Fluid Power System Simulation Hand in Hand

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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




© 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




© 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




© 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.




© 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

L9

x|fach

L10

x|fach

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xWRCE100xWRCE160

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p

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AntriebSSchmiedePumpen

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Schmiedesteuerung1

SMSMEER Korrektur_OT

Korrektur_UT

Rueckzug

Schmieden

xUTUT

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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




© 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

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Integrierer1

Integrierer2

Integrierer3

Integrierer4

E_Pumpe

E_Sum_DV

E_Niederhalter

E_Nietbolzen

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+Signal25

Signal26

Integrierer5

P_Sum_Ventilblock E_Sum_Ventilblock

SchlauchKP1

x|fach

P_SKP1

SchlauchKP2

x|fach

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x|fach

P_SKP5

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x|fach

P_SKP4

SchlauchKP3

x|fach

P_SKP3

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+Integrierer6

P_Sum_SKP1-2 E_Sum_SKP1-2

Integrierer7

E_Sum_SKP3-5

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E_Setzzylinder

E_Verlust

Summe10

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R2a

P_R2a

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R3a

P_R3a

R1a

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Ta

P_Ta

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+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




© 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




© 2013 FLUIDON

Content

Motivation 1




Summary 5




© 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




© 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




© 2013 FLUIDON

Content

Motivation 1




Summary 5




© 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




© 2013 FLUIDON


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




© 2013 FLUIDON


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 .




© 2013 FLUIDON


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




© 2013 FLUIDON

Content

Motivation 1




Summary 5




© 2013 FLUIDON

CFD Model Set-up in AcuSolve


off-line coupling

(data table export)


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




© 2013 FLUIDON

off-line coupling

(data table export)

AcuSolve CFD

Automated Simulation with HyperStudy


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





© 2013 FLUIDON

Pressure Loss Table in


off-line coupling

(data table export)

AcuSolve CFD


Step 3:

Post processing of the

CFD results and import

as pressure loss lookup

table into .

Pressure losses are flow

and temperature

dependent.




© 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




© 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




© 2013 FLUIDON

Pressure Loss Simulation at T = 50 °C

Flow [l/min]

Pre

ssure

Loss [b

ar]

Measurement 50 °C

Improved Simulation

Initial Simulation




© 2013 FLUIDON

Content

Motivation 1




Summary 5




© 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