Vehicle Design - Part 1

University Transilvania of Braov, Laboratory of Fluid Power and Sonics Professor Horia Abaitancei, PhD, h.abaitancei@unitbv.
ro,
Overview on Research Projects
idea simulation experiment
Summer 2011
University Transilvania of Brasov
Institute ProDD Department D02
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Overview on contents
Overall vision Simulation / Research possibilities
Examples of research projects

ICE Fluid power Vehicle testing Agricultural systems Conclusions
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Development vision
Research activities: fundamental research demonstration models applied / industry research Systems:
Vehicle propulsion systems engine gas exchange systems injection system valve train systems
hydraulic & sonic propulsion energy recovery free piston engine Concept car Working devices recovering energy for lifting systems hydraulic log lifting system pumping devices bicycle Energy systems pumping system for heat pumps street energy recovery system
Methods: CAE : CAD CFD FEA MBA - MPA Experimental system analysis fluid power measurments noise and vibration measurements engine performance and emissions Neuro fuzzy system identification Dynamical system theory
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Overview on Research Facilities

Software
CAD: CATIA V5 CFD: Fluent Hydraulics: DSH+ MBA: LMS Virtual.Lab; MSC Adams MSA: LMS Amesim; MSC Easy 5 FEA: LMS Virtual.Lab; MSC Patran / Nastran Special AVL Partnership: Boost 1D engine CFD Hydsim fluid power Fire 3D CFD Excite MB / FEA Cruise vehicle dynamics
Testing facilities
Engine test rig Horiba Emission control system AVL
Fuel properties testing rig

Mobile Hydraulic pressure and flow measurement system Vehicle vibrations and dynamics testing equipment Concept car
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Overview on research projects and partners

fundamental research ICE gas exchange systems ICE pressure wave analysis of ice injection systems Fluid Power Systems power transmission using waves in liquids hydraulic systems dynamical phenomena NVH vibration system identification
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Overview on industry research projects and partners

Support / joint research industry projects:
pressure wave supercharger CFD analysis dynamical analysis of valve train
RO
identification and optimisation of pressure waves of the injection system

RO DE AT BE/RO DE USA DE
gas exchange system optimization

friction analysis vibration analysis mobile hydraulic hammer
partnerships under
construction
RO
USA/RO DE/RO
DE/RO
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EXAMPLES OF Internal Combustion Engines APPLICATIONS
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Pressure Wave Supercharger

Torque
420 400 380 360 340 320 300 800 1000 1200 1400 1600 1800 2000 2200
Torque(N.m)
Goal torque curve

Torque TC (N.m) Torque PWSC (N.m)
Engine speed(rpm)
The TC model
Goal: replacing turbocharger with pressure wave supercharger for low speed torque and dynamic response improvement
Boost pressure
2.7
Pressure MeasuringPoint 1(bar)

2.6
Pressure(bar)
2.5 2.4 2.3 2.2 2.1
Ideal engine charging pressure for goal Engine speed(rpm) torque curve
800 1000 1200 1400 1600
1800
2000
2200
The PWS model

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PWS Process Simulation 1D simulation influence of cell length

Air High Pressure
0.132 0.13 0.128
0.17
Burned Gases High Pressure

93mm(MPa) 110mm(MPa) 150mm(MPa)
0.16
Pressure(MPa)
0.126 0.124 0.122 0.12 0.118 0.116 0.114 0.112 0 90 180 270 360 450 540 630 720
Pressure(MPa)
0.15 0.14 0.13 0.12 0.11 0 90 180 270 360 450 540 630 720
CRANKANGLE(deg)
CRANKANGLE(deg)
Air Low Pressure

0.0965 0.096
0.1055
Burned Gases Low Pressure

0.105
Pressure(MPa)
0.0955 0.095 0.0945 0.094 0.0935 0.093 0 90 180 270 360 450 540 630 720
Pressure(MPa)
0.1045 0.104 0.1035 0.103 0.1025 0 90 180 270 360 450 540 630 720
CRANKANGLE(deg)
CRANKANGLE(deg)
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PWS Process Simulation 1D simulation influence of cell length
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PWS Process Simulation mechanical analysis Normal modes analysis 1st normal frequency: 540 Hz Thermal analysis: Maximum displacement 0,48 mm / 700 K
Structural analysis: at 15000 rev/min
Maximum stress: 108 MPa

University Transilvania of Brasov Institute ProDD Department D02
11/40
Acoustical supercahrging
Goal: acoustical engine supercharging Research steps: 1D geometry identification for maximum pressure wave amplitude depending on engine speed 3D CAD integrated on given engine geometry Results: pressure wave amplitude, CAD Model
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Combustion chamber flow analysis

Goal: identification of ICE cylinder flow for different inlet geometries to improve cylinder turbulence Research steps: CAD generation Definition of different inlet system shapes 3D CFD dynamic analysis Results: diagonal positioning for maximum flow coefficient and turbulence generation
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Injection process analysis
Goal: identification of injection process and spray development Research steps: Constant volume chamber fast image recording 3D spray simulation (Fire) Results: model calibration influence of injection pressure on spray development
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Exhaust system analysis
Goal: Coupled mechanical and CFD (1D, 3D analysis) Analysis of identification of injection process and spray development
Research steps: Normal modes analysis for different geometry 1D thermodynamic analysis of engine and exhaust pipe system; pressure wave amplitude identification for different geometries
Results: Optimized geometry for mechanical and exhaust pressure wave amplitudes
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Dynamic flow process analysis ICE injection system

Experiment vs Simulation difference [%]
3 2
1
0 -180-160-140-120-100 -80 -60 -40 -20 0 -1 -2
20 40 60 80 100 120 140 160 180
Goal: pressure wave ICE injection systems Research steps: Injection system model design for different geometries; Model calibration Identification of optimum geometry for minimum pressure wave amplitudes Results: geometry of the injection system
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Bio-fuels combustion research

Goal: identification of optimum combustion chamber shape using biofuels
Research steps: Combustion chamber shape definition Fuel definition Spray simulation (Fire)
Results: fuel distribution, emissions
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Engine valve train analysis tappet rotation
Goal: valve train valve assembly rotation Research steps: Multi body (Virtual Lab) simulation Results: Influence of geometry parameters on tappet rotation
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Homogeneous Mixture in Compression Ignition Engine
Gasoline HCCI engine with camphasers (gas trapping method)
HCCI engine model AVL Boost
HCCI operating parameters cylinder prerssure, valve lifts, injection timing)

University Transilvania of Brasov Institute ProDD Department D02
19/40
Engine friction analysis
Goal: ICE friction analysis Research steps: thermodynamic model, engine kinematics modeljournal bearing model Results: Crank angle dependent minimum oil film thickness Crank angle dependent friction power loss
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FEA mechanical / thermal / normal modes
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EXAMPLES OF FLUID POWER APPLICATIONS
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Example of integrated project conception solution development vehicle integration
Goal: integrated model; pressure wave engine coupled with hydrostatic transmission integrated on a vehicle Research steps: Pressure wave engine definition Running resistance definition CFD / FEA analysis Fluid power actuation scheme Results: CAD model Digital mock-up CFD/FEA
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Timber lifting system

Goal: Hydraulic / mechanical design of a timber lifting system Research steps: Multy domain analysis : planar mechanical / fluid power analysis Results: system forces, mechanical, fluid power, control parameters
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Timber lifting system - continued
CAD Model
MB Analysis
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Timber lifting system - continued
mechanical parameters
fluid flow parameters
control parameters
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Hydraulic Hybrid propulsion system
Goal: Development of simulation and experimental demonstration vehicle with series hydraulic hybrid propulsion system integrating shock and brake energy recovery Research steps: Simulation model (Amesim) Experimental model Results: Overall efficiency evaluation Simulation model Concept vehicle A hydraulic propulsion, + engine running conditions B brake energy recovery + 40% C shock absorber energy recovery + 8%
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Hydraulic hybrid propulsion system - performances
Engine speed Emissions Consumption
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Shock absorber energy recovery
Goal: Principle demonstration of shock absorber energy recovery Research steps: Simulation model (Amesim) Test rig Test vehicle Results: Oscillation computation & measurement
1st price Youth Innovation Fair 2007 organised by the Romanian Youth Ministry
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Fluid power optimisation vision

advantages
Fluid power energy source
Free piston solution
Thermodynamic efficiency () Mechanical
Transmission line
Pressure wave based transmission Sonic system
power loss simple system
Hydraulic actuators
Sonic motors and cylinders brakes, shock absorber, lifting systems
power loss simple system
Recovery systems
overall efficiency
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Free piston solution for efficient fluid power energy generation project start - up
Free piston solution
free shape of compression function + efficiency; simple variable engine displacement + consumption; + emissions. compact + lower mass
Conventional coupling of ICE with hydraulic pump sine function for piston movement, friction losses;
Goal: Principle demonstration and performance evaluation Research steps: Simulation model (1D multy domain, CFD, FEA), Test rig model; Vehicle application
Results: to be evaluated end spring 2012
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Sonic propulsion system based on pressure waves propagated in liquids - principle demonstration
Goal: Principle demonstration as vehicle propulsion system and fluid power actuation system Research steps: Concept, optimum system structure development Influences on liquid pressure waves identification Simulation model (1D multy-physics< CFD; FEA) Test rig model, Concept car
Results: Ongoing testing: efficiency evaluation
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EXAMPLES OF INTEGRATED VEHICLE APPLICATIONS
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Running cycle comparison of alternative propulsion systems

using propulsion system model with driver and test cycle models (Amesim)
Fuel economy EPA Highway [mg/s]

Conventional propulsion Automatic drive Series electric hybrid
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Vehicle dynamics & vibration analysis

Goal: Vehicle active control suspension testing Research steps: Oscillation measurement for different running conditions
active suspension main parts
Results: Data for multy physics model calibration
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EXAMPLES OF AGRICULTURAL SYSTEMS APPLICATIONS
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Joint force analysis coupled with FEA of agricultural working devices
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Dynamic analysis of seeding devices and traction and working devices Seeding device sub system kinematics and dynamics
Goal: Agricultural equipment development Research steps: Modeling of system dynamics Results: Concepts and experimental, tested solutions
System assembly identification
Integrated device for soil treatment and sapling seeding

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Conclusions
Joint participation at research projects
Research projects with subventions from the Romanian State
Bachelor, Master, PhD thesis with subjects from industry
Development of continuous education centre joint participation at student / engineering design / innovation competitions: e.g. mini baja
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Thank You for Your Attention !
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University Transilvania of Braov, Laboratory of Fluid Power and Sonics Professor Horia Abaitancei, PhD, h.abaitancei@unitbv.

Overview on Research Projects

idea simulation experiment

University Transilvania of Brasov

Institute ProDD Department D02

Overall vision Simulation / Research possibilities

Examples of research projects

University Transilvania of Brasov

Institute ProDD Department D02

University Transilvania of Brasov

Institute ProDD Department D02

Overview on Research Facilities

Fuel properties testing rig

University Transilvania of Brasov

Institute ProDD Department D02

Overview on research projects and partners

University Transilvania of Brasov

Institute ProDD Department D02

Overview on industry research projects and partners

identification and optimisation of pressure waves of the injection system

gas exchange system optimization

University Transilvania of Brasov

Institute ProDD Department D02

EXAMPLES OF Internal Combustion Engines APPLICATIONS

University Transilvania of Brasov

Institute ProDD Department D02

Pressure Wave Supercharger

Goal torque curve

Pressure MeasuringPoint 1(bar)

2.5 2.4 2.3 2.2 2.1

The PWS model

University Transilvania of Brasov

Institute ProDD Department D02

PWS Process Simulation 1D simulation influence of cell length

Burned Gases High Pressure

93mm(MPa) 110mm(MPa) 150mm(MPa)

Air Low Pressure

Burned Gases Low Pressure

93mm(MPa) 110mm(MPa) 150mm(MPa)

University Transilvania of Brasov

Institute ProDD Department D02

PWS Process Simulation 1D simulation influence of cell length

University Transilvania of Brasov

Institute ProDD Department D02

Structural analysis: at 15000 rev/min

Maximum stress: 108 MPa

University Transilvania of Brasov

Institute ProDD Department D02

Combustion chamber flow analysis

University Transilvania of Brasov

Institute ProDD Department D02

Injection process analysis

University Transilvania of Brasov

Institute ProDD Department D02

Exhaust system analysis

University Transilvania of Brasov

Institute ProDD Department D02

Dynamic flow process analysis ICE injection system

20 40 60 80 100 120 140 160 180

University Transilvania of Brasov

Institute ProDD Department D02

Bio-fuels combustion research

Results: fuel distribution, emissions