart Somers (TU/e) Members: Ir. Jarno Strik (DAF Trucks N.V.)

Ir. Görkem Argalıoğlu (DAF Trucks N.V.)

Ir. Bogdan Albrecht (DAF Trucks N.V.)

Dr. Ir. Peter Heuberger (TU/e) Dr. Ir. Bram de Jager (TU/e)

Dr. Ir. Jeroen van Oijen (TU/e)

The design that is described in this report has been carried out in accordance with the rules of the TU/e Code of Scientific Conduct.

Contact Address

Eindhoven University of Technology Department of Mathematics and Computer Science MF 5.072, P.O. Box 513, NL-5600 MB, Eindhoven, The Netherlands +31 402743908

Partnership This project was supported by Eindhoven University of Technology and DAF Trucks N.V. Published by Eindhoven University of Technology

Stan Ackermans Institiute PDEng-report 2019/076

Preferred reference

Single-Cylinder to Multi-Cylinder Engine Performance Simulation Framework: A Step Toward Multi-Cylinder Engine Performance Prediction Using Single-Cylinder Engine Ex-periments, Eindhoven University of Technology, PDEng Report, October 2019. (PDEng Report 2019/076)

Abstract This report is aimed at establishing a simulation framework that enables attribution of sin-

gle-cylinder engine performance to that of a multi-cylinder engine. Such a framework would enable combined combustion modeling and turbo-matching analyses and accelerates the development process. The report lays out the context of the project. Then explains the framework’s development process in a step-by-step manner. Ultimately, suggestions and recommendations regarding further development of the framework concludes the report. This study showed that this framework as a novel modeling approach, has a great potential to reduce development time.

Keywords Simulation Framework, Single-cylinder Engine, Multi-cylinder Engine, Combustion Mod-

eling, Turbo-matching, 1-D Engine Simulation. Disclaimer Endorsement

Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its en-dorsement, recommendation, or favoring by the Eindhoven University of Technology or DAF Trucks N.V. The views and opinions of authors expressed herein do not necessarily state or reflect those of the Eindhoven University of Technology or DAF Trucks N.V., and shall not be used for advertising or product endorsement purposes.

Disclaimer Liability

While every effort will be made to ensure that the information contained within this report is accurate and up to date, Eindhoven University of Technology makes no warranty, repre-sentation or undertaking whether expressed or implied, nor does it assume any legal liabil-ity, whether direct or indirect, or responsibility for the accuracy, completeness, or useful-ness of any information.

Trademarks Product and company names mentioned herein may be trademarks and/or service marks of

their respective owners. We use these names without any particular endorsement or with the intent to infringe the copyright of the respective owners.

Copyright Copyright © 2019. Eindhoven University of Technology. All rights reserved. No part of the material protected by this copyright notice may be reproduced, modified, or

redistributed in any form or by any means, electronic or mechanical, including photocopy-ing, recording, or by any information storage or retrieval system, without the prior written permission of the Eindhoven University of Technology and DAF Trucks N.V.

i

Foreword Engine and Aftertreatment development is largely driven by the reduction of pollutant and Green House Gas emissions. This requires adequate definition of the Engine and Aftertreatment (sub-) systems individually as well as the integrated system. To improve the combustion and air management systems independently and enhance the integration of both, the combined use of Single Cylinder Engine measurements and air management simulation is evident. Within the developed framework an approach is defined to incorporate Single Cylinder Engine measurement data to account for the combustion characteristics in the DAF used simulation tools. The framework will be used to analyze and assess the integrated performance of newly defined combustion and air management system. Mohammad’s contribution in setting up this framework is highly appreciated and gives a solid base for integrat-ed analysis and assessment of new combustion and air management developments. Jarno Strik October 2019

iii

Preface A Single-Cylinder Test Facility was established within The Engine Test Center at DAF a few years ago, and this has created an immense opportunity for the simulation engineers to better test and develop high-efficiency low-emission engines. At every given time, many tests are ongoing on the single-cylinder engine. In the context of single-cylinder engine research studies at DAF, the need for a method to correlate the performance of single-cylinder engine to that of a six-cylinder engine has been the motivation to carry out this study. This report is the outcome of an eight-month study on the single-cylinder to multi-cylinder performance simulation framework. This novel study was conducted at DAF Trucks N.V. Engine Integration & Validation (EI&V) in Eindhoven from February 2019 to October 2019. Throughout the course of this study, the path toward the goal branched out in many different instances, each yielded invaluable insights to the matter. However, this report outlines the final outcomes concisely, neglecting the small details. The effort has been made to make the story line as clear as possible, yet include the critical information that the audience of this text would have to be informed of. GT-Power suite was a key tool in this study, therefore, knowledge of that would serve the readers in better understanding and reproduction of the re-sults. In general, the engine performance simulation engineers are the foremost audience of this study. That is due to the highly industry oriented nature of this type of research studies. Engineers would highly benefit from a simu-lation framework that leads them to multi-cylinder engine performance prediction based on single-cylinder ex-periments. Furthermore, individuals studying non-parametric combustion modeling approaches would be poten-tial users of this research. Mohammadsadegh Ariannazar October 2019 Eindhoven

v

Acknowledgements I would like to take the opportunity to extend my warmest gratitude to the people who have helped, assisted, guided and supervised me and my work throughout the course of this project. First and foremost, Mr. Gorkem Argalioglu (DAF Trucks) for his resourcefulness, assistance and guidance. His direct inputs has been a source of influence and inspiration for me. Furthermore, I would like to thank Mr. Jarno Strik (DAF Trucks) and Dr. Bart Somers (TU/e) for their supervision, guidance, and support. Their inputs lit the way toward successful real-ization of the goals of this project. Moreover, I am humbly grateful for the assistance, and insightful comments of Mr. Sankar Chandrasekar and Mr. Ignace van den Heuvel. Ultimately, I would like to thank Dr. Peter Heuberger, the managing director of Automotive Systems Design program for his honest guidance and support and Mrs. Ellen van Hoof-Rompen the Administrative Secretary of the program for her helpfulness and kindness toward me, over the course of the last two years of my stay in Eindhoven. Mohammadsadegh Ariannazar October 2019 Eindhoven

1

1.Executive Summary This chapter provides an insight to the context, including the relevant background of this research, the objec-tives, conclusion, and undertaken project management approach.

1.1 The Objectives The engine development process usually includes making choices between multitude of options for each engine components. Usually, different engine components influence each other’s performance through the feedback they induce on each other. For example, the performance of the combustion system on a Multi-Cylinder engine is inextricably influenced by the turbocharger’s performance. The components’ isolated performance study does not necessarily yield enough insight to properly select components for an engine. For example, the combustion system A could outperform B and C in an isolated performance study, however, once coupled with a certain turbocharger, combustion system B could be the top performer. The selection process is inherently a cumber-some task, since most of the times, the number of options are pretty large. This renders the testing of the engine performance under all of the imaginable combinations impossible. Moreover, usually the experiments are per-formed on a Single-Cylinder engine which is structurally different than a Multi-Cylinder engine. Making a cor-relation between the Single-Cylinder test results and the Multi-Cylinder engine performance compounds the selection task substantially. The purpose of this project is to serve as a preliminary roadmap that lays out the major steps in the establish-ment of a Single-Cylinder to Multi-Cylinder engine performance simulation framework. Such a framework is expected to bring the two types of engines closer in the simulations, and accelerate the engine development pro-cess.

Figure 1.1 - Typical Engine Development Procedure.

1.2 The Context This study is aimed at establishing the foundation of a simulation framework that allows for translation of a Sin-gle-Cylinder Engine (SCE) test results to that of a multi-cylinder engine (MCE) (Figure 1.2). The ultimate simu-lation framework would enable research engineers to predict the MCE performance based on the SCE tests. In other words, what the results would be, if the tests were done on an MCE instead of an SCE.

2

Figure 1.2 - Single-Cylinder To Multi-Cylinder Engine Simulation Framework One can list many reasons why SCEs have become so popular in research and development of the internal com-bustion engines. The following states a few:

• SCEs allow for more flexible boundary conditions that might not be feasible on an MCE. • SCEs are designed to be easy to troubleshoot, and cost-effective. • Addition and removal of different components such as piston bowls, injectors etc. is faster and easier

on an SCEs. • SCEs need less recalibration and when need be, they are more easily calibrated.

All of the abovementioned items are great advantages of having an SCE test facility. However, what finally is sought by the research studies is the performance of the MCE product. There comes the need for a framework to methodically correlate an SCE test results to that of an MCE. On the other hand, MCEs have characteristics that distinguishes them from SCEs:

• Auxiliary units (e.g. pumps) mainly rely on the engine itself. • The Turbocharger induces a feedback loop on the engine performance. • Tests’ boundary conditions are limited, though more realistic. • Preparations for tests are more time-consuming.

The first step in establishing a performance simulation framework is to recognize the subjects of analogy and the similarities and differences between them. After that, the efforts has to be made to maximize the benefits of similarities and minimize the gap between aspects of difference. The research on this topic is unbelievably scarce. This is mainly due to the industrial nature of the need for such a translation framework. The research on this subject is preserved in the companies and is treated as confiden-tial. One of the earliest published research studies on this subject can be found in (Topinka et al.), although it would only serve as an introductory material to this topic. Prior to the current study, a similar study but with a fundamentally different approach had been done at DAF (Vaidhiyanathan). The challenges in establishment of a valid simulation framework come from the structural differences between an SCE and an MCE. An SCE is equipped with many auxiliary units to support its functions. For example, it includes an EGR pump to ensure the desired EGR percentage even if the pressure boundary condition does not allow that to happen spontaneously. This was only one example and the list of the auxiliary units is quite long. The other major difference is the lack of a turbocharger on the SCE test facility. The desired boost pressure and the pressure drop across the engine is set by auxiliary units that are not available on a standard MCE. Therefore, the framework has to be able to address these issues in a comprehensive and methodical manner. Ultimately, the goal of this study is to specify the steps to be followed to predict MCE performance based on SCE test results. In addition to that, investigation of this approach’s potentials for conducting further studies on MCEs performance would provide great insights into this matter.

3

1.3 Problem Solving Approach The simulation framework aims to replicate the SCE combustion on the MCE. In order to do so, it has to ad-dress the differences between the two types of engines and compensate for them. Most importantly, it should combine the turbo-matching procedure with combustion modeling.

Figure 1.3 - Problem Solving Approach. The development process started with a thorough parameter identification that laid out the correlation status of the two engines. That activity identified certain characteristics of the two engines and also a number of other parameters as equal. After combustion modeling and proper adjustment made prior to transition from single-cylinder to multi-cylinder model, a turbo-matching activity completed the transition process.

1.4 Conclusion Combustion modeling is still an exciting topic in the automotive industry. Extensive research studies has been carried out on the optimization of overall engine performance throughout the history of the internal combustion engines. SCEs are great research tools that allow for tests beyond commercial MCEs’ potential. Yet the means and methods to correlate the SCE performance to that of an MCE are scarce, underdeveloped and hidden. This study was an initial attempt to establish a simulation framework at DAF Trucks Engine Integration & Valida-tion. The current study showed that this novel approach in combustion modeling has the potential to reduce modeling and test time, while predictability has been maintained. Moreover, this approach is unique in combining com-bustion modeling and turbo-matching, a feature that expedites developments. The need for running extensive tests on the SCE could be a downside of this approach, however, that need (usually extensive tests) is also pre-sent in any other test-based modeling approach. ■

5

A. Project Management This section provides an overview of the project management plans of the current study. The stakeholders anal-ysis and the position of this study has been demonstrated by way of diagrams. The initial, intermediary and final status of the project plan is laid out. Ultimately, the project retrospectives specifying lessons learnt concludes this chapter.

A.1 Stakeholders Analysis The following demonstrates the organizational chart of the stakeholders involved in this study. The main com-pany stakeholders of each phase has been outlined by a red line (Figure A-1). The project was initially divided into two phases. The first being a MATLAB-based Energy Balance Tool (EBT) development, and the second being the simulation framework establishment. Figure A-2 shows the position and significance of the current study in the overall engine development process. The SCE2MSCE simulation framework expedites the devel-opment process by attributing the SCE performance to that of the MCE directly and combining combustion modeling and turbo-matching altogether.

Figure A-1 Stakeholder Analysis - Organizational Charts

Figure A-2 Positioning The Project In The Grand Scheme Of The Engine Development At DAF.

6

To be noted, the main channel of communication with the stakeholders was meetings. In addition to that, elec-tronic correspondence with the stakeholders was a common way of contact.

A.2 Project Plan Initially, the project was planned according to Figure A-3. At the beginning, it was believed that the project would have two equally important sub-phases being the MATLAB-based in-house Energy Balance Tool (EBT) development and Pumping Work conversion.

Figure A-3 Initial Project Plan The development of the EBT was accomplished by taking a V-Cycle approach (Figure A-4).

Figure A-4 Initial Project Plan

After a while though, the dynamics of the project shifted more toward the second phase (i.e. Simulation Frame-work) as it turned out to be of higher priority for the stakeholders. Therefore, the planning changed with the priorities (Figure A-5). As the end of the project was approaching, more interesting ideas in answer to “what-else could be done?” began to form. Ultimately, the following shows the actual roadmap of the project.

7

Figure A-5 Final Project Roadmap

A.3 Project Retrospective There is no doubt that industry level experience is a must to a comprehensive education. The opportunity to work at DAF for this project was a top-level unparalleled one. In addition to the technical support, the exercise of professionalism by the colleagues was a great source of inspiration. No project is carried out in a perfect, ideal situation. Part of the challenge is adaptation to the situation and op-timization of the performance. That is a great lesson that an engineer can learn, only by working in a real com-pany environment. Usually at the beginning, the progress is slow because many aspects of the project is un-known to everyone. An engineer should learn how to handle the start of the project to be smooth, and how to layout a big picture for everyone associated. Benjamin Franklin's phrase "If you fail to plan, you plan to fail” is a good motto to remember. Although the projects and their requirements are very dynamic and this makes plan-ning difficult, always having a plan of approach is beneficial. The projects such as this are usually the first industry experience of the trainees. They are great opportunities for these people to practice soft skills such as communication, time management and organization. To fully unlock the growth potential, an engineer should utilize appropriate tools for the work. Tools used in technical and non-technical aspects of the project. As long as technical tools are concerned, proper acquaintance serves the engi-neers well. Regardless of the rigorousness of the work schedule, a proportionate amount of time should be as-signed to self-training, specifically on required technical tools. The importance of proper documentation cannot be emphasized enough. Having a continuous and consistent documentation method is crucial to the success of any project. Especially for relatively long term projects where from the start till the end, the work will branch out at many instances. A consistent documentation helps engi-neers capture the evolution of the project. Moreover, technical people are not fond of documentation usually, however if the project is documented continuously, it will not be agonizing anymore. Last but not least, maintaining a positive attitude, proper communication of concerns, and a healthy level of self-confidence are the key ingredients of success.

9

About the Author

Mohammadsadegh Ariannazar has a bachelor’s degree in Mechanical Engi-neering from Amirkabir University of Technology (Iran) and a Master’s de-gree form Sharif University of Technology (Iran) in Automotive Engineer-ing. Throughout his years of study, he specialized in Combustion and Ther-mo-Fluid Systems Modeling and Numerical Analysis. He is interested in multi-physics phenomena modeling, numerical simulations and testing. He has been pursuing a Professional Doctorate in Engineering (PDEng) at The University of Eindhoven from October 2017 to October 2019 where he worked on the present study in collaboration with DAF Trucks N.V. Engine Integration & Validation as a partial fulfillment of his degree.

Where innovation starts