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Development of Tools to Automate the Analysis of Turbo-MachineryTom Lincoln / Jaideep BangalTom Lincoln / Jaideep Bangal
Cooper Standard / Altair Engineering, Inc.
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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
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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
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History
2011
2012
20052006
2007
2007
1960 1999 2000 2004
2010
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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
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Global Customers
RENAULT
HYUNDAI
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Breadth of Product & Segments
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Thermal Management – Key Capabilities
Heating and cooling management systems for
hybrids, electric vehicles and internal combustion engines
Electromechanical DevicesThermal DevicesThermal Integration
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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
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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.
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Early CFD Analyses – August 2005
• Combination Tet and Hex cells
• Uniform mesh size• Significant time to set-up
manually
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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
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5000 7000 9000 11000 13000
Pre
ssur
e G
ain
Flow Rate
Comparison Between Measured Data and CFD Prediction
Measured Pressure GainPredicted Pressure Gain
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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
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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
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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
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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
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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
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0.800
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1.200
0.000 0.200 0.400 0.600 0.800 1.000 1.200
Test …First Run
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Boundary Layer = 1.4 mmMesh Size 7 mm
Flow
Pre
ssur
e G
ain
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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
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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
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AcuSolve Results
Contours of Static Pressure Contours of Velocity
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AcuSolve Results
Velocity Profile
Pressure Distribution
Velocity Profile
Pressure Distribution – fluid
volume
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AcuSolve Results
Contours of Pressure on Planes Cut Through a Pump
Contours of Velocity on Planes Cut Through a Pump
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AcuSolve Results
Pressure Distribution Velocity Profile
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AcuSolve Results
Pressure Distribution Velocity Profile
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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
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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
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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
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AcuSolve Results
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Thank You