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University Transilvania of Braov, Laboratory of Fluid Power and Sonics Professor Horia Abaitancei, PhD, h.abaitancei@unitbv.

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Overview on Research Projects

idea simulation experiment

Summer 2011

University Transilvania of Brasov

Institute ProDD Department D02

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Overview on contents

Overall vision Simulation / Research possibilities

Examples of research projects


ICE Fluid power Vehicle testing Agricultural systems Conclusions

University Transilvania of Brasov

Institute ProDD Department D02

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Development vision
Research activities: fundamental research demonstration models applied / industry research Systems:

Vehicle propulsion systems engine gas exchange systems injection system valve train systems
hydraulic & sonic propulsion energy recovery free piston engine Concept car Working devices recovering energy for lifting systems hydraulic log lifting system pumping devices bicycle Energy systems pumping system for heat pumps street energy recovery system

Methods: CAE : CAD CFD FEA MBA - MPA Experimental system analysis fluid power measurments noise and vibration measurements engine performance and emissions Neuro fuzzy system identification Dynamical system theory

University Transilvania of Brasov

Institute ProDD Department D02

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Overview on Research Facilities


Software
CAD: CATIA V5 CFD: Fluent Hydraulics: DSH+ MBA: LMS Virtual.Lab; MSC Adams MSA: LMS Amesim; MSC Easy 5 FEA: LMS Virtual.Lab; MSC Patran / Nastran Special AVL Partnership: Boost 1D engine CFD Hydsim fluid power Fire 3D CFD Excite MB / FEA Cruise vehicle dynamics

Testing facilities
Engine test rig Horiba Emission control system AVL

Fuel properties testing rig


Mobile Hydraulic pressure and flow measurement system Vehicle vibrations and dynamics testing equipment Concept car

University Transilvania of Brasov

Institute ProDD Department D02

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Overview on research projects and partners


fundamental research ICE gas exchange systems ICE pressure wave analysis of ice injection systems Fluid Power Systems power transmission using waves in liquids hydraulic systems dynamical phenomena NVH vibration system identification

University Transilvania of Brasov

Institute ProDD Department D02

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Overview on industry research projects and partners


Support / joint research industry projects:
pressure wave supercharger CFD analysis dynamical analysis of valve train
RO

identification and optimisation of pressure waves of the injection system


RO DE AT BE/RO DE USA DE

gas exchange system optimization


friction analysis vibration analysis mobile hydraulic hammer

partnerships under
construction

RO

USA/RO DE/RO

DE/RO

University Transilvania of Brasov

Institute ProDD Department D02

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EXAMPLES OF Internal Combustion Engines APPLICATIONS

University Transilvania of Brasov

Institute ProDD Department D02

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Pressure Wave Supercharger


Torque
420 400 380 360 340 320 300 800 1000 1200 1400 1600 1800 2000 2200

Torque(N.m)

Goal torque curve


Torque TC (N.m) Torque PWSC (N.m)

Engine speed(rpm)

The TC model
Goal: replacing turbocharger with pressure wave supercharger for low speed torque and dynamic response improvement
Boost pressure
2.7

Pressure MeasuringPoint 1(bar)


2.6

Pressure(bar)

2.5 2.4 2.3 2.2 2.1

Ideal engine charging pressure for goal Engine speed(rpm) torque curve
800 1000 1200 1400 1600

1800

2000

2200

The PWS model


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University Transilvania of Brasov

Institute ProDD Department D02

PWS Process Simulation 1D simulation influence of cell length


Air High Pressure
0.132 0.13 0.128
0.17

Burned Gases High Pressure


93mm(MPa) 110mm(MPa) 150mm(MPa)
0.16

Pressure(MPa)

0.126 0.124 0.122 0.12 0.118 0.116 0.114 0.112 0 90 180 270 360 450 540 630 720

Pressure(MPa)

93mm(MPa) 110mm(MPa) 150mm(MPa)

0.15 0.14 0.13 0.12 0.11 0 90 180 270 360 450 540 630 720

CRANKANGLE(deg)

CRANKANGLE(deg)

Air Low Pressure


0.0965 0.096
0.1055

Burned Gases Low Pressure


93mm(MPa) 110mm(MPa) 150mm(MPa)
0.105

Pressure(MPa)

0.0955 0.095 0.0945 0.094 0.0935 0.093 0 90 180 270 360 450 540 630 720

Pressure(MPa)

93mm(MPa) 110mm(MPa) 150mm(MPa)

0.1045 0.104 0.1035 0.103 0.1025 0 90 180 270 360 450 540 630 720

CRANKANGLE(deg)

CRANKANGLE(deg)

University Transilvania of Brasov

Institute ProDD Department D02

9/40

PWS Process Simulation 1D simulation influence of cell length

University Transilvania of Brasov

Institute ProDD Department D02

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PWS Process Simulation mechanical analysis Normal modes analysis 1st normal frequency: 540 Hz Thermal analysis: Maximum displacement 0,48 mm / 700 K

Structural analysis: at 15000 rev/min

Maximum stress: 108 MPa


University Transilvania of Brasov Institute ProDD Department D02

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Acoustical supercahrging
Goal: acoustical engine supercharging Research steps: 1D geometry identification for maximum pressure wave amplitude depending on engine speed 3D CAD integrated on given engine geometry Results: pressure wave amplitude, CAD Model

University Transilvania of Brasov

Institute ProDD Department D02

12/40

Combustion chamber flow analysis


Goal: identification of ICE cylinder flow for different inlet geometries to improve cylinder turbulence Research steps: CAD generation Definition of different inlet system shapes 3D CFD dynamic analysis Results: diagonal positioning for maximum flow coefficient and turbulence generation

University Transilvania of Brasov

Institute ProDD Department D02

13/40

Injection process analysis

Goal: identification of injection process and spray development Research steps: Constant volume chamber fast image recording 3D spray simulation (Fire) Results: model calibration influence of injection pressure on spray development

University Transilvania of Brasov

Institute ProDD Department D02

14/40

Exhaust system analysis

Goal: Coupled mechanical and CFD (1D, 3D analysis) Analysis of identification of injection process and spray development

Research steps: Normal modes analysis for different geometry 1D thermodynamic analysis of engine and exhaust pipe system; pressure wave amplitude identification for different geometries
Results: Optimized geometry for mechanical and exhaust pressure wave amplitudes

University Transilvania of Brasov

Institute ProDD Department D02

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Dynamic flow process analysis ICE injection system


Experiment vs Simulation difference [%]
3 2

1
0 -180-160-140-120-100 -80 -60 -40 -20 0 -1 -2

20 40 60 80 100 120 140 160 180

Goal: pressure wave ICE injection systems Research steps: Injection system model design for different geometries; Model calibration Identification of optimum geometry for minimum pressure wave amplitudes Results: geometry of the injection system

University Transilvania of Brasov

Institute ProDD Department D02

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Bio-fuels combustion research


Goal: identification of optimum combustion chamber shape using biofuels
Research steps: Combustion chamber shape definition Fuel definition Spray simulation (Fire)

Results: fuel distribution, emissions

University Transilvania of Brasov

Institute ProDD Department D02

17/40

Engine valve train analysis tappet rotation

Goal: valve train valve assembly rotation Research steps: Multi body (Virtual Lab) simulation Results: Influence of geometry parameters on tappet rotation

University Transilvania of Brasov

Institute ProDD Department D02

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Homogeneous Mixture in Compression Ignition Engine

Gasoline HCCI engine with camphasers (gas trapping method)

HCCI engine model AVL Boost

HCCI operating parameters cylinder prerssure, valve lifts, injection timing)


University Transilvania of Brasov Institute ProDD Department D02

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Engine friction analysis

Goal: ICE friction analysis Research steps: thermodynamic model, engine kinematics modeljournal bearing model Results: Crank angle dependent minimum oil film thickness Crank angle dependent friction power loss

University Transilvania of Brasov

Institute ProDD Department D02

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FEA mechanical / thermal / normal modes

University Transilvania of Brasov

Institute ProDD Department D02

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EXAMPLES OF FLUID POWER APPLICATIONS

University Transilvania of Brasov

Institute ProDD Department D02

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Example of integrated project conception solution development vehicle integration

Goal: integrated model; pressure wave engine coupled with hydrostatic transmission integrated on a vehicle Research steps: Pressure wave engine definition Running resistance definition CFD / FEA analysis Fluid power actuation scheme Results: CAD model Digital mock-up CFD/FEA

University Transilvania of Brasov

Institute ProDD Department D02

23/40

Timber lifting system


Goal: Hydraulic / mechanical design of a timber lifting system Research steps: Multy domain analysis : planar mechanical / fluid power analysis Results: system forces, mechanical, fluid power, control parameters

University Transilvania of Brasov

Institute ProDD Department D02

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Timber lifting system - continued

CAD Model

MB Analysis
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University Transilvania of Brasov

Institute ProDD Department D02

Timber lifting system - continued

mechanical parameters

fluid flow parameters

control parameters

University Transilvania of Brasov

Institute ProDD Department D02

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Hydraulic Hybrid propulsion system

Goal: Development of simulation and experimental demonstration vehicle with series hydraulic hybrid propulsion system integrating shock and brake energy recovery Research steps: Simulation model (Amesim) Experimental model Results: Overall efficiency evaluation Simulation model Concept vehicle A hydraulic propulsion, + engine running conditions B brake energy recovery + 40% C shock absorber energy recovery + 8%

University Transilvania of Brasov

Institute ProDD Department D02

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Hydraulic hybrid propulsion system - performances

Engine speed Emissions Consumption

University Transilvania of Brasov

Institute ProDD Department D02

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Shock absorber energy recovery

Goal: Principle demonstration of shock absorber energy recovery Research steps: Simulation model (Amesim) Test rig Test vehicle Results: Oscillation computation & measurement

1st price Youth Innovation Fair 2007 organised by the Romanian Youth Ministry

University Transilvania of Brasov

Institute ProDD Department D02

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Fluid power optimisation vision


advantages

Fluid power energy source

Free piston solution

Thermodynamic efficiency () Mechanical

Transmission line

Pressure wave based transmission Sonic system

power loss simple system

Hydraulic actuators

Sonic motors and cylinders brakes, shock absorber, lifting systems

power loss simple system

Recovery systems

overall efficiency

University Transilvania of Brasov

Institute ProDD Department D02

30/40

Free piston solution for efficient fluid power energy generation project start - up
Free piston solution
free shape of compression function + efficiency; simple variable engine displacement + consumption; + emissions. compact + lower mass

Conventional coupling of ICE with hydraulic pump sine function for piston movement, friction losses;

Goal: Principle demonstration and performance evaluation Research steps: Simulation model (1D multy domain, CFD, FEA), Test rig model; Vehicle application

Results: to be evaluated end spring 2012

University Transilvania of Brasov

Institute ProDD Department D02

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Sonic propulsion system based on pressure waves propagated in liquids - principle demonstration

Goal: Principle demonstration as vehicle propulsion system and fluid power actuation system Research steps: Concept, optimum system structure development Influences on liquid pressure waves identification Simulation model (1D multy-physics< CFD; FEA) Test rig model, Concept car

Results: Ongoing testing: efficiency evaluation

University Transilvania of Brasov

Institute ProDD Department D02

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EXAMPLES OF INTEGRATED VEHICLE APPLICATIONS

University Transilvania of Brasov

Institute ProDD Department D02

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Running cycle comparison of alternative propulsion systems


using propulsion system model with driver and test cycle models (Amesim)

Fuel economy EPA Highway [mg/s]


Conventional propulsion Automatic drive Series electric hybrid

University Transilvania of Brasov

Institute ProDD Department D02

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Vehicle dynamics & vibration analysis


Goal: Vehicle active control suspension testing Research steps: Oscillation measurement for different running conditions

active suspension main parts

Results: Data for multy physics model calibration

University Transilvania of Brasov

Institute ProDD Department D02

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EXAMPLES OF AGRICULTURAL SYSTEMS APPLICATIONS

University Transilvania of Brasov

Institute ProDD Department D02

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Joint force analysis coupled with FEA of agricultural working devices

University Transilvania of Brasov

Institute ProDD Department D02

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Dynamic analysis of seeding devices and traction and working devices Seeding device sub system kinematics and dynamics

Goal: Agricultural equipment development Research steps: Modeling of system dynamics Results: Concepts and experimental, tested solutions

System assembly identification

Integrated device for soil treatment and sapling seeding


Institute ProDD Department D02

University Transilvania of Brasov

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Conclusions
Joint participation at research projects

Research projects with subventions from the Romanian State

Bachelor, Master, PhD thesis with subjects from industry

Development of continuous education centre joint participation at student / engineering design / innovation competitions: e.g. mini baja

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Institute ProDD Department D02

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Thank You for Your Attention !

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Institute ProDD Department D02

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