Converge UGM 2014

September 23, 2014, Madison, Wisconsin

Optimization of a Rotary Engine in Terms of

Performance and Consumption with
the Help of Converge

Dipl.-Ing. Johann Spreitzer

Univ. Prof. Dr. techn. Bernhard Geringer
Dipl.-Ing. Felix Zahradnik

Rotary Engine AE R7
Design: single-rotor rotary engine
Displacement: 405 cm
Engine speed: 7.000 rpm
Bearings:
friction bearing

Fuel-System:
semi-direct-injection (PFI)

Ignition-System:
two Sparkplugs

Cooling-System:
trochoid: water-cooled

rotor: oil-cooled
eccentric shaft room: oil-cooled

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 2

Rotary Engine | Wankel-Basics

Principle of operation mode
Wankel is an SI 4-Stroke-Engine

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 3

Rotary Engine | Wankel-Basics

Nomenclature of the Wankel-Engine-Trochoide

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 4

Rotary Engine | Wankel-Basics

Pros
good NVH beaviour (low vibrations, complete mass balance possible, )
compact design (no valve train necessary, )
less friction losses
specific performance (good weight and volume to performance ratio, )

Cons
worse thermal efficiency (lunate combustion chamber contour,
surface-volume ratio)
higher fuel and oil consumption
higher production costs

high position of power dissipating shaft

compression-ignition engines only with great technical effort (e.g. RollsRoyce)

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 5

Rotary Engine | R&D-Environment @ IFA

Laboratory
engine test bench
combustion analysis
emission measurement
Blow-By-measurement
Spray-Tec
High-Speed-Camera

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 6

Rotary Engine | R&D-Environment @ IFA

Simulation-Tools
1D-Simulation (GT-Power)

CFD-Simulation (Converge)

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 7

CFD-Simulation | Goals
The following effects will be analyzed with the help of CFD simulation:
Flow in the combustion chamber as a function of the rotor recess
shape and position
Flow phenomena during the gas exchange cycle
Flame propagation during the combustion process
Mixture preparation: Distribution of the fuel in the combustion chamber

The efforts should lead to:

Optimal rotor recess shape and position
Location of the spark plugs
Optimization of the inlet- & outlet-port

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
Date (23.09.2014) | Madison, Wisconsin | J. Spreitzer | Slide 8

CFD-Simulation | Pre-Processing
ConvergeTM von Convergent Science
editing the surface triangles
defining the boundaries

Imported STL-File from CAD

specification of motion
defining the regions
combustion chamber 1-3
inlet- & exhaust-port
inlet- & exhaust-manifold
spark plug holes 1+2
initialization of the model
specification of the ignition
energy and position

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 9

CFD-Simulation | Pre-Processing
Surface prepared for Converge-Solver

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 10

CFD-Simulation | Flow Field

Turbulence Model

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 11

CFD-Simulation | Flow Field

R7: two leading-Plugs, = 9,6, n = 6.000 rpm, WOT, motored

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 12

CFD-Simulation | Flame Propagation

Combustion Model

Simulation of Combustion by a given Reaction Mechanism

model fuel: IC8H18 (isooctane)
69 chemical reaction equations (CHEMKIN-Format)

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 13

CFD-Simulation | Flame Propagation

2 L-Plugs, = 9,6, n = 6.000 rpm, WOT, Ignition Time = -6 EW

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 14

CFD-Simulation | Flame Propagation

2 L-Plugs, = 9,6, n = 6.000 rpm, WOT, Ignition Time = -6 EW

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 15

CFD-Simulation | Flame Propagation

2 L-Plugs, = 9,6, n = 6.000 rpm, WOT, Ignition Time = -6 EW

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 17

CFD-Simulation | Flame Propagation

Strong Squish-Flow

Mass flow from trailing side to leading side for a long time, because trailing
side is compressed, while the leading side expands.
Converge User Group Meeting 2014
Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 18

CFD-Simulation | Flame Propagation

Strong Squish-Flow

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 19

CFD-Simulation | Comparison between different rotor

recesses & T-Side spark plug
Rotor recess influences strongly
gas exchange

flow field and residual gas content

flow field during intake stroke

air/fuel mixture formation
combustion initiation
flame propagation

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 20

CFD-Simulation | Gas Exchange

Influence of the rotor recess position on residual gas content & flow field
@ 6.000 rpm, WOT

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 22

CFD-Simulation | Gas Exchange

Residual gas content @ 6.000 rpm, WOT for different rotor recesses

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 23

CFD-Simulation | Flow field during intake stroke

Influence of the rotor recess position on the flow field during intake stroke
@ 6.000 rpm, WOT

air/fuel mixture formation

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 24

CFD-Simulation | Flame Propagation

Turbulent kinetic energy (TKE) and flow field @ ignition time
@ 6.000 rpm, WOT

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 25

CFD-Simulation | Flame Propagation

Simulated heat release rate @ 6.000 rpm, WOT

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 26

CFD-Simulation | Flame Propagation

Simulated ignition delay @ 6.000 rpm, WOT

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 27

CFD-Simulation | Flame Propagation

Influence of rotor recess position on p-V diagram @ 6.000 rpm, WOT

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 29

CFD-Simulation | Flame Propagation

Influence of rotor recess position on IMEP @ 6.000 rpm, WOT

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 30

CFD-Simulation | Flame propagation

Converge User Group Meeting 2014

Optimization of a Rotary Engine in Terms of Performance and Consumption with the Help of Converge
23.09.2014 | Madison, Wisconsin | J. Spreitzer | Slide 31

Thank you for your Attention!

Dipl.-Ing. Johann Spreitzer

johann.spreitzer@ifa.tuwien.ac.at