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8/9/2019 Cooper Standard - Tom Lincoln
http://slidepdf.com/reader/full/cooper-standard-tom-lincoln 1/27
Development of Tools to Automate
the Analysis of Turbo-Machinery
om nco n a eep anga
Cooper Standard / Altair Engineering, Inc.
8/9/2019 Cooper Standard - Tom Lincoln
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Executive Summary
• Cooper Standard (CS) Corporate Overview
• History of CFD at Cooper Standard
• Cooper Standard adoption of AcuSolve for enhanced CFD efficiencies
and accuracy
• Additional AcuSolve Applications at Cooper Standard
8/9/2019 Cooper Standard - Tom Lincoln
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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 100North American Suppliers: Rank 35
2011 Sales: $2.85 B
8/9/2019 Cooper Standard - Tom Lincoln
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History
2011
2012
2005
2006
2007
2007
1960 1999 2000 2004
2010
8/9/2019 Cooper Standard - Tom Lincoln
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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 Countries 2004 - 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
8/9/2019 Cooper Standard - Tom Lincoln
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Global Customers
RENAULT
HYUNDAI
8/9/2019 Cooper Standard - Tom Lincoln
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Breadth of Product & Segments
8/9/2019 Cooper Standard - Tom Lincoln
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Thermal Management – Key Capabilities
Heating and coolingmanagement systems for
hybrids, electric vehicles andinternal combustion engines
Electromechanical DevicesThermal DevicesThermal Integration
8/9/2019 Cooper Standard - Tom Lincoln
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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 BestAchievement of Design for SixSigma
• Coolant Water Valve
Over 500 Patents Globally
• Daylight Opening Modules
• Engineered Stretched Plastics
• Occupant Detection Systems
•
• 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
• Quick Connect Fluid Couplings• Core process methods
cooperstandard
8/9/2019 Cooper Standard - Tom Lincoln
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Cooper Standard’s History With Pumps
• Cooper Standard identified a market for electrically driven coolant
pumps.
• Development began in 2005, CFD was used from the start.
• Cooper Standard offers pumps to replace the vehicle main water pump
and auxiliary supplemental flow.
• Wattages range from <20 W to 1 kW.
8/9/2019 Cooper Standard - Tom Lincoln
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Early CFD Analyses – August 2005
• Combination Tet and Hexcells
• Uniform mesh size• Significant time to set-up
manually
8/9/2019 Cooper Standard - Tom Lincoln
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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
0.00
0.20
0.40
0.60
0.80
1.00
1.20
5000 7000 9000 11000 13000
P r e s s u
r e G a i n
Flow Rate
Comparison Between Measured Data andCFD Prediction
MeasuredPressureGainPredictedPressureGain
8/9/2019 Cooper Standard - Tom Lincoln
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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
8/9/2019 Cooper Standard - Tom Lincoln
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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 ste s calculation
11
22
BoundaryConditions
Inlet / Outlet
Automeshing
Auto time stepcalculations
SOLVE
10minutes
Setup time
• Setup multiple flow pointsand run it batch mode
44
33
8/9/2019 Cooper Standard - Tom Lincoln
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Cooper Standard Pump Analysis
• Goal: Predict pump performance,Flow Curve
• Reduce Setup and Solution time
• Enable CSA Engineering team to
Meshed Impeller
Pump – Meshed Model
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve’s Rotating Machinery Process
• First run
• Very fast setup and solution
• Helped understand process and setup before adding more
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
TestFirst Run
16
Boundary Layer = 1.4 mmMesh Size 7 mm
Flow
P r e s s u r e G a i n
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve’s Rotating Machinery Process
• Refined Mesh
• Analysis converged in 9th 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
P
r e s s u r e G a i n
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
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve Results
Contours of Static Pressure Contours of Velocity
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve Results
Pressure Distribution
Pressure Distribution – fluid
volume
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve Results
Contours of Pressure on
Planes Cut Through a Pump
Contours of Velocity onPlanes Cut Through a Pump
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve Results
Pressure Distribution Velocity Profile
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve Results
Pressure Distribution Velocity Profile
8/9/2019 Cooper Standard - Tom Lincoln
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8/9/2019 Cooper Standard - Tom Lincoln
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Additional Collaboration - Thermal Analysis –Pump
• Cooper Standard engaged Altair in a consulting project to set-up the
initial AcuSolve models
• Altair transferred knowledge to Cooper Standard for future product
development
3D CAD Model Simplified FEA 3D Model
8/9/2019 Cooper Standard - Tom Lincoln
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Additional Collaboration - Thermal Analysis -Pump
IR Camera Image AcuSolve Thermal Analysis results
AcuSolve predicted high temperature component locations and were laterconfirmed by IR camera
8/9/2019 Cooper Standard - Tom Lincoln
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AcuSolve Results