Lithium-Ion Battery Simulation for Greener Ford Vehicles

HVAC
SPACECLAIM CORP., CONCORD, MA
3D Direct Modeling Streamlines Micro-Cogeneration System
Design and Analysis Processes
Multiphysics software is used to analyze and optimize heat conduction and thermal structure interaction.
SPACECLAIM CORP., CONCORD, MASSACHUSETTS
SYNGAS specializes in thermal and
micro-thermal technology, and designs
and analyzes pre-production heating,
cooling, and thermal insulation systems
for a variety of applications. They
provide engineering support to research
centers and fuel cell manufacturers working
with complex catalyst and hydrogen
fuel cells for micro-generation systems.
Micro-cogeneration systems are refined
to be as effective as possible at
utilizing fuel cell power. These micro-cogeneration
systems are built to provide
efficient heating and cooling systems for
home and commercial use by converting
materials like kerosene or natural gas
into hydrogen, which then powers the
fuel cell and manages the energy flow for
either heating or cooling. In homes, these
systems are used for both heating and
air conditioning applications. In commercial
applications such as airplanes,
there is never any shortage of heat due
to the engines, and the systems are used
to provide much needed air conditioning
to keep passengers comfortable.
The company uses SpaceClaim and
COMSOL software to analyze and optimize
heat conduction and thermal
COMSOL Results of Heat Exchange and chemical
reactions that occur while reforming hydrocarbons.
This cross-section shows the temperature
field and heat flux between two reactors.
structure interaction. In order
to design systems that get
the most out of fuel cells, the
company needs to constantly
iterate the 3D geometry and
test it in COMSOL to figure
out what works and what
doesn’t. Previously, the company
had to request edits from
trained CAD experts or struggle
with CAD on their own,
which slowed implementation
of ideas, consumed valuable
time, and reduced the ability
to serve new customers.
In search of a better solution, the company
found SpaceClaim and saw that it
was being utilized by numerous COM-
SOL users as a tool for analysis preparation
and for 3D geometry editing and
creation. SYNGAS uses SpaceClaim to
analyze and edit more designs, enabling
them to improve and increase the quality
and the rate of output.
SpaceClaim imports geometry directly
from SolidWorks and other CAD systems,
significantly easing the process
of making edits and updates to existing
data. The company can easily de-feature
CAD geometries — removing any parts,
faces, or holes that are irrelevant to
analysis — and then move to COMSOL
to test the quality and efficiency of the
model, and, if required, return the model
to the native CAD system.
For concept modeling, SYNGAS is also
developing new ideas in SpaceClaim.
SYNGAS’s complex models, many of
which were originally created in Solid-
Works, can be directly opened in Space-
Claim, which enables all the disparate
parts to be merged into one solid to drive
the analysis. In these assemblies, there
are often numerous instances of small
features such as screws in holes, which
are problematic for COMSOL. Space-
SpaceClaim Model of the Reactors and Heat Exchangers for
a compact reforming system that produces hydrogen for a
100kW fuel cell stack.
Claim is used to first delete the screw
design and then fill in the hole by extending
surrounding material. Additionally,
many SYNGAS models are drawn with
fillets or round edges, which are often
necessary to avoid stress concentrations
at the straight intersections but are unnecessary
for simulation. SpaceClaim
allows modification of the drawing and
the ability to change the angles to make
sure everything is properly arranged
for analysis.
SYNGAS focuses on conceptualization,
not production, and a fully featured
parametric CAD system was not
the right tool to create and simulate
concepts. Without intensive and timeconsuming
training, users became proficient
with SpaceClaim’s 3D Direct Modeling
tools and were able to immediately
concentrate their energy on their areas
of expertise. The company’s work is
not to draw plans for machining, but
to imagine and conceive new systems,
which is done efficiently and effectively
with SpaceClaim.
This work was done by Paul Gateau
of SYNGAS using software from
SpaceClaim and COMSOL. For more
information, visit http://info.hotims.com/
28057-151. ■
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