Fluid Power System Simulation Hand in Hand
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Transcript of Fluid Power System Simulation Hand in Hand
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 1 FLUIDON at HTC 2013
© 2013 FLUIDON
COMPETENCE IN FLUID POWER SYSTEMS SIMULATION
KOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEME
and AcuSolve
Fluid Power System
Simulation Hand in Hand
Dr. Heiko Baum
FLUIDON GmbH
2013 European Altair Technology Conference
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 2 FLUIDON at HTC 2013
© 2013 FLUIDON
HyperGraph Result Analysis
MotionSolve Multi-Body co-simulation
of mechatronic
systems
flexibility of components
RADIOSS Finite Element
data for stress analysis
CAE supported design level
HyperStudy Parameter Optimization
Measurements Validation
validation level
How The Presentation Fits into the CAE Development Process with
Use of CFD for the pressure loss determination of complex flow
channel geometries and the integration of these pressure losses in
the 1D simulation
off-line coupling
(data table export)
AcuSolve CFD
1D System Simulation
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 3 FLUIDON at HTC 2013
© 2013 FLUIDON
Content
Motivation 1
Application Example 2
Classic Modeling Method in 1D Simulation Programs such as 3
Use of Computational Fluid Dynamics (AcuSolve) 4
Summary 5
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 4 FLUIDON at HTC 2013
© 2013 FLUIDON
Motivation
At present the energy optimization of production processes gains increasingly in
significance.
The optimization of the machines but also the optimization of their operating
cycles provide a contribution to the desired energy savings.
FLUIDON is involved in numerous engineering projects and research projects, that focus
on the simulation of energy optimized processes.
As a consequence for FLUIDON, the demanded quality and the level of detail for the
required 1D system simulation in rise continuously.
If only the essential resistances of the system were modeled in the past, then the smaller
resistances are taken into account nowadays, too.
In this context the classic modeling method of the 1D system simulation is pushed to its
borders.
The presentation will show how the combination of 1D system simulation with the CFD
simulation is capable of improving the simulation accuracy.
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 5 FLUIDON at HTC 2013
© 2013 FLUIDON
QSLSumme1
1
23
QSL1
QSL2
WK5
Dekompression1a
Geschwindigkeitsregler1a
NS250 NS130RNS130L
QNS130L QNS130RQNS250
VZRVZL
RZRRZL
Hochtank
Hyd
Pneu
vPresse
S3b
VSB
M2
M1
RM1
2
RF
Solldruck
ZPRH1
Speicherblock1
WRCE32
SWRC160
FG_WRC160
SWRC100
FG_WRC100
VS3a
NS100_WRC100 NS100_WRC160
Vol1
Gaskolben
Hyd
Pneu
SL2
x-fach
VS3
S3a
SG_FOut
VA2SL1
x-fach
Q_Tankklappe
Tankklappe
Blende1
QSVA
Diffusor2Diffusor1
L1
x|fach
L3
x|fach
L2
x|fach
L4
x|fach
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x|fach
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xWRCE100xWRCE160
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Q
Huebe
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XPresse
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Q_WRCE100Q_WRCE160
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K
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VS2
RSP
VS0
Q_SP
Q_DBV_SP
DBV_SP
nPumpeS
AntriebSSchmiedePumpen
VS1
Q_WRCE32
VR5VR4
VR2
VR1
RRP
VR0
Q_RP
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nPumpeR
AntriebRRueckzugPumpen
ZPRS
Schmiedesteuerung1
SMSMEER Korrektur_OT
Korrektur_UT
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Schmiedezylinder5Flaechen1
Motivation: Reduction of Energy Losses in Heavy Equipment Valve Blocks
Push-down type forging press with two columns
Fluidtronic - A Design
Environment for Fluid
Technical Mechatronical
Systems
Source:
Image Brochure of
RUPPEL Hydraulik
Südstraße 2
31848 Bad Muender OT Bakede
Germany
Example of a valve block drawing. The
pressure losses due to these flow
channels are currently neglected in
most 1D system simulations.
Component oriented valve
block assembly in the
simulation model
Simulation
Model
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 6 FLUIDON at HTC 2013
© 2013 FLUIDON
Motivation: Reduction of Energy Losses in Production Duty-Cycles
P_DV_6
P_DV_5
P_DV_4
P_DV_3
P_DV_2
P_Pumpe
Demultiplexer3
Node3
Sub_Druckversorgung2
Demux2Sub_Setzzylinder1
Ventil24
K
Eilgang
K
DU1
K
Solldruck
K
SolldruckNiederhalter
K EilgangRueck
K
SolldruckVB
K
DU2
K
TZwPZw
A2A A3A A1A
A1ZA3ZA2Z
Node2
x_Niederhalter
x_Nietbolzen
Q_NB2
v_Niederhalter
v_Nietbolzen
Q_NB1
Q_NH1
A1
A3
A2
T
PVentilblock
KSolldruck
KLeerlauf1
KRichtung
KEilgang
Signal1
P
TVentilblock
Signal2
Signal3
QTank
KLeerlauf2
QPumpe
Sub_Ventilblock2
P_Ventilblock
Demultiplexer1
P1
P2
P3
P4
P5
P6
P7
P_Nietbolzen
P_Niederhalter
Summe1
+
Summe2
+
Signal19
P_Sum_DV
Integrierer1
Integrierer2
Integrierer3
Integrierer4
E_Pumpe
E_Sum_DV
E_Niederhalter
E_Nietbolzen
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+
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+ Summe5
+Signal25
Signal26
Integrierer5
P_Sum_Ventilblock E_Sum_Ventilblock
SchlauchKP1
x|fach
P_SKP1
SchlauchKP2
x|fach
P_SKP2
SchlauchKP5
x|fach
P_SKP5
SchlauchKP4
x|fach
P_SKP4
SchlauchKP3
x|fach
P_SKP3
Summe6
+P_Sum_SKP3-5_1
Summe7
+Integrierer6
P_Sum_SKP1-2 E_Sum_SKP1-2
Integrierer7
E_Sum_SKP3-5
Summe8
+
Summe9
+
E_Setzzylinder
E_Verlust
Summe10
+E_Verif
R2a
P_R2a
Summe11
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Ta
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Summe13
+Signal50
RIVSET® Gen2
Self-pierce riveting in its new generation
© Bollhoff Verbindungstechnik GmbH
ESEMO - development of self-monitoring
energy optimized assembly robotics
Project Funding:
Simulation Model
Component oriented valve
block assembly in the
simulation model
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 7 FLUIDON at HTC 2013
© 2013 FLUIDON
Motivation: Improved Energy-Efficientcy of Vehicle Hydraulic Systems
Baum, H. ; Ulrich, H.:
Digitale Simulation bei der Entwicklung fluidtechnischer Fahrzeugsysteme.
Haus der Technik, Essen, 2003
Project Partner:
OptiELF - Optimization of energy efficiency at the power transmission of
vehicle hydraulic systems.
Problem
• Increasing fuel consumption due to energy losses at the multiple resistances
Sectional view of a hydraulic steering line Standard steel pipe
Flexible fabric hose
Tunerline
Compression
Restrictor
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 8 FLUIDON at HTC 2013
© 2013 FLUIDON
Content
Motivation 1
Application Example 2
Classic Modeling Method in 1D Simulation Programs such as 3
Use of Computational Fluid Dynamics (AcuSolve) 4
Summary 5
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 9 FLUIDON at HTC 2013
© 2013 FLUIDON
Application Example: Power Steering Hose Line Hose Design Overview
Pump
Steering
38
7 12
240 155 96 38
43 120
190 30
angenommen
115 620
5
5
16
4
4 St-Tuner
Pipe Section with Multiple Bends
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 10 FLUIDON at HTC 2013
© 2013 FLUIDON
Application Example: Power Steering Hose Line Pressure Loss Measurement of the Section with Multiple Bends
Flow Direction
Pressure Sensor P1 Pressure Sensor P2
Temperature Sensor
Pressure Loss of the Pipe Segment with Multiple Bends
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 11 FLUIDON at HTC 2013
© 2013 FLUIDON
Content
Motivation 1
Application Example 2
Classic Modeling Method in 1D Simulation Programs such as 3
Use of Computational Fluid Dynamics (AcuSolve) 4
Summary 5
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 12 FLUIDON at HTC 2013
© 2013 FLUIDON
Pipe section of the OptiELF power
steering line with multiple pipe bends
Pressure-Loss Calculation of Pipes with Multiple Bends Classical Method in 1D System Simulation
Q, pIn
Q, pOut
Simplified pipe section with multiple
pipe-bends to explain the "classical
method"
Other Examples of pipes with multiple bends
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 13 FLUIDON at HTC 2013
© 2013 FLUIDON
Pressure-Loss Calculation of Pipes with Multiple Bends Classical Method in 1D System Simulation
2
R v2d
Lp
DpR,1
DpR,2
DpR,3
DpR,4
Pipe Segments
2
2vpF
Pipe BElbows
DpF ,1
DpF ,2
DpF ,3
ElbowsPipeSegmentsPipeVOutIn ppppp
Q, pIn
Q, pOut
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 14 FLUIDON at HTC 2013
© 2013 FLUIDON
Pressure-Loss Calculation of Pipes with Multiple Bends Classical Method in 1D System Simulation
Q = 18 L/min
n = 104 mm2/s
= 858 kg/m3
Re = 476
D = 7,7 mm L = 369 mm
Bend 1 u. 2: R = 12 mm, d = 50°
Bend 3: R = 12 mm, d = 20°
Calculation methode
p in bar
Original
[1] [2] [3] [4] [5] [6]
1,34 1,66 1,20 1,21 1,28 1,33
[1] to [6] represent different literature sources to calculate the pressure loss coefficient .
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 15 FLUIDON at HTC 2013
© 2013 FLUIDON
Pressure-Loss Calculation of Pipes with Multiple Bends Classical Method in 1D System Simulation
Q, pIn Q, pOut
Weaknesses of the
classical method are:
Loss coefficients for form pieces result from
different sources with and without attention of
the Reynolds number.
Loss coefficients are not available for all form
piece geometries.
Order and geometric orientation of the
individual elements are not taken into account.
The inlet flow and outlet flow in the individual
test for the determination of the loss coefficient
is different from the real application.
ElbowsPipeSegmentsPipeVOutIn ppppp
More information can be found in:
„Einsatz von CFD zur Bestimmung von Druckverlusten
in laminar durchströmt gebogenen Rohrelementen
für die 1D-Simulation„
Key-Note Speach at FLUIDON Conference 2012
Prof. Axel Faßbender
Laboratory for Vehicle Hydraulic
Institute for Vehicle Technology – FH Köln
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 16 FLUIDON at HTC 2013
© 2013 FLUIDON
Content
Motivation 1
Application Example 2
Classic Modeling Method in 1D Simulation Programs such as 3
Use of Computational Fluid Dynamics (AcuSolve) 4
Summary 5
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 17 FLUIDON at HTC 2013
© 2013 FLUIDON
CFD Model Set-up in AcuSolve
HyperStudy Parameter Optimization
off-line coupling
(data table export)
1D System Simulation
Main geometry data:
d = 8 mm
L = 480 mm
Bend 1: R = 20 mm, d = 61°
Bend 2: R = 20 mm, d = 77°
Bend 3: R = 20 mm, d = 53°
Bend 4: R = 20 mm, d = 59°
Bend 5: R = 20 mm, d = 66°
Bend 6: R = 20 mm, d = 90°
Step 1:
Model Set-up of the
bending pipe segment
in AcuSolve
AcuSolve CFD
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 18 FLUIDON at HTC 2013
© 2013 FLUIDON
off-line coupling
(data table export)
AcuSolve CFD
Automated Simulation with HyperStudy
1D System Simulation
Step 2:
Automated simulation of
the pressure loss at
characteristic operation
points
Temperature form
-10 °C to 80 °C
in 10 °C steps
Flow form
1 l/min to 12 l/min
in 1 l/min steps
Altogether 120 design
points
HyperStudy Parameter Optimization
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 19 FLUIDON at HTC 2013
© 2013 FLUIDON
Pressure Loss Table in
HyperStudy Parameter Optimization
off-line coupling
(data table export)
AcuSolve CFD
1D System Simulation
Step 3:
Post processing of the
CFD results and import
as pressure loss lookup
table into .
Pressure losses are flow
and temperature
dependent.
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 20 FLUIDON at HTC 2013
© 2013 FLUIDON
Representation of the Pressure Loss Ratios in the 1D Simulation
In the final pipe model the fluid
inertia and the pressure losses
due to a straight pipe are
represented through .
Pressure losses due to pipe
bends and secondary flow
effects are covered through
CFD simulations.
Bend
Pressure Loss
Secondary Pipe
Pressure Loss
Bendp
2
22Q
AKBend
Secondaryp
2
22Q
AKSecundary
OutIn pp
Overall
Pressure Loss
= + +
Combined pressure Losses are derived from CFD results.
pIn pOut
Bend 1
Bend 2
Bend 3
Bend 4
Bend 5
Bend 6
Primary Pipe
Pressure Loss
Qr
Lstraight
4
.8
Primaryp
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 21 FLUIDON at HTC 2013
© 2013 FLUIDON
P2
P1
Simulation model of the entire power steering hose line
Pressure Loss Simulation of a Steering Hose Line
P1
P2 38
7 12
240 155 96 38
43 120
190 30
angenommen
115 620 5
16 23
5
5
5
7 63
Line segment overview
Bended
Pipe
Section
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 22 FLUIDON at HTC 2013
© 2013 FLUIDON
Pressure Loss Simulation at T = 50 °C
Flow [l/min]
Pre
ssure
Loss [b
ar]
Measurement 50 °C
Improved Simulation
Initial Simulation
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 23 FLUIDON at HTC 2013
© 2013 FLUIDON
Content
Motivation 1
Application Example 2
Classic Modeling Method in 1D Simulation Programs such as 3
Use of Computational Fluid Dynamics (AcuSolve) 4
Summary 5
This copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Slide 24 FLUIDON at HTC 2013
© 2013 FLUIDON
Summary
CFD simulations are an appropriate remedy to model minor
pressure losses in a 1D system simulation.
With and AcuSolve working hand in hand
a HyperWorks user has access to all necessary tools
for such a workflow.
Thank you for your attention