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Multidisciplinary optimization of an
ethanol SI-engine
Bernardo Reis Dreyer de Souza, M.Sc.
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Agenda
About Sygma Motors
Motivation and Objectives
Problem Definition
Multidisciplinary Workflow
Disciplinary Workflows
Preliminary Results
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To provide innovative
solutions, with high
technological content and
environmentally
responsible, to be used in
internal combustion
engines.
Mission
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VSE Vale Solues em Energia: Ethanol / VNG
Engines Project.
VSE - Vale Solues em Energia: Ethanol GenSet
Project.
Customers & Projects
FPT FIAT Powertrain Technologies: Engines
Characterization Services
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Performance Modeling
INFRA-STRUCTURE
LAB
DIGITALMODELLING,
SIMULATION &ANALYSIS
Rapid Prototyping
Mechanical Design
SCRE Single Cylinder Research
EnginePIV Particle Image Velocimetry
Digital Scanning
Valve train bench
MoTeC dSpace FLEX DI ECU
Engine Control Systems
Infra-Structure
Combustion Visualization
Systems
Spray Visualization System
CFD Computational Fluid Dynamics
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Motivation and Objectives
Motivation Engine design is a multidisciplinary process
Ethanol engines are receiving more attention
Lower carbon emissions
Higher knocking resistance compared to gasoline
Renewable
Objectives
Demonstrate an application of multidisciplinary design optimization ininternal combustion engines
Apply the process for a research engine
Models are validated
Show some techniques that aid in the integration of several disciplines inmodeFRONTIER
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Problem Definition
Optimize the engine efficiency Indicated Efficiency
Engine efficiency without taking friction into account
Volumetric Efficiency
Breathing capacity
Enables the engine to deliver more power
Design Variables
Piston bowl geometry
Keeping the compression ratio
Lift profiles for intake and exhaust valves
Ignition timing
Fuel mass per cycle Constraints
Valvetrain dynamic behavior
Avoid collision between valves and piston
Piston maximum temperature
Piston maximum stress
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Analysis and Design Process
ParameterizedGeometry
Dynamics
Optimization
Thermo-mechanical Analysis
Performance
Analysis
Parameterized
Kinematics
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Workflow Implementation
The worfkflow is divided into disciplinary subsystems
Data packges are exchanged between disciplines
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Typical disciplinary implementation in modeFRONTIER
Receive Data
Disciplinary Variables
Deliver Data
Process Execution
External Variables
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GG - Geometry Generation
Piston bowl shape parameterization Separate models for mesh generation and performance analysis
Full piston model for mesh generation
Piston crown model for performance analysis
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VKD - Valvetrain Kinematics Design
Kinematic Design and Analysis Valve lift profiles parameterization
Polynomial segments
Cam profile generation
Valve/Piston collision analysis
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PFA Performance Analysis
1-D thermodynamic simulation of the four-stroke cycle Calculates the efficiencies, heat flow and pressure
Runs a predictive combustion model
Pressure
Heat Flow
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Influence of piston bowl geometry on combustion
Predictive combustion model Interaction between flame front and combustion chambers walls
Example:Flame front area Fuel burn rate
p-V Diagram
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TMA Thermo-mechanical analysis
Piston finite element meshing Temperature analysis
Stress analysis
Pressure
Heat Flow
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VDD Valvetrain Dynamics Design
Checks if the valvelifts profiles generated by VKD satisfy dynamicconstraints
Enters a local optimization for each valve, if constraints are violated
Nested workflows
Check dynamics Optimize dynamics
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VDO Valvetrain Dynamics Optimization
Optimizes specific variables of the dynamic domain of the valvetrainsystem
The same dynamic model from VDD is used
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Results
Preliminary results using Surrogate models Radial Basis Functions interpolation
Optimization run with NSGA-II
Population of 50 individuals
100 generations
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Results
Parallel chart for Pareto frontier
High Indicated Efficiency Profile
High Volumetric Efficiency Profile
Opposite trend obtained from CFD!
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Correlation on Pareto frontier
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Conclusions
Multidisciplinary design optimization will help us design competitivetechnologies
More disciplines have to be included
Obtain turbulence parameters by CFD
swirl, tumble and squish
Models need to be improved
Emissions prediction
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Acknowledgements
Patrick CardosoClayton Zabeu
Giovanni Kotinda
Jean Rezende
Felipe Cardoso
Leandro VieiraOlindo Cruz
Oswaldo Franca Jr.
Ivan Trindade
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