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Computer aided engineering applied to engine design
GT-Power UGM - Saclay
RESEARCH & DEVELOPMENT
Clément Dumand - [email protected]
Team Manager in Scientific & Future Technologies Department
May 17th 2017
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2016 2025 2020
Present
Digital Validation Boost
Full Digital Ambition
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Nowadays status in Groupe PSA
3
Level 4 : No Physical Test needed
Level 3 : Good maturity of Simulation
/ No Physical adjustment needed
Level 2 : Physical adjustments are
needed to reach performance target
Physical Testing validation cost
for which CAE is used (%)
Physical Testing validation cost
for which CAE is NOT used (%)
2025 target is to have CEA everywhere with
a confidence index higher or equal to 3
Confidence / fidelity index
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11 MAIN CAE FIELDS
4
Functional Simulation
Multi Body
Finite / Volume Element
Legend :
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Part design challenges – Nowadays methods
5
Most of designs are iterative and “manual” design using a single simulation tool
Challenges :
• To improve models accuracy
• To improve simulation cost / complexity
• To define new criterions for numerical design
High fidelity
Tool
User
Constraints /
Objectives
Best
tradeoffs
First steps of the full
digital design project
RECHERCHE & DEVELOPPEMENT
Part design challenges – Nowadays methods
6
Simulation domain tends to grow : multi-physics simulation or co-simulation
Challenges :
• To avoid to many interface between codes all in one code
• To manage complexity (high number of parameters, objectives, constraints, etc.)
High fidelity
Tool A
High fidelity
Tool B
Users
Constraints /
Objectives
Best
tradeoffs
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Engine
acoustics
Combustion
process
Supervisor
Combustion systems design strategies
7
Speed
Torq
ue
1D / 3D coupling for
each operating points
Combustion system optimization for
several operating conditions
Simulation complexity tends to grow : tools managed by automatic optimization methods
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Automatic optimization of combustion system
8
For a single operating condition
Parametrized piston shape
Supervisor
Constraints /
Objectives
Best
tradeoffs
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Automatic optimization of combustion system
9
For a single operating condition
Optimization result
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Automatically design combustion systems for gasoline
and Diesel engines
Objectives :
• To maximize the whole efficiency and max torque curve
• To maximize the exhaust temperature for aftertreatment systems
lightoff (Diesel part loads, gasoline starting)
• To fulfill constraints (noise, emissions targets, stability criterion,
mechanical limits)
Final outputs : Overall gains / maps
IFSC Torque
2020 objectives – Combustion system design
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2020 objectives – Remaining challenges to achieve full digital design (gasoline engines)
11
To use CFD to calibrate 1D combustion model
• To determine intake and exhaust pressure drops (steady
state simulations)
• To find a way to calibrate combustion speed and knock
limits in 1D from 3D results
To improve models accuracy
• Knock
• Soot (PN / PM)
To enrich optimization with new criterions
• Combustion stability
• Low speed pre-ignition
Supervisor
Constraints /
Objectives
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Complex system approach, with a global overview of the whole system : Engine example
• Engine BSFC – cycle fuel consumption
• Raw emission and after treatment behavior (transient)
• Engine cooling and part thermo-mechanical stress (transient)
• Engine friction
• Engine control
We need global simulation tools in order to simulate the whole complex system
Challenges :
• Simulation accuracy
• Interface with specific codes
• Simulation time (up to real time)
• Global optimization
2020 objectives – Complex system validation
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2020 objectives – Complex system validation
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A global and collaborative simulation for complex systems
High fidelity
Tool A
High fidelity
Tool B
Supervisor
All in one or
co-simulation
tool
High fidelity
Tool B High fidelity
Tool B
High fidelity
Tool A High fidelity
Tool A
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2025+ objectives – Continue to improve the conception efficiency
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More and more complex systems
Artificial Intelligence to manage the design process
AI Data base
Low fidelity
tools
High fidelity
tools
Constraints /
Objectives
Best tradeoffs
Management
strategies
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Full digital design
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2025 target
Global optimization
Supervisor AI for design
Simulations accuracy & speed-up
New criterions for
robust design
Complex systems
simulations
4 topics have to be improved
Labs
Industries
& Labs
Codes suppliers
& Labs
Industries &
codes suppliers
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Thanks for your attention
