Detailed Engine Thermal Model for Vehicle Energy Management ...

Detailed Engine Thermal Model for Vehicle EnergyManagement SimulationsGT-User Conference 2011, 24.10.2011, Frankfurt/MainDr. M. Weinrich, R. Rossmann, Daimler AGDr. M. Grill, A. Tonev, M. Sossio, FKFS/

Agenda• Project goals• Test Bench• Heat Balance Measurements• Friction at low temperatures• Operating points and model validation• Hydraulic and thermal modeling• Results• Integration in vehicle environment• Summary and OutlookGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 2

GoalsMeasurementsModel Calibration& Engine SimulationExtendedHeatBalanceBenefits:• Reduction of measurement points and duration• Further conclusions for• non-measured operating points• Effect of minor changes in hardware• Effect of application changes• Future development:Use of a simplified model (fast running model) invehicle simulationreal worldtest bench environmentvirtual worldtest bench environmentVehicle Simulationvirtual worldvehicle enironmentGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 3

Test Bench – Heat Balance(1) Test bench environment with conditioning• Measurement technique used for outerheat balance as a standard process• Cooling of coolant, oil and intake air withexternal conditioning• Measurements extended with full pressureindicationp cylinder(2) Measured parameter for outer heat balance• rotational speed, torque, different fluidtemperatures and pressuresPowerExhaust gas heatCoolant heatOil heatIntercooler heat…T water_in1 2 3coolantconditioning intercoolerT water_out4 5 6T oil_inoil conditioningT oil_outT 2T cylinderT 3(3) Measured parameter for inner heat balance• Cylinder pressure• Low pressure indication• ECU data: injection etc.GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 4

Friction test benchFriction Test bench• Measurement are necessary to develop a frictionmodel• Operating range from -20°C to 100°C• Correlation for oil sump temperature to frictionpointsP crankcaseT surfacep intake cyl2T water_inT surface cylinder headT oil_panM friction torqueT main_bearing_4T main_bearing_2T water_outT oil_sumpT oil galeryp oil galeryT surfacep intake cyl5GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 5

Operating points for model calibration and validation1. Measurements of 18 stationary operatingPoints2. Measurement of friciton dragmeasurementsBMEP [bar]engine speed [rpm]temperature [°C]3. Engine warm up measurementsT_water_outT_water_intemperature [°C]Necessary measurements1. Stationary points (fired) for validation ofdetailed engine model and heatdistribution (heat balance)2. Stationary points (motored) at differenttemperatures for friction model3. Transient warm up for over allcalibration of thermal net and completemodeltime [s]GT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 6

Hydraulic model of the coolant circuit1. Discretisation2. Export usingGEM3D3. StructuringGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 7

Stationary Points - Simulation vs. MeasurementRadiation, oil- and coolant enthalpyRadiationQ_oil (T_oil 130°C)Q_coolant (T_water 105°C)S M S M S M S M S MGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSS = SimulationM = MeasurementFolie 8

Engine Model in Test Bench EnvironmentCombustion &gas dynamicsSimple ECU modelCouplingWatercircuitOilcircuit &thermalmassesGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 9

Integration into full vehicle simulation environment• Full Vehicle simulation: slow with coupleddetailed gas dynamic and combustion model• Coupling of engine and vehicle circuits• Investigations for engine heating up andthermal comfort for passengersGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 10

Example for Vehicle Simulation - NEDCGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 11

Example for Vehicle Simulation - Cabin Heating UpGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 12

Summary and OutlookSummary• Measurement of inner and outer heat balance (high and low pressure indication)• Modeling of a detailed gas exchange and a predictive combustion model• Use of GEM3D for creation of the hydraulic network• Additional friction investigations at low temperatures and extended friction model• Manual generation of the thermal networkBenefits:• Calculation of not measured operating points• Different level of detail for model depending on investigation focus• Investigation of changes in combustion and minor hardware changesOutlook• Focus on gasoline engine• Simple FE structure model for thermal network• Fast Running Model of the detailed gas exchange and combustion model• Integration of detailed ECUGT-User Conference 2011, Dr. M. Weinrich, R. Rossmann, Daimler AG; Dr. M. Grill, A. Tonev, M. Sossio, FKFSFolie 13