the role of simulation at changemdx2.plm.automation.siemens.com/...1-p2...bauer_0.pdfdaimler ag •...
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![Page 1: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/1.jpg)
The Role of Simulation at Change
![Page 2: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/2.jpg)
Daimler AG
Full Vehicle Thermal Management (VTM)
Seite 2The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
How is simulation integrated into the development process?
What are the success factors of simulation of today?
Are simulation and testing equivalent ?
![Page 3: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/3.jpg)
Daimler AG
• ca. 400 000 cells
• 3 weeks of computation time
• 9 months for meshing
• Role of simulation: nice to have
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 3
First Generation of Simulation Model for Underhood (1990)
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Daimler AG
•1.4 Mio cells in total
•1.0 Mio engine compartment
•0.2 Mio underbody
•0.2 Mio external region
•Role of simulation: treated more serious
Second Generation of Simulation Model for Underhood
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 4
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Daimler AG
Latest Generation of Simulation Model for VTM
Seite 5The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
•120 Mio cells (Hexahedral mesh)
•40 Mio cells (Polyhedral mesh)
•Role of simulation: fully accepted
![Page 6: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/6.jpg)
Daimler AG
� Vehicle components
� Exhaust system
� Heat exchange package
� engine
� Dynamic load cases
� Reproduction of the time depend temperature behavior of all thermal relevant components
Latest Generation of VTM Physical Modeling
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 6
![Page 7: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/7.jpg)
Daimler AG Seite 7The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
Load case vmaxLoad case up hill drive
Load Cases - vmax, up hill drive,
etc.
Full VTM Process Testing
Simulation -
which boundary conditions ?
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Daimler AG8
Safety of Prediction Flexibility Efficiency
General Requirements on Full VTM Simulation
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 8
Omission of Vehicle
Hardware Substitution
by Simulation
Shortening and Modifications of
Development Process
“Mass Production of VTM
Simulation”
0
10
20
30
40
50
60
70
Duration of a CFD Simulation [days]
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Daimler AG
Continuous Improvement Process for VTM Simulation
Source: M. Disch (upcoming Ph.D thesis, FKFS)
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 9
Dissertation Dr. Weidmann
„Engine Soak“�
Dissertation Mario Disch
Simulation Transient Driving Up hill
Dissertation Frau Michel
„Transient Load Cases TAG E/E“
Dissertation Frau Urban
„Water Separation“
Dissertation Herr Enriquez-Geppert
„Modeling Full Exhaust System“�
�
75
85
95
105
115
300 600 900 1200 1500 1800 2100
Zeitachse [s]
Tem
pe
ratu
r [°
C]
0
5
10
15
20
25
30
35
40
Ges
ch
win
dig
ke
it [
km
/h]
Oberflächentemperatur Bauteil Geschwindigkeit
PHASE 1Aufheizung
PHASE 2stationär
PHASE 3Nachheizen
Dissertation Frau Pulz
„Modeling Full Engine/Transmission“�
�
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Daimler AG Seite 10The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
Generic Digital Prototype Process
![Page 11: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/11.jpg)
Daimler AG Seite 11The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
Full Vehicle Thermal Management Process
Evaluation
Component Temperatures
Digital E-Vehicle
Evaluation
Global Concept
Digital Phase 1
Evaluation
Local Concept
Digital Phase 2
Digital B-Vehicle
E-Vehicle-
Testing
B-Vehicle-
Validation
Start of Project SoP
Optimization Component
Temperatures
Digital AssessmentDigital and Physical
Assessment
Tandem of simulation engineer and testing engineer is responsible for VTM
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Daimler AG
VTM Co-Simulation
Seite 12
Thermal Convection
Thermal Conduction
Thermal Radiation
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
• Change from pure CFD
engineer towards VTM
engineer
• Increase of the complexity
of simulation
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Daimler AG
Costs of VTM
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 13
Flow Mesh
Generation
Solid Mesh
Generation
Analysis
Analysis
Result
Preparation
Result
Preparation
Co
Sim
CAD data
preparation
Result
Assessment
License costsEngineer service costs ? Engineer service costs ?
Reducing the number of physical prototypes increases costs for digital prototypes
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Daimler AG14
Efficient Full VTM Simulation Process
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 14
Pre-ProcessingTools used: TIG** , STAR-CCM+
• Need for Automation
• Investment in Software
CAD-PreparationTool used: Model Manager**
• Need for Automation
• Investment in Software
**Customized Software Tools for Daimler
ProcessingTools used: Event Manager,**
STAR-CCM+
• Need for Automation
• Investment in Software
Post ProcessingTools used: Post Tools,** STAR-CCM+
• Need for Automation
• Investment in Software
0
2
4
6
8
10
12
14
Vehicle 1 Vehicle 2 Vehicle 3 Vehicle 4
Number of Referenz Vehicles per DPT Loop
0
1000
2000
3000
4000
5000
6000
7000
8000
2008 2009 2010 2011 2012
Number of Components per Vehicle
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Daimler AG15
Imprinting of adjacent Component Parts by means of LFE Tools
The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 / Seite 15
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Daimler AG
Full VTM Post Processing
Seite 16The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
![Page 17: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/17.jpg)
Daimler AG
Key Factors for successful VTM simulation
• Geometrical Data for Pre processing
• Powerful Simulation tool
• Post processing
• Simulation process
Robust and flexible
Costs effective
• External Costs for VTM
• License Fee
• Engineering Services
• Software Development
Seite 17The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
![Page 18: The Role of Simulation at Changemdx2.plm.automation.siemens.com/...1-P2...Bauer_0.pdfDaimler AG • ca. 400 000 cells • 3 weeks of computation time • 9 months for meshing • Role](https://reader035.vdocuments.us/reader035/viewer/2022070901/5f493bb9d9402e7b7e293a73/html5/thumbnails/18.jpg)
Daimler AG
New Role of Full VTM Simulation
Simulation is
• dominating the development process
• accepted by the management
• under costs and time pressure more than ever
• comparable to testing
Simulation engineers have more responsibility
Seite 18The Role of Simulation at Change/Walter Bauer RD/FNT / 01.06.2016 /
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Thank you for your attention!