xvii. econ conference annual meeting for ansys users · disc brake thermal analysis thermo-dynamics...

Knorr-Bremse Group

Budapest, 19. April 2018

Actualities and Challenges in Technical Modelling and Simulations for Commercial

Vehicle Systems

Árpád Veress

Knorr-Bremse Brake Systems Ltd.

R&D Center Budapest

XVII. eCon Conference

Annual Meeting for ANSYS Users

Knorr-Bremse Group

Knorr-Bremse CVS – R&D Center Budapest

Actualities in Technical Modelling and Simulation

Advanced Simulation Problems and Challenges

Agenda

│2

Engineering Calculations

Knorr-Bremse Group

Every day, more than a billion people rely on systems from Knorr-Bremse

SYSTEMS FOR RAIL VEHICLES

• High-speed trains

• Regional & commuter trains

• Metros

• LRVs

• Monorails

COMMERCIAL VEHICLE SYSTEMS

• Trucks

• Trailers

• Buses

• Engines

• Special vehicles

• Locomotives

• Passenger cars

• Freight cars

• Off-train

3

Knorr-Bremse Group

Knorr-Bremse Group

Every day, more than a billion people rely on systems from Knorr-Bremse

Knorr-Bremse CVS

COMMERCIAL VEHICLE SYSTEMS

• Trucks

• Trailers

• Buses

• Engines

• Special vehicles

SYSTEM COMPETENCIES

• Braking Systems

• Dampers

• Compressors

• Engine Air

• Transmission Management

• Air Treatment

4

• Electronic Systems

• Steering Systems

• Valves

• Disc Brakes

• Drum Brakes

• Actuators

• Tools and Diagnostics

Knorr-Bremse Group

0

50

100

150

200

1995 2000 2005 2010 2015

TCH is integral part of the KB’s world-wide R&D structure

Budapest is the largest R&D location of the Group

Knorr-Bremse CVS in Hungary - R&D activities at commercial vehicle systems

division

Research & Development

│5

Knorr-Bremse CVS

R&D headcount

R&D Center Budapest Test Center Kecskemét

100 %

50 %

0 %

Knorr-Bremse Group │6

Knorr-Bremse CVS Hungary

Engineering Calculations Group – The Professional Team

Knorr-Bremse Group




Agenda

│7



Structural and Fatigue Analyses of Clutch Components

The compressor clutch components suffer from

high load at nominal operation.

Static structural and fatigue analyses are carried

out to determine the capability of the assembly

against the applied loads.

The resulted variables are the von Mises stress

distributions, deformations, mean and alternating

stresses.

Static structural behavior and fatigue durability

can be determined by the presented analysis.

Animation with 32x magnification

Problem Setup Results and Practical Importance

Static Structural and Fatigue Analyses


The exhaust brake modules are mounted in the

pipe system and are exposed to high frequency

engine vibration loads.

Modal and PSD analyses are completed to

determine the natural frequencies and durability

behavior of the structure.

The outcomes of the analysis are the

eigenfrequencies, the system response, stress

and damage parameter.

Parameter sensitivity analyses can be completed

to determine the effect of the increased model

stiffening.


Vibration Analysis of Exhaust Brake

Harmonic and Random Vibrations


Crankshaft Oil Impact Calculation

A specific compressor assembly is tilted in

case of a non-conventional truck application.

The modified oil level can increase the load of

crankshaft, pistons and bearings.

Free surface flow simulation is completed to

determine the loads.

Based on results, the flow forces can be

determined on the crankshaft, pistons and

bearings.

The outcomes of the feasibility study can be

used for determining the possible application of

the compressor.


Fluid Dynamics


The temperature distribution of the rotor and

wheel end needs to be calculated for a new axle

application at the constant brake pad and brake

disc surface temperatures.

Steady state thermal analyses are completed at

constant RPM to determine the temperatures in

the system.

The temperature distribution is the outcome of

the analyses.

The effect of different design scenarios can be

compared with each other and modifications can

proposed.


Disc Brake Thermal Analysis

Thermo-Dynamics and Heat Transfer


Magnet Holder Injection Molding Simulation

The geometry and the molding process have

strong influence on the final dimensions of the

plastic components.

The main goal of the simulation is to examine the

melting flow pattern and to check the deformation

field of the plastic part after the molding process.

The molding parameters could be analyzed

and optimized.

The shape distortion of the part is similar to

the manufactured sample.

The design could be refined before the

tooling.

Deformation scale: 10 x


Plastic Molding

Knorr-Bremse Group

Vertical Impact Rod Test for the Housing of a Pneumatic Component

│13

Qualitative validation of the simulation results


The plastic components on the out side part of the

trucks are exposed to stone chipping.

Vertical impact rod test is completed to investigate

the effect of stone chipping for the structural

integrity.

The outputs of the dynamic simulations are

the stress and deformation fields.

The results of the simulations approximate

well the results of the real test.

Design modifications can be proposed in

case of unexpected behavior.

Explicit Dynamics


New ADB Hysteresis Investigations

The new air disc brake concept has some contact

conditions where friction occurs.

The contribution of these friction forces to the

overall hysteresis should be calculated.

Problem Setup

A multibody-dynamics model was built

that can reproduce the hysteresis

measured on the test bench.

Further analysis will show how the

individual frictional contacts affect the

hysteresis.

Results and Practical Importance

Multi-Body Dynamics

Frod

0 2000 4000 6000 8000 10000 120000

2

4

6

8

10

12

14

16x 10

4

FZylinder

[N]

FZ

uspann [

N]

Hysteresismeas

=148.2[kN2]; Hysteresissim

=118.05[kN2]

Measurement (LS=0,KR=12)

Simulation


Simulation and Optimization of Wheel Speed Sensor

The wheel speed sensor provides information

about the RPM of the wheel.

The operation of the wheel speed sensor is

modelled and the goal function of the optimization

is the minimum mass at the required induced

voltage.

The results of the analyses are the induced

voltage during transient simulation.

The model is validated by measurements and the

optimized geometry is the benefit of the analyses.

Wheel

Speed

Sensor


Electro-Magnetics


Optimization of a Visco-Damper

The structural optimization of torsional vibration

damper can reduce weight with increased

material utilization.

The optimization of a visco-damper is completed

for mass reduction at given allowable max.

stress.

A real damper is rather complex for the process of parametric optimization.

A simplified 3D model was created (calculation time was reduced).

Then a full model was built up (as a real) from the results of the optimization. Hence, the simplified model was checked by the results of the full model.

Optimized

geometry

(grey shaded)

Initial

geometry


Optimization

75 % 100 % 100 %

[h]

Knorr-Bremse Group

ISO/TS 16949

Internal Process Description and Standard

PSE Standard by NAFEMS

The Quality Assurance is Based on Multiple Frameworks

│17


https://www.google.de/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj4r7DJ-drXAhVDKlAKHQOhB50QjRwIBw&url=https://www.ciria.org/CIRIA/Navigation/Events/Event_Display.aspx?EventKey%3DE14234&psig=AOvVaw0T9r5n2An9UjYu_w32zdsl&ust=1511741360795633

https://www.google.de/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwii3orh-drXAhWIK1AKHSmFBnoQjRwIBw&url=https://www.nafems.org/&psig=AOvVaw2Sb_oK-RGbtqYCrWNFjnIg&ust=1511741412424427

Knorr-Bremse Group




Agenda

│18



ABS ECU – Feasibility Investigation of Plastic Enclosure

Goal of the simulation was to investigate the

feasibility of a plastic enclosure to replace the

sheet metal housing - check whether it can

provide sufficient cooling for the electronics.

Steady-state thermal analysis has been prepared

for the examination of the thermal management

problem.

Problem Setup

Thermo-camera and thermocouple

measurements have also been prepared for

simulation validation purposes. The average

error was less than the prescribed maximum

value. The plastic housing could enter the next

implementation phase according to the

simulation results.

Results and Practical Importance

Thermo-camera image of the PCB Simulation results for the PCB

Challenging in Modelling and Simulations

Knorr-Bremse Group

Simulation number of plastic parts is constantly

increasing - classic simulation method does not

calculate with anisotropy of short fiber reinforced

composites.

The goal is to increase the accuracy of the

simulations and calculate with the materials

anisotropy.

Improvements on FEM Analyses of Plastics and Short Fiber Reinforced Polymer

Composites

Get more accurate results of polymer parts

during FEA (calculate with nonlinearity and

anisotropy).

Improvement on the polymer parts in design

procedure.



Equivalent Stress

Isotropic case

Anisotropic case

Knorr-Bremse Group

The loads from bending and collision act on the

air flow controlled reed valves.

The Fluid Structure Interaction based simulation

is completed, as it can provide only reliable

information about the developed flow field and

the stresses in the reed valve.

Developments on Reed Valve Modeling - FSI

Integration of the valve development process can

reduce the iteration steps of the design.

Validation is an unavoidable step of the

development with especial care for p-V diagram;

displacement of valves; F.A.D and Blow by.

Performance and reliability of the valves could be

increased by FSI.

Simulation model

preparation

(CFD - Mechanical)

GT model

preparation

Determination of the

v alv e opening moment

CFD

Simulation Mechanical

Simulation 2-way coupled FSI

Ev aluation Ev aluation

Fatigue

Ev aluation Project

Report

GT-based FSI

Process

Description

ANIMATION

CFD & Mechanical

Evaluation



Knorr-Bremse Group

An increasing demand of model exchange for

OEMs and development partners is expected,

while encryption of technology information is vital.

Numerous simulation tools are used, therefore a

standardized interface is necessary. FMI

standard can be used for that purpose.

Vehicle Model Developments in MATLAB-SIMULINK Environment for Components

with Especial Care for FMUs

Allows to fulfill the model exchange related

expectations of OEMs meanwhile protecting IP.

FMUs (Functional Mock-up Units) and a

standardized platform can also facilitate product

development, integration and virtual prototyping.

Source: https://uk.mathw orks.com/products/connections/product_detail/product_88391.html

(26.11.2017) (left)

https://w ww.yumpu.com/en/document/view /14176920/das-functional-mockup- interface-zum-

austausch-qtronic/7 (26.11.2017) (top)



Knorr-Bremse Group

The crank shaft fatigue analyses are completed

to determine the suitable geometry for infinite life.

Several steps need high number human actions.

The goal is to develop an automatization process

for completing crankshaft fatigue analysis.

Automatization of Crankshaft Fatigue FEA Analysis

The automatization process and the method are

completed.

The verification of the simulation results is

performed via several test cases.

The risk for possible human uncertainty is

decreased.



Knorr-Bremse Group

Thank you very much for your attention!

│24

Phone: +36-1-3829-963

Mobile: +36 204578964

Email: [email protected]

www.knorr-bremse.com

Árpád Veress

Knorr-Bremse Fékrendszerek Kft.

Research & Development Center

Major utca 69 / Budapest 1119, Hungary

mailto:[email protected]






http://www.knorr-bremse.com/



xvii. econ conference annual meeting for ansys users · disc brake thermal analysis thermo-dynamics...

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