Comprehensive Software

for Thermal Energy

Management Optimization
www.ecs.steyr.com
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Who we are?

Who we are?
25.01.2011

Gregor Breuer

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Who we are? The Company

MAGNA International
Magna
Seating

Seating
Systems

Magna Exteriors and Interiors

Interior
Systems

Exterior
Systems

Magna Mirrors &

Magna Closures

Vision
Systems

Closure
Systems

Cosma
International

Body & Chassis

Systems

Magna Steyr

Engineering
& Assembly

Roof
Systems

Magna Powertrain

Powertrain &
Engineering

E-Car Systems
(J.V.)

Hybrid &
Electric
Vehicles

Electronic
Systems

ECS Engineering Center Steyr

Complete Vehicle Engineering
Technology & Software Development
Vehicle Testing

08.12.2011

Gregor Breuer

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ECS @ a Glance
World leading engineering service provider
focused on:
Innovation
System Engineering
Commercial Vehicle Engineering
Improved transport efficiency
Execution within a global network

IMG

e-drive

Oct. 2013

Author: W. Dantendorfer

HCU

Range of Services:
Commercial Vehicle Engineering
Powertrain Systems
Software & Simulation
Electronics & Electric
Testing Services
Low Volume Production
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Thermal- and Energy- Management

Thermal Management
Simulation / Testing:
- under hood flow
- component temperatures
- coolant/oil circuits
- charge air circuits
Optimization of VTMS
Operating Strategies
Product Specification
and Testing:
- Fan/Cooler
- Pumps (oil/coolant)
- Entire Cooling Package
- Thermostat / Valves
Vehicle testing:
- chassis dynamometer
- test track
- on track
Date: May 2013

Author: Clemens Gamsjaeger

HVAC

Energy Management

AC Concepts
AC Power
(Heating/Cooling)
Comfort
Deicing / Demisting

HVAC Measurements
(test rig / road)

Alternative Powertrains

Battery conditioning
Operating strategy
Component specification

Driving Performance
Consumption
CO2 Optimization
Energy Balance
Operating Strategy

Aerodynamics:
- under hood
- circulation
- lift / drag

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Who we are? The KULI Team

Department Energy & Fluid Simulation
Department Leader
E&F Simulation
Christian Rathberger

Sales
Rolf Salomon

Software
Thomas Naderhirn

Services
Dr. Christoph Stroh

Software Developers and Software Users exist under one umbrella!

25.01.2011

Gregor Breuer

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What is KULI?

What is KULI?
25.01.2011

Gregor Breuer

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Thermal Management Software

Powertrain Cooling

Air Conditioning

Consideration of all
Thermodynamic Key Values

Temperatures
Pressures
Mass flow
Heat flow
Other Energy flows

Windows Desktop Software for the 1D-Simulation of the Vehicle Thermal Energy Management

25.01.2011

Gregor Breuer

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Thermal Management Software

Component
& Function
Toolbars

2D Fluid
Network
View

Project
Organization

3D Air
Network
View

Analysis
Progress
Info

1-dimensional Fluid Network Analysis Quasi 1-dimensional Air Flow Network Analysis

25.01.2011

Gregor Breuer

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10

Energy Management Software

Transient
Conditions
Engine
Model

AC System

Cooling
System

E-mobility
recuperation

CoSimulation

Optimization
CFD
Analysis
25.01.2011

Gregor Breuer

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COM-Interface

12

Typical
Applications
15.04.2011

Gregor Breuer

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13

Typical Application Top Tank Temperature

Input
KULI data for fans and coolers
Volume flow data for all
participating fluids
Ambient temperature
Driving velocity
Rejected heat by the condenser
Amount of glycol in the coolant

Results
Top tank temperature
Air to boil
Analysis of the operating points of the
fans/coolers
Additional results:
Parameter variation (fan speeds, volume flows,...)
on the above mentioned measurable variables

25.01.2011

Gregor Breuer

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15

Typical Application Concept Studies

Compare direct and indirect charge air cooling

low temperature
radiator

conventional CAC
water-cooled CAC
25.01.2011

Gregor Breuer

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16

Typical Application Minimize Package Size

Reduce heat exchanger sizes
according to performance
limits

400 mm
300 mm

297 mm
259 mm

08.07.2011

Gregor Breuer

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17

Typical Application Transient Simulation

Avoid oversizing of components due to steady state operating points
Zusatzwasserkhler
In 2
In
Out
Out

In 2

Cooler

CA

Thermostate

CAC

In 1

Thermostat ByPass

Out
In 1

Airpath
[Water]
In
In

Out

Out

Thermal capacities
considered

RPM_#ECU [1/min]

CF

In

BMEP_#ECU [bar]

Exit temperature OM

In

SPEED_#ECU [km/h]
Oil

In

ECU
In
Out

Out

2
X1

X1
Out

X2

In

BMEPcorrected

Out

Oil
x

X2

Out

Volume flow IM
Temperature
Pressure

X3

BMEP_#Amb [bar]
RPM_#Amb [1/min]
SPEED_#Amb [km/h]
p_#Amb [hPa]

Out

X1

SPEEDcorrected

Speed

p_#Ambient

Ambient temperature

Temperature

Mean eff. pressure

BMEP

Ambient pressure

RPM

RPM

Out 1

Out

SPEED

In

Out

Pressure
Out

Out

T_#Amb [C]

X2
Out

SP

RPMcorrected

Out 2

Out

1.49

KULI Engine Model

08.07.2011

Gregor Breuer

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18

Typical Application Cool Down Simulation

Find evaporator heat load
such that passenger cabin
cool down requirements
are met

25.01.2011

Gregor Breuer

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19

Typical Application Energy Management

Energy Management Simulation for a Hybrid Truck

Driving Cycle (HUDDS)

Heavy-Duty Urban Dynamometer Driving Schedule

Fuel Saving Potentials

Parallel Hybrid Vehicle

Battery, Coolant Temperature

25.01.2011

Gregor Breuer

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21

Application Cell Temperature Optimization

Battery type (Li-Ion, NiMh,)

Internal resistance
= f(current, temperature, SOC)
Open circuit voltage characteristic
= f(temperature, SOC)
Heat source
= f(current, internal resistance)
Cell cooling
Thermal network

25.01.2011

Gregor Breuer

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22

Why to use KULI?

Why to use KULI?

25.01.2011

Gregor Breuer

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23

Costs

Fuel Consumption
Gregor Breuer

Inlet area decreasing (design)

New technologies (e.g. hybrid)
More components / auxiliaries

Durability

25.01.2011 Author:

Engine power increasing

Comfort

Emissions

Why Thermal Energy Management?

Legislative Standards

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24

Why to use Computer Simulation?

System
Comprehension

Understand complex component interactions easily

Effects of single measures can be within measurement
accuracy

Concept Studies

Fast analysis and solutions: Rapid Prototyping

Save time and cost (test bench, prototypes)

Support Test Bench

25.01.2011

Improve test quality through plausibility checks

Reduce hardware test loops

System
Optimization

Quickly find measures for improvement

Find control strategies for auxiliaries
Computation only possibility of optimum validation

Minor Model
Update

Easy handling of engine upgrades

Component replacements: compare different suppliers

Gregor Breuer

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26

Why to use KULI? Low Hardware Demands

Desktop Application
Works on any Laptop

Quick Simulation
Steady state results within seconds

November 2010: KULI on iPad

25.01.2011

Gregor Breuer

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27

Why to use KULI? Realistic Results at Low Effort

Component
& Function
Toolbars

2D Fluid
Network
View

Project
Organization

3D Air
Network
View

Analysis
Progress
Info

Learn to use within 2 days of Training

25.01.2011

Gregor Breuer

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28

Why to use KULI? Tailored to Customer Needs

From Engineers for Engineers

Specialized: Automotive Industry

Transient
Conditions
AC System

Engine Model

Cooling
System

Driving
Cycles
2000
1500
1000
500
0

200

400

600

800

1000

1200

1400

1600

1800

Time [s]

CoSimulation

Optimization

CFD Analysis

Modular Structure

25.01.2011

Gregor Breuer

COMInterfa
ce

Flexible Software: simple & complex

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29

Why to use KULI? Multitude of Features

Postprocessor
Output Analysis
Presentation Material for Management
Uniform Component Library
Extendable Media Library
Water/Glycol, Oil, Exhaust, Refrigerant
Unit Converter
Optimization Package
Optimization, Parameter Variation
Software Interfaces

Excel, Matlab, CFD codes,

25.01.2011

Gregor Breuer

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30

 Global Presence
EASTERN + WESTERN EUROPE
NORTH AMERICA

Enterex America

JAPAN

CHINA

SOUTH KOREA

INDIA

SOUTH AMERICA

Passenger Cars Trucks Construction/Farm Machines Trains | OEMs Suppliers Researchers

22.10.2014

Gregor Breuer

ECS / Disclosure or duplication without consent is prohibited

31

Why to use KULI? Best Software Support

KULI Team

Support is given by all members of

the KULI Team

Department
E&F Simulation

Expertise through product overview

Expertise though product insight
Expertise through product practice

Sales

Software

Services

Friendly and personal

Working to YOUR advantage
Quick response
usually within 24 hours
Facility to enhanced support
Paid services for quick and reliable solutions

kuli_support@ecs.steyr.com
25.01.2011

Gregor Breuer

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32

Why to use KULI?

Low hardware demands

Realistic results at low

effort

Tailored to customer
needs

Desktop PC
Short analysis time

Clear and brief GUI

Easy to learn: fit in 2 days
No hidden data

from Engineers for Engineers

Specialized Software
Flexible Software
Modular structure

Multitude of features

Worldwide usage

Best software support

Uniform Component Library

Extendable Media Library
Postprocessor
Optimization Package
Software Interfaces

KULI data available from

majority of suppliers

Quick response
Expertise through practical
use
Facility of enhanced support
(simulation services)

25.01.2011

Gregor Breuer

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33

Who to use KULI?

Who to use KULI?

25.01.2011

Gregor Breuer

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34

Who to use KULI?

Engineers related to Thermal Management (not restricted to Automotive Industry)

OEMs
Design-Engineers

25.01.2011

Gregor Breuer

Suppliers

Engineering Service
Companies

Researchers

CAE-Engineers

Test-Engineers

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35

When to use KULI?

When to use KULI?

25.01.2011

Gregor Breuer

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36

When to use KULI? - Product Development Process

Key Milestones:

PT1

PT2

PPAP

R@R

Disp

Program Management
Product Specification
Concept Development
Virtual Model

Product Design
Simulation / DMU / Validation
1. Prototypes / Mules

2. Prototypes / Pre-Production

Functional- / Fatigue- / Vehicle Testing

Product Validation
Product Definition

Product Creation

Concept

25.01.2011

Gregor Breuer

Simulation

Industrialization

Prototyping

Funct. Testing

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Vehicle Testing

37

SOP

How to use KULI?

How to use KULI?

25.01.2011

Gregor Breuer

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39

How to use KULI? Data Structure

OEM
SUPPLIER

Vehicle Data

Simulation
Conditions

Design
Engine

Ambient
Operating Status

Component
Data

Boundaries &
Targets

Dimensions
Characteristics

Max. Dimensions
Max. Top Hose
Temperatures

25.01.2011 Author:

Gregor Breuer

Simulation
Model

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40

How to use KULI? Workflow

Component
Setup

Input data
(Geometry,
Characteristic)

Save in
Component
Library

System Setup

Load
components
(from Library)

Define Media
Properties

Simulation

Run Analysis

Optimize, Vary
Parameters

Results

Get Output
from
Postprocessor,
Excel Sheet,

Compare with
System
Measurement
Data

25.01.2011

Gregor Breuer

Position and
Connect
Components

Input
Simulation
Parameters

Interpret
Results,
Reporting

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41

How to use KULI? KULI lab Output

Temperature
levels and
Pressure Drops

Userdefined Units

Heat Turn-over
and Efficiency of
Package

Data Filter
Detailed
Conditions and
amounts of
Cooling Air

Optimized
Parameters
depending on
Targets

25.01.2011

Gregor Breuer

Various Graphics

Variant Comparison

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42

Where to get KULI?

Where to get
KULI?
25.01.2011

Gregor Breuer

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43

 Global Contact
EASTERN + WESTERN EUROPE
JAPAN
Rolf SALOMON

NORTH AMERICA
Albert TUERTSCHER
AT engineering LLC
1891 Denver West Ct. #1432
Golden, CO 80401-0924

Yoshiyuki MOTOYANAGI

Magna Powertrain
Engineering Center GmbH & CoKG
Steyrer Strasse 32
4300 St. Valentin, Austria
Phone: +43 7435 501 2382
rolf.salomon@ecs.steyr.com

Phone: +1 734 276 5516

kuli.usa@ecs.steyr.com

Magna International Japan Inc.

Yaesu Center Building 5F
1-6-6 Yaesu, Chuo-ku,
Tokyo 103-0028, Japan
Phone: +81 3 3548 0310
yoshiyuki.motoyanagi@magnaint.co.jpp
CHINA
Terra CAI
Magna International China
801-813, Tower A, Eton Place
69 Dongfang Road, Pudong,
Shanghai PRC 200120
Phone: +86 21 6165 1649
terra.cai@magnapowertrain.com
SOUTH KOREA

INDIA

Jong-Kwan PARK
Yogesh RAHANE

SOUTH AMERICA
Leandro GARBIN
VirtualCAE
Servicos de Sistemas Ltda.
Rua Tiradentes 160 - Sala 22
So Caetano do Sul,
So Paulo (CEP 09541-220 )
Phone: +55 11 4229-1349
vendas@virtualcae.com.br

Tata Autocomp Systems Ltd.

Sr. No. 280 Village Mann,
Tal Mulshi, Hinjewadi Phase II,
Pune 411 057 Pune
Phone: +91 20 6675 5496
yogesh.rahane@tacogroup.com

TAE SUNG S&E Inc.

Seoulforest Kolon Digital Tower II 10F
Seongsu-dong2-ga, Seongdong-gu,
133-120, Seoul, KOREA
Phone: +82 2 3431 2442
jkpark@tsne.co.kr

Passenger Cars Trucks Construction/Farm Machines Trains | OEMs Suppliers Researchers

25.01.2011

Gregor Breuer

Disclosure or duplication without consent is prohibited

44

Contact & Summary

Rolf SALOMON
Magna Powertrain
Engineering Center GmbH & CoKG
Steyrer Strasse 32
4300 St. Valentin, Austria
Phone: +43 7435 501 2382
rolf.salomon@ecs.steyr.com

Characteristics
Quasi 1-dimensional Analysis of the Air Flow
Consideration of Pressure Drops and Overlapping
Tool for Developing, Analyzing and Testing Engineers

Input
Measurements of Components from Suppliers
Temperature Measurements of Vehicle if available
Demanded Dimensions and Positions of
Components
Coolant Flow Rates and its Heat Amount
Operating Points of Vehicle and Boundary Conditions

Output
Heat Turn-over and Efficiency of Cooling Packages
Temperature Levels
Detailed Conditions and Amounts of Cooling Air

Benefits

22.10.2014

Gregor Breuer

Comfortable Handling
Quick Analysis and Solutions
High Flexibility
Save Time and Cost

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45