Comprehensive Software for Thermal Energy Management Optimization

www.ecs.steyr.com
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Who we are?

Who we are?
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Who we are? The Company

MAGNA International
Cosma International Magna Seating Magna Mirrors Magna Closures Magna Powertrain Magna Car Top Systems Magna Steyr Magna Electronics

Magna Exteriors & Interiors

Body & Chassis

Interior Systems

Exterior Systems

Seating Systems

Vision Systems

Closure Systems

Powertrain & Engineering

Roof Systems

Engineering & Assembly

Electronic Systems

ECS Engineering Center Steyr Complete Vehicle Engineering Technology & Software Development Vehicle Testing

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Who we are? The KULI Team

Department Energy & Fluid Simulation Department Leader E&F Simulation Christian Rathberger

Sales Rolf Salomon

Software Thomas Naderhirn

Services Dr. Christoph Stroh

Software Developers and Software Users exist under one umbrella!

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What is KULI?

What is KULI?
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Thermal Management Software

Powertrain Cooling Air Conditioning

Consideration of all Thermodynamic Key Values Temperatures Pressures Mass flow Heat flow Other Energy flows

Windows Desktop Software for the 1D-Simulation of the Vehicle Thermal Energy Management

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Gregor Breuer

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Thermal Management Software

Component & Function Toolbars

2D Fluid Network View

Project Organization

3D Air Network View

Analysis Progress Info

1-dimensional Fluid Network Analysis Quasi 1-dimensional Air Flow Network Analysis

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Gregor Breuer

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Energy Management Software

Transient Conditions
AC System Engine Model

Cooling System

Driving Cycles
2000 1500 1000 500 0 200 400 600 800 1000 1200 1400 1600 1800

Time [s]

Optimization CFD Analysis

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CoSimulation
COM-Interface

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Typical Applications
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Typical Application Top Tank Temperature

Input
KULI data for fans and coolers Volume flow data for all participating fluids Ambient temperature Driving velocity Rejected heat by the condenser Amount of glycol in the coolant

Results
Top tank temperature Air to boil Analysis of the operating points of the fans/coolers Additional results: Parameter variation (fan speeds, volume flows,...) on the above mentioned measurable variables

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Typical Application Concept Studies

Compare direct and indirect charge air cooling

low temperature radiator

conventional CAC water-cooled CAC

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Typical Application Minimize Package Size

Reduce heat exchanger sizes according to performance limits

400 mm 300 mm

297 mm 259 mm

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Typical Application Transient Simulation

Avoid oversizing of components due to steady state operating points
Zusatzwasserkhler
In 2 In Out Out In 1 In 2

Cooler

Thermostate

CA

CAC

Out In 1

Thermostat ByPass

Airpath [Water]
In In Out Out

Thermal capacities considered

X1 Out

CF
Exit temperature OM Oil ECU
In Out Out In Out

RPM_#ECU [1/min]
In

BMEP_#ECU [bar]
In

SPEED_#ECU [km/h]
In

BMEPcorrected RPMcorrected SPEEDcorrected p_#Ambient Temperature

2
X1

Oil x
Out

SP
Speed Ambient temperature Mean eff. pressure Ambient pressure RPM
In Out 1

Volume flow IM Temperature Pressure

X2

X2

X3

BMEP_#Amb [bar] RPM_#Amb [1/min] SPEED_#Amb [km/h] p_#Amb [hPa]

X2

BMEP
Out Out

RPM SPEED

Out

Pressure
Out

Out

T_#Amb [C]
Out

Out 2

Out

X1

1.49

KULI Engine Model

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Typical Application Cool Down Simulation

Find evaporator heat load such that passenger cabin cool down requirements are met

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Typical Application Energy Management

Energy Management Simulation for a Hybrid Truck

Driving Cycle (HUDDS)

Heavy-Duty Urban Dynamometer Driving Schedule

Fuel Saving Potentials Parallel Hybrid Vehicle

Battery, Coolant Temperature

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Application Cell Temperature Optimization

Battery type (Li-Ion, NiMh,) Internal resistance = f(current, temperature, SOC) Open circuit voltage characteristic = f(temperature, SOC) Heat source = f(current, internal resistance) Cell cooling Thermal network

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Why to use KULI?

Why to use KULI?

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Why Thermal Energy Management?

Fuel Consumption

Emissions

Engine power increasing

Costs

Durability

Inlet area decreasing (design) New technologies (e.g. hybrid) More components / auxiliaries Legislative Standards

Comfort

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Why to use Computer Simulation?

System Comprehension
Concept Studies Support Test Bench System Optimization Minor Model Update

Understand complex component interactions easily Effects of single measures can be within measurement accuracy
Fast analysis and solutions: Rapid Prototyping Save time and cost (test bench, prototypes)

Improve test quality through plausibility checks Reduce hardware test loops Quickly find measures for improvement Find control strategies for auxiliaries Computation only possibility of optimum validation Easy handling of engine upgrades Component replacements: compare different suppliers

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Why to use KULI? Low Hardware Demands

Desktop Application Works on any Laptop

Quick Simulation Steady state results within seconds

November 2010: KULI on iPad

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Why to use KULI? Realistic Results at Low Effort

Component & Function Toolbars

2D Fluid Network View

Project Organization

3D Air Network View

Analysis Progress Info

Learn to use within 2 days of Training

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Why to use KULI? Tailored to Customer Needs

From Engineers for Engineers

Transient Conditions AC System Engine Model

Specialized: Automotive Industry

Cooling System

Driving Cycles
2000 1500 1000 500 0 200 400 600 800 1000 1200 1400 1600 1800

Time [s]

Optimization

CoSimulation

CFD Analysis

COMInterfa ce

Modular Structure

Flexible Software: simple & complex

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Why to use KULI? Multitude of Features

Postprocessor
Output Analysis Presentation Material for Management Uniform Component Library Extendable Media Library

Water/Glycol, Oil, Exhaust, Refrigerant

Unit Converter Optimization Package Optimization, Parameter Variation Software Interfaces Excel, Matlab, CFD codes,

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Why to use KULI? Used by Global Customers

NORTH AMERICA EASTERN + WESTERN EUROPE

JAPAN

Enterex America
CHINA

SOUTH KOREA

INDIA

SOUTH AMERICA

Passenger Cars Trucks Construction/Farm Machines Trains | OEMs Suppliers Researchers

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Why to use KULI? Best Software Support

KULI Team

Support is given by all members of the KULI Team Expertise through product overview Expertise though product insight Expertise through product practice Friendly and personal

Department E&F Simulation

Sales

Software

Services

Working to YOUR advantage

Quick response

usually within 24 hours

Facility to enhanced support

Paid services for quick and reliable solutions

kuli_support@ecs.steyr.com
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Why to use KULI?

Low hardware demands

Desktop PC Short analysis time

Realistic results at low effort

Clear and brief GUI Easy to learn: fit in 2 days No hidden data

Tailored to customer needs

from Engineers for Engineers Specialized Software Flexible Software Modular structure

Multitude of features
Uniform Component Library Extendable Media Library Postprocessor Optimization Package Software Interfaces

Worldwide usage
KULI data available from majority of suppliers

Best software support

Quick response Expertise through practical use Facility of enhanced support (simulation services)

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Who to use KULI?

Who to use KULI?

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Who to use KULI?

Engineers related to Thermal Management (not restricted to Automotive Industry)

OEMs Design-Engineers Suppliers Researchers Engineering Service Companies Test-Engineers

CAE-Engineers

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When to use KULI?

When to use KULI?

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When to use KULI? - Product Development Process

Key Milestones: E K PT1 P PT2 B
PPAP R@R Disp

SOP

Program Management Product Specification Concept Development Virtual Model Product Design Simulation / DMU / Validation 1. Prototypes / Mules 2. Prototypes / Pre-Production

Functional- / Fatigue- / Vehicle Testing Product Validation Product Definition Product Creation Industrialization

Concept

Simulation

Prototyping

Funct. Testing

Vehicle Testing

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How to use KULI?

How to use KULI?

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How to use KULI? Data Structure OEM SUPPLIER

Vehicle Data
Design Engine

Simulation Conditions
Ambient Operating Status

Component Data
Dimensions Characteristics

Boundaries & Targets

Simulation Model

Max. Dimensions Max. Top Hose Temperatures

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How to use KULI? Workflow

Component Setup

Input data (Geometry, Characteristic)

Save in Component Library

System Setup

Load components (from Library)

Define Media Properties

Position and Connect Components

Input Simulation Parameters

Simulation

Run Analysis

Optimize, Vary Parameters

Results

Get Output from Postprocessor, Excel Sheet,

Compare with System Measurement Data

Interpret Results, Reporting

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How to use KULI? Postprocessor Output

Temperature levels and Pressure Drops

Heat Turn-over and Efficiency of Package

Userdefined Units

Data Filter
Detailed Conditions and amounts of Cooling Air Optimized Parameters depending on Targets

Various Graphics

Variant Comparison

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Where to get KULI?

Where to get KULI?

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 Global Contact
EASTERN + WESTERN EUROPE JAPAN NORTH AMERICA Albert TUERTSCHER AT engineering LLC 1891 Denver West Ct. #1432 Golden, CO 80401-0924 Phone: +1 734 276 5516 kuli.usa@ecs.steyr.com Rolf SALOMON Magna Powertrain Engineering Center GmbH & Co KG Steyrer Strasse 32 4300 St. Valentin, Austria Phone: +43 7435 501 2382 rolf.salomon@ecs.steyr.com CHINA Terra CAI Magna International China 801-813, Tower A, Eton Place 69 Dongfang Road, Pudong, Shanghai PRC 200120 Phone: +86 21 6165 1649 terra.cai@magnapowertrain.com SOUTH KOREA INDIA Yogesh RAHANE SOUTH AMERICA Leandro GARBIN VirtualCAE Servicos de Sistemas Ltda. Rua Tiradentes 160 - Sala 22 So Caetano do Sul, So Paulo (CEP 09541-220 ) Phone: +55 11 4229-1349 vendas@virtualcae.com.br Tata Autocomp Systems Ltd. Sr. No. 280 Village Mann, Tal Mulshi, Hinjewadi Phase II, Pune 411 057 Pune Phone: +91 20 6675 5496 yogesh.rahane@tacogroup.com TAE SUNG S&E Inc. Seoulforest Kolon Digital Tower II 10F Seongsu-dong2-ga, Seongdong-gu, 133-120, Seoul, KOREA Phone: +82 2 3431 2442 jkpark@tsne.co.kr Jong-Kwan PARK Terue GOTO Magna International Japan Inc. Yaesu Center Building 5F 1-6-6 Yaesu, Chuo-ku, Tokyo 103-0028, Japan Phone: +81 3 3548 0310 teruegoto@magnaint.co.jp

Passenger Cars Trucks Construction/Farm Machines Trains | OEMs Suppliers Researchers

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Summary
Rolf SALOMON Magna Powertrain Engineering Center GmbH & Co KG Steyrer Strasse 32 4300 St. Valentin, Austria Phone: +43 7435 501 2382 rolf.salomon@ecs.steyr.com

Characteristics
Quasi 1-dimensional Analysis of the Air Flow Consideration of Pressure Drops and Overlapping Tool for Developing, Analyzing and Testing Engineers

Input
Measurements of Components from Suppliers Temperature Measurements of Vehicle if available Demanded Dimensions and Positions of Components Coolant Flow Rates and its Heat Amount Operating Points of Vehicle and Boundary Conditions

Output
Heat Turn-over and Efficiency of Cooling Packages Temperature Levels Detailed Conditions and Amounts of Cooling Air

Benefits
Comfortable Handling Quick Analysis and Solutions High Flexibility Save Time and Cost

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