Automating Analysis of Turbo-Machinery
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The document summarizes Cooper Standard's adoption and use of AcuSolve software for computational fluid dynamics (CFD) analysis of turbo-machinery like pumps. It describes how AcuSolve automated the setup process, reduced analysis time from days to hours, and provided accurate results that matched test data. Cooper Standard engineers can now independently conduct early-stage design evaluations to improve product development efficiency.
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Automating Analysis of Turbo-Machinery
- 1. Development of Tools to Automate the Analysis of Turbo-Machinery Tom Lincoln / Jaideep Bangal Cooper Standard / Altair Engineering, Inc.
- 2. Executive Summary • Cooper Standard (CS) Corporate Overview • History of CFD at Cooper Standard • Cooper Standard adoption of AcuSolve for enhanced CFD efficiencies and accuracy • Additional AcuSolve Applications at Cooper Standard
- 3. About Cooper Standard Headquarters: Novi, MI Established: 1960 Employees: 21,500+ Our Mission Locations: 70+ in 19 Countries Provide outstanding service, support 2010 Top 100 Global Suppliers: Rank 62 and innovative solutions to our 2010 Top 100 North American Suppliers: Rank 35 customers benefiting all stakeholders of Cooper Standard. 2011 Sales: $2.85 B
- 4. History 2012 2011 2010 2007 2007 2006 2005 2004 1960 1999 2000
- 5. Strategic Footprint Key Headquarters Sales / Administration Technical Center Manufacturing Manufacturing / Technical Center North America Europe Asia Pacific South America Joint Ventures Countries Cooper-Standard Saiyang Wuhu 94% /6% Australia Czech Republic Japan Romania Cooper-Standard NISCO 40% / 60% Belgium France Korea Thailand Brazil Germany Mexico United Kingdom Cooper Hubei Jingda 37% / 63% Canada India Netherlands United States Metzeler India 74% / 26% China Italy Poland Cooper Hasco China 47.5% / 47.5% / 5% Guyoung Tech Korea 20% / 80% Cooper Standard France 51% / 49% 2012 - Located in 19 Countries Nishikawa Tachaplalert Cooper Limited 20% / 80% 2004 - Located in 14 Countries
- 6. Global Customers RENAULT HYUNDAI
- 7. Breadth of Product & Segments
- 8. Thermal Management – Key Capabilities Heating and cooling management systems for hybrids, electric vehicles and internal combustion engines Electromechanical Devices Thermal Devices Thermal Integration
- 9. Technology Global Six Sigma Award Best • Automotive News PACE Award Achievement of Design for Six Sigma Honorable Mention • Coolant Water Valve • Electric Water Valve Assembly • Thermoplastic Rear Door Glass Over 500 Patents Globally • Daylight Opening Modules Seal Assembly • Engineered Stretched Plastics • Metal to Plastic Fluid Connection with • Occupant Detection Systems Overmolded Anti-Rotation Retainer • Low Fuel Permeation Nylon Tubing • Day Light Opening (DLO) System • Quick Connect Fluid Couplings • Society of Plastics Engineers • Core process methods Most Innovative Use of Plastic: Finalist • Electric Water Valve Assembly • Transmission Thermal Valve Assy • Electric Brushless Pump cooperstandard
- 10. Cooper Standard’s History With Pumps • Cooper Standard identified a market for electrically driven coolant pumps. • Development began in 2005, CFD was used from the start. • Cooper Standard offers pumps to replace the vehicle main water pump and auxiliary supplemental flow. • Wattages range from <20 W to 1 kW.
- 11. Early CFD Analyses – August 2005 • Combination Tet and Hex cells • Uniform mesh size • Significant time to set-up manually
- 12. CFD Analyses – June 2010 • ~5M cells ranged from 0.2 mm to 2 mm • Manual set-up required a full day and 6- 10 hours to converge each flow point Comparison Between Measured Data and CFD Prediction 1.20 1.00 Pressure Gain 0.80 0.60 Measured 0.40 Pressure Gain Predicted 0.20 Pressure Gain 0.00 5000 7000 9000 11000 13000 Flow Rate
- 13. Early CFD - Challenges • Results were good but • Model set-up would take 8+ hours • Each flow point would take 4 – 10 hours to converge • 6 flow points for one pump = 40+ hours • Meshing was manual and required expertise to generate a good mesh
- 14. AcuSolve Process Automation Import CAD / • Process intelligence 1 HM mesh • Fast setup: 4 steps Define • Solids • Auto meshing • Stationary Fluid • Rotational Volume • Angular velocity • Auto solving strategy • Rotation axis 2 • Auto Time steps calculation Boundary • Setup multiple flow points Conditions and run it batch mode Inlet / Outlet 10 3 minutes Automeshing Setup time Auto time step 4 calculations SOLVE
- 15. Cooper Standard Pump Analysis • Goal: Predict pump performance, Flow Curve • Reduce Setup and Solution time • Enable CSA Engineering team to analyze designs early Pump – Meshed Model Meshed Impeller
- 16. AcuSolve’s Rotating Machinery Process • First run • Very fast setup and solution • Helped understand process and setup before adding more details • Setup Time: 1 hour from receipt of CAD impeller • Solution Time: 12 flow points – 10 hours 1.200 Test… 1.000 First Run Pressure Gain 0.800 0.600 0.400 Boundary Layer = 1.4 mm Mesh Size 7 mm 0.200 0.000 0.000 0.200 0.400 0.600 0.800 1.000 1.200 Flow 16
- 17. AcuSolve’s Rotating Machinery Process • Refined Mesh • Analysis converged in 9th iteration • AcuSolve results matched test results • Setup Time: Unchanged • Solution Time: 12 flow points-24 hours 1.200 1.000 Pressure Gain 0.800 0.600 Test Pressure Gain Final Converged Run Boundary Layer = 0.1 mm 0.400 Mesh Size 2 mm (on Impeller) 0.200 0.000 0.000 0.200 0.400 0.600 0.800 1.000 1.200 Flow 17
- 18. AcuSolve Results Contours of Static Pressure Contours of Velocity
- 19. AcuSolve Results Velocity Profile Pressure Distribution – fluid volume Pressure Distribution
- 20. AcuSolve Results Contours of Pressure on Planes Cut Through a Pump Contours of Velocity on Planes Cut Through a Pump
- 21. AcuSolve Results Pressure Distribution Velocity Profile
- 22. AcuSolve Results Pressure Distribution Velocity Profile
- 23. AcuSolve’s Rotating Machinery Process • 1-hour setup • Automeshing ensures optimized mesh near critical flow/impeller features • Accurate results • Standardized inputs built into the tool • 5 flow points can be run in 10 hours on a 4 core laptop • The tool is being rolled out to the Product Engineers to handle increased demand 23
- 24. Additional Collaboration - Thermal Analysis – Pump • Cooper Standard engaged Altair in a consulting project to set-up the initial AcuSolve models • Altair transferred knowledge to Cooper Standard for future product development 3D CAD Model Simplified FEA 3D Model
- 25. Additional Collaboration - Thermal Analysis - Pump IR Camera Image AcuSolve Thermal Analysis results AcuSolve predicted high temperature component locations and were later confirmed by IR camera
- 26. AcuSolve Results
- 27. Thank You