MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE GT-CONFERENCE FRANKFURT AM MAIN, 09/10/2017

Transcription

1 MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE GT-CONFERENCE FRANKFURT AM MAIN, 09/10/ / PRESENTATION NAME IN CAPITALS ARIAL BOLD, 10PT

2 PRESENTATION OVERVIEW COMPANY OVERVIEW LAYOUT OF A MOTORCYCLE COOLING CIRCUIT OUR WORKFLOW FOR 1D THERMAL CALCULATIONS SUMMARY 2 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

3 COMPANY OVERVIEW 3 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

4 HEADQUARTERED IN MATTIGHOFEN (AUT) 2931 EMPLOYEES (BY 31 ST DECEMBER 2016) READY TO RACE 500 EMPLOYEES IN R&D SOLD BIKES (2016) KTM & HUSQVARNA MOTORCYCLES ON ROAD- / OFF ROAD-MOTORCYCLES / AUTOMOTIVE 4 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

5 KTM SX - Motocross KTM EXC - Enduro KTM Freeride E KTM Adventure - Travel KTM - RANGE OF MODELS KTM RC - Supersport KTM SuperDuke Naked KTM SuperDukeGT Sports Tourer 5 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE KTM X-Bow RR Supersportscar

6 LAYOUT OF A MOTORCYCLE COOLING CIRCUIT 6 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

7 LAYOUT OF A MOTORCYCLE COOLING CIRCUIT Performing parametric studies Avoiding trial and error procedures Motorcycle Concept Domain Of Application Predesign Package Cooling-System Calculation Prototype Testing Response Analysis 7 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE Release Best Version

8 LAYOUT OF A MOTORCYCLE COOLING CIRCUIT Past Component level development Component Measurements Cooling System Stationary Operating Conditions 3D-Calculations We had all parts but no system to combine them! 8 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

9 LAYOUT OF A MOTORCYCLE COOLING CIRCUIT Past Component level development Present System level development Cooling System 1D-Cooling System 9 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

10 LAYOUT OF A MOTORCYCLE COOLING CIRCUIT CONCLUSION 1D-Calculations offer more variance and flexibility to find the optimum faster Time dependent system behavior becomes observable Optimize in realistic operating conditions for a variety of drive cycle analysis Improved our engineering process 10 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

11 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS 11 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

12 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS INPUT: Engine Data Geometry Data Calculation & Measurements Operating Conditions 12 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

13 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS MEASURED DATA INPUT 13 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

14 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS INPUT: Engine Data Geometry Data Calculation & Measurements Operating Conditions OUTPUT: Engine / System Temperatures Pressure Drop vs. Volume Flow Fan Operating Conditions BENEFIT: Optimized Cooling-System Reduced Test Bench Hours 14 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

15 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F M794 Engine Displacement KTM SX 450 (M794) 1-Cylinder, 4-stroke, 4-Valve Gasoline-Injection 449,4cm³ Compression 12,75:1 Power Torque RPM max. Cooling 9500/min 7000/min 11500/min Water-cooled KTM 450 SX-F Mj / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

16 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F Optimization Targets: Cooling system P & Q Routing structure Optimum radiator Packaging Additional: Cylinder temperature prediction Engine Load Cases Full Load (Engine Temperature Prediction) Stationary Point (Radiator Optimization) Standard Small 100% 8500/min 50% 6000/min Medium 16 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

17 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F ENGINE TEMPERATURES Use the Customized FE Structure Define identical input for Customized FE & 3D calculation Evaluate critical Cylinder HOTSPOTS Additional: Adapt Simplified-FE for similar engine projects 17 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

18 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F ENGINE TEMPERATURES Customized FE Structure Piping Heat-Quantity 18 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

19 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F 3D-CHT / CFD INPUT 3D-CHT HTC Water-Jacket & Cylinder 3D-CFD Water-Jacket Pressure Drop 19 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

20 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F ENGINE TEMPERATURES Benefits: Time Saving Calculation Duration Cylinder Hot-Spot Validation Evaluate Engine Warmup Behavior 3D-CFD 22 Processors Cells 20 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE Simplified FE 1 Processors Cells

21 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F RADIATOR INVESTIGATION Standard Medium Small 21 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

22 OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F RADIATOR INVESTIGATION Initial Settings: Engine-Speed: 6000rpm Power: 20kW, 50% Load Temp-Air: 21 C Temp-Water: 70 C Model Calibration-Process: Baseline-Model has to fit Measurements As Used Radiator Scaling Define Air-Velocity at Radiator Velocity: 50km/h Changing Radiators & Piping 22 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

23 Water-Temperature [ C] Air-Temperature [ C] OUR WORKFLOW FOR 1D THERMAL CALCULATIONS EXAMPLE 450 SX-F RADIATOR INVESTIGATION Temperature Results 25 24, , , , , Time [s] GT-Calculation = Measurement Standard Testbench Standard T_Water Testbench T_Water Standard GT-SUITE T_Water Standard GT-SUITE T_Water Medium GT-SUITE T_Water Small GT-SUITE Testbench T_Water T_Air Testbench T_Air 1D Calculation T_Air 1D Calculation T_Air 23 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

24 SUMMARY 24 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

25 SUMMARY Customized FE Cylinder Structure 1D-Thermal-Modelling Faster calculation duration as 3D-Calc Optimized Cooling-System Good accuracy for Temperature distribution Optimized Structure & Water Temperatures Additionally Additionally Adapt FE-Model for similar engine projects Pre-Layout radiator; pump; & fan; combinations Drive-cycle and warm-up analyses Add complete Motorcycle to 1D -Model Temperature controlled Co2 and Fuel-Economy improvements 25 / MOTORCYCLE COOLING CIRCUIT CALCULATIONS WITH GT-SUITE

26 THANK YOU FOR YOUR ATTENTION! B.ENG. MAXIMILIAN KOCH, KTM AG MATTIGHOFEN (AUT) DIPL.-ING. CHRISTIAN MAYRHOFER / M.SC BENCE SOMOGYI / ING. WOLFGANG GIERBL M.SC PRATIK MEHTA GOPESH 26 / PRESENTATION NAME IN CAPITALS ARIAL BOLD, 10PT