development of tools to streamline the analysis of turbo-machinery - cooper standard
DESCRIPTION
Cooper Standard partnered with Altair to create a tool in AcuSolve to speed the set-up of centrifugal pump CFD analyses. This tool steps the Engineer through the selection of the components to the pump and then automatically identifies and meshes the surfaces in the model. This presentation will detail how the AcuSolve move has been a huge success with Cooper Standard.TRANSCRIPT
Development of Tools to Automate the Analysis of Turbo-MachineryTom Lincoln / Jaideep BangalTom Lincoln / Jaideep Bangal
Cooper Standard / Altair Engineering, Inc.
Executive Summary
• Cooper Standard (CS) Corporate Overview
• History of CFD at Cooper Standard
• Cooper Standard adoption of AcuSolve for enhanced C FD efficiencies
and accuracy
• Additional AcuSolve Applications at Cooper Standard
About Cooper Standard
Our Mission
Headquarters: Novi, MI
Established: 1960
Employees: 21,500+
Locations: 70+ in 19 Countries
Provide outstanding service, support
and innovative solutions to our
customers benefiting all stakeholders
of Cooper Standard.
2010 Top 100Global Suppliers: Rank 62
2010 Top 100 North American Suppliers: Rank 35
2011 Sales: $2.85 B
History
2011
2012
20052006
2007
2007
1960 1999 2000 2004
2010
Strategic Footprint
North America
Europe Asia Pacific
HeadquartersSales / AdministrationTechnical CenterManufacturingManufacturing / Technical Center
Key
South America
AustraliaBelgiumBrazilCanadaChina
JapanKoreaMexicoNetherlandsPoland
CountriesCzech RepublicFranceGermanyIndiaItaly
RomaniaThailandUnited KingdomUnited States
2012 - Located in 19 Countries2004 - Located in 14 Countries
Cooper-Standard Saiyang Wuhu 94% /6%Cooper-Standard NISCO 40% / 60%Cooper Hubei Jingda 37% / 63%Metzeler India 74% / 26%Cooper Hasco China 47.5% / 47.5% / 5%Guyoung Tech Korea 20% / 80%Cooper Standard France 51% / 49%Nishikawa Tachaplalert Cooper Limited 20% / 80%
Joint Ventures
Global Customers
RENAULT
HYUNDAI
Breadth of Product & Segments
Thermal Management – Key Capabilities
Heating and cooling management systems for
hybrids, electric vehicles and internal combustion engines
Electromechanical DevicesThermal DevicesThermal Integration
Technology
• Automotive News PACE Award
Honorable Mention• Electric Water Valve Assembly
• Thermoplastic Rear Door Glass
Seal Assembly
• Metal to Plastic Fluid Connection with
Overmolded Anti-Rotation Retainer
Global Six Sigma Award Best Achievement of Design for Six Sigma
• Coolant Water Valve
Over 500 Patents Globally• Daylight Opening Modules• Engineered Stretched Plastics• Occupant Detection Systems• Low Fuel Permeation Nylon TubingOvermolded Anti-Rotation Retainer
• Day Light Opening (DLO) System
• Society of Plastics Engineers
Most Innovative Use of Plastic: Finalist• Electric Water Valve Assembly
• Transmission Thermal Valve Assy
• Electric Brushless Pump
• Low Fuel Permeation Nylon Tubing• Quick Connect Fluid Couplings• Core process methods
cooperstandard
Cooper Standard’s History With Pumps
• Cooper Standard identified a market for electricall y driven coolant
pumps.
• Development began in 2005, CFD was used from the st art.
• Cooper Standard offers pumps to replace the vehicle main water pump
and auxiliary supplemental flow.
• Wattages range from <20 W to 1 kW.• Wattages range from <20 W to 1 kW.
Early CFD Analyses – August 2005
• Combination Tet and Hex cells
• Uniform mesh size• Significant time to set-up
manually
CFD Analyses – June 2010
• ~5M cells ranged from 0.2 mm to 2 mm • Manual set-up required a full day and 6-
10 hours to converge each flow point
0.00
0.20
0.40
0.60
0.80
1.00
1.20
5000 7000 9000 11000 13000
Pre
ssur
e G
ain
Flow Rate
Comparison Between Measured Data and CFD Prediction
Measured Pressure GainPredicted Pressure Gain
Early CFD - Challenges
• Results were good but• Model set-up would take 8+ hours
• Each flow point would take 4 – 10 hours to converge
• 6 flow points for one pump = 40+ hours
• Meshing was manual and required expertise to generate a good mesh
AcuSolve Process Automation
Import CAD / HM mesh
Define• Solids• Stationary Fluid• Rotational Volume
• Angular velocity• Rotation axis
• Process intelligence
• Fast setup: 4 steps• Auto meshing
• Auto solving strategy
• Auto Time steps calculation
11
22
Boundary Conditions
Inlet / Outlet
Automeshing
Auto time step calculations
SOLVE
10 minutes
Setup time
• Auto Time steps calculation
• Setup multiple flow points and run it batch mode
44
33
Cooper Standard Pump Analysis
• Goal: Predict pump performance, Flow Curve
• Reduce Setup and Solution time
• Enable CSA Engineering team to analyze designs early
Meshed Impeller
Pump – Meshed Model
analyze designs early
AcuSolve’s Rotating Machinery Process
• First run
• Very fast setup and solution
• Helped understand process and setup before adding m ore details
• Setup Time: 1 hour from receipt of CAD impeller
• Solution Time: 12 flow points – 10 hours
0.000
0.200
0.400
0.600
0.800
1.000
1.200
0.000 0.200 0.400 0.600 0.800 1.000 1.200
Test …First Run
16
Boundary Layer = 1.4 mmMesh Size 7 mm
Flow
Pre
ssur
e G
ain
AcuSolve’s Rotating Machinery Process
• Refined Mesh
• Analysis converged in 9 th iteration
• AcuSolve results matched test results
• Setup Time: Unchanged
• Solution Time: 12 flow points-24 hours1.200
17
Boundary Layer = 0.1 mmMesh Size 2 mm (on Impeller)
Flow
Pre
ssur
e G
ain
0.000
0.200
0.400
0.600
0.800
1.000
0.000 0.200 0.400 0.600 0.800 1.000 1.200
Test Pressure Gain
Final Converged Run
AcuSolve Results
Contours of Static Pressure Contours of Velocity
AcuSolve Results
Velocity Profile
Pressure Distribution
Velocity Profile
Pressure Distribution – fluid
volume
AcuSolve Results
Contours of Pressure on Planes Cut Through a Pump
Contours of Velocity on Planes Cut Through a Pump
AcuSolve Results
Pressure Distribution Velocity Profile
AcuSolve Results
Pressure Distribution Velocity Profile
AcuSolve’s Rotating Machinery Process
• 1-hour setup
• Automeshing ensures optimized mesh near critical flo w/impeller
features
• Accurate results
• Standardized inputs built into the tool
• 5 flow points can be run in 10 hours on a 4 core la ptop• 5 flow points can be run in 10 hours on a 4 core la ptop
• The tool is being rolled out to the Product Enginee rs to handle
increased demand
23
Additional Collaboration - Thermal Analysis –Pump
• Cooper Standard engaged Altair in a consulting proj ect to set-up the
initial AcuSolve models
• Altair transferred knowledge to Cooper Standard for future product
development
3D CAD Model Simplified FEA 3D Model
Additional Collaboration - Thermal Analysis -Pump
IR Camera Image AcuSolve Thermal Analysis results
AcuSolve predicted high temperature component locations and were later confirmed by IR camera
AcuSolve Results
Thank You