Simcenter Amesim/STAR-CCM+ co-simulation – Aircraft ECS with its cabin and passengers

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Simcenter Amesim/
STAR-CCM+ co-simulation
Aircraft ECS with its cabin and passengers

Agenda
• Introduction to the product portfolio
• Motivation for this co-simulation study
• Setup of the Simcenter Amesim model
• Setup of the STAR-CCM+ model
• Results of the Simcenter Amesim/
• Going further

Simcenter™ Portfolio for Predictive Engineering Analytics
Simcenter System Simulation Solutions
Simcenter Amesim
Simcenter
System
Synthesis
Simcenter
Sysdm

STAR-CCM+
STAR-CCM+

Cloud
Licensing
flexibility
Cornerstones for a future-proof engineering approach
Covering full range of
methods
Analytics, reporting &
exploration
Deployment flexibility
Openness &
Scalability
User experience
Industry &
engineering expertise
Systems approach
Collaboration &
workflow
Multidiscipline
& multiphysics
R
F
L
P
Controls
1D
3D
TEST
CFD

Agenda
• Results of the Simcenter Amesim /
• Going further

Context and motivation
Purpose: Development of an efficient
Environmental Control System (ECS)
Main ECS functions
• Air conditioning
• Cabin pressurization
• Ice protection
• Cross engine starting
Air conditioning for passenger comfort:
• Controls temperature and humidity
• Extracts air from the bleed ports of engine
• Contains filtering systems
• Ensures equipment safety
One of the biggest consumers onboard - interconnected
to several systems (ATA chapters 28, 29, 30, 47, 7X) and
impacting specific fuel consumption (SFC)

1D system simulation and 3D CFD approaches
Simcenter Amesim and STAR-CCM+
AMEsim
Simcenter Amesim
STAR-CCM+
• Multi-domain and multi-level components
assembled together to model physical behavior
of complex systems
• Predict operating points and scenarios to
manage transient boundary conditions (pressure,
temperature, flow rates…)
Simcenter Amesim - System level (1D)
• Detailed geometrical representation of a component
• Resolve flow and thermal situations where 3D effects
are predominant and access local variables
STAR-CCM+ - Geometric level (3D)

Context and motivations
Virtual prototyping & Digital Twin to improve, secure
and accelerate product development
• 3D CFD and 1D system simulation are complementary
• Reduce conservatism by improving boundary
conditions
Take the best from both world
• Co-simulation with strong coupling
• 3D CFD zooming to improve system level modeling or
to anticipate hot spots

Agenda
• Going further

Scalable multiphysics behavioral modeling and analysis
Simcenter Amesim
48 libraries
6,500 multi-physics models
Fluids EnergyThermodynamics Control Liquid
propulsion
Mechanical Electrical
High-fidelity plant models (SIL, HIL)
Support of real-time platforms
Standards
Interfaces to simulation
Multiple 3D CAE
Applications
Open, mechatronics simulation platform
Scalable
system
to
component
Flight controls Flight
dynamics
Environmental
control system
Fuel systems Electrical
systems
Landing
systems
Propulsion
systems
Engine
equipment
Integrated
systems
Hydraulic
systems

Case description
• Regional twin engine aircraft with 100
passengers and 3 crew members
• Engine bleed air systems
• Consumers: WAI, FTIS, WTPS, APU, etc.
• Air conditioning units - ECS packs
• Fuselage structure – global conductance
model or nodal thermal model
• Aircraft zoning – based on lumped approach
- pressure & temperature in different zones
(cockpit, forward cabin, etc)
Simcenter Amesim model of the ECS with its subsystems

Zooming into the thermal behavior of the cabin
• To refine the passenger comfort evaluation, the
forward cabin 1D model is removed by a 3D CFD
model of the cabin – zooming into the thermal
behavior of the cabin
• Passenger and equipment comfort can be
assessed in different operating conditions
• Pull-up and pull-down transients can be refined
assessing perceived comfort in detail (seat
temperatures, etc)
• Failure cases can be performed to assess overall
system performance in case of malfunctions
Assessing passenger comfort requires access
to local variables inside the 3D CFD cabin
(temperature gradients & local air speed).

Agenda
• Going further

Co-simulation - Strong coupling
Inlet mass flow
Inlet temperature
Heat loads
Cabin temperature
• Dynamics of interfaced models have same order of magnitude
• One of the most important dynamics lies in the coupling itself
Simcenter Amesim STAR-CCM+
Strong coupling
Two-way coupling

3D STAR-CCM+ model – CFD cabin model description
Boundary conditions
• 1 row cabin model-4 passengers with periodic boundaries
• Lower/upper blowers (mass flow inlets)
• Recirculation grid (pressure outlets)
• Cabin wall, with specific heatflux (environment)
Mesh
• 2 million polyhedral elements
• Prismatic layers
Physics
• Accounts for natural and forced convection (ideal gas and
gravity models enabled)
• Other material properties are temperature-dependent
(viscosity, specific heat, thermal conductivity)
• Thermal comfort (physiological activity of passengers) STAR-CCM+
Cabin model

3D STAR-CCM+ model – Passenger comfort
STAR-CCM+Air flow streamlines
Passengers Gillian and Jack
Temperature set-point
Passenger comfort requirements are imposed by the aeronautical rules:
• Minimum fresh flow per passenger
• Velocities inside the cabin
• Cabin stabilized pressure and temperature
• Differential temperature between body parts (head/feet, shoulders…)

Evaluation of cabin thermal environment
Passenger comfort needs to be estimated for different flight scenarios:
• Different occupancy configurations
• During hot and cold day
• During day and night…
• Ground, cruise and in-flight missions
• In the event of a component failure (e.g. loss of an ECS pack for instance)

Agenda
• Going further

Scenarios description
3 conditions investigated:
• Pull-up
• Cool-down on ground
• Loss of one ECS pack in cruise conditions
Initial temperatures for pull-up and cool-down
conditions:
• ISA –55°C
• ISA +25°C
• Half an hour simulated time based on
regulations for these ground cases
Failure case analysis: 1 pack fails after 100 (sec.)
• OAT = -30 °C
• Altitude = 35 000 ft
• Mach = 0.85
• Less than 10 min are simulated
Simcenter Amesim
ECS pack failure
after 100 sec.

1D co-simulation results in Simcenter Amesim
• Pack loss after 100 s (cruise
condition)
• Flow control and X-bleed valves
closed
• Temperature increase in cabin
zones due to cooling power loss
• Temperature regulation still in
operation Simcenter Amesim
ECS variables of interest are exposed in the Dashboard

1D co-simulation results in Simcenter Amesim
• Monitor air flows delivered by air
conditioning units to the cabin
• Air flows bled off impacting
engines’ performance
• ECS pack failure
• Pack loss counterbalanced by
left pack in high flow-rate mode
Simcenter Amesim
Evolution of the ECS variables – Failure case

3D CFD co-simulation results in STAR-CCM+
STAR-CCM+
STAR-CCM+ Relative velocity over passenger bodies
for Gillian and Jack

3D CFD co-simulation results in STAR-CCM+
STAR-CCM+
STAR-CCM+
Temperature evolution around
Gillian and Jack
Left/right temperature ratio

Agenda
• Going further

STAR-CCM+/Simcenter Amesim co-simulation user guide in the
Simcenter Amesim online documentation

System Driven Product Development
Enabling Verification and Validation in the Age of System Engineering
SYSTEMS DRIVEN PRODUCT DEVELOPMENT
PREDICTIVE ENGINEERING ANALYTICSSYSTEM MOCK-UP
MULTI-DOMAIN TRACEABILITY, CHANGE AND CONFIGURATION
3D TEST
ANALYTICS - REPORTING
Digital
twin
VERIFICATION & VALIDATION
1D VIACFD

3D SIMULATION
CFD SIMULATION
1D SIMULATION
From disconnected models and data …
Customer Usage data
Simulation data
Test data TEST MODELING
Historical data
CONTROLS

…to a performance Digital Twin
3D SIMULATION
CFD SIMULATION
1D SIMULATION
Customer Usage data
Simulation data
Test data
CONTROLS
TEST MODELING
Historical data

Realize innovation.
Matthieu STASIA
STAR-CCM+
Olivier BROCA
Simcenter Amesim Aerospace and Defense
Stéphane NEYRAT
Karim NASSAR
Simcenter Amesim Platform
Siemens PLM / Simulation & Test Solutions Department

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