Breakout Session

Temperature prediction of windings is of importance during development of an oil-cooled electric motor. A new method using a particle-based CFD software solution has been tested and validated against experimental data with the aim to simulate violent multi-phase flow more efficiently than with traditional CFD codes based on finite volume method. The fluid simulation was used to acquire a heat transfer coefficient (HTC) map whereas an advanced technique of simulating air and oil flow field separately with different particle sizes was utilised at this stage. The HTC map was subsequently applied to a steady state finite element thermal model in order to solve for temperature field. The correlation with the experimental data was deemed satisfactory within the targeted tolerance.

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Pierburg Pump Technology Italy Spa | Giorgio Peroni
Electrically-Actuated High-Speed Pumps: Layout Definition and Integrated Procedure to Design Optimization

Electrically-actuated pumps for automotive applications belong to the Pierburg Pump Technology product portfolio since more than two decades. They consist typically of a hydraulic system, featuring dynamic or volumetric concept, driven by a dedicated electric motor and controlled by an electronics module. They found their field of application within the traditional ICE vehicles as well as within the alternative propulsion vehicles: with water systems (cooling), oil systems (lubricating, cooling) or air systems (braking assistance).
More recently, among the electro-actuated pumps the family of high-speed pumps has become more interesting for PPT since new applications have raised to be attractive for the automotive market. We refer specifically to the Active Purge Pump for Evaporative Emission Control System (EVAP) application and the Hydrogen Recirculation Blower for FCEV application.
As high-speed electro-actuated pumps we usually indicate devices having rotational speed above 20.000 rpm. Their working fluid is typically a gas, air or gaseous mixture. Their global layout is quite similar each other, consisting of a shaft fitting the dynamic impeller and the magnetic rotor and supported by roller bearings. Anyway, they may have dimensions and power absorption quite different, of course within the limits typically imposed to the automotive applications.
From the engineering process point of view, high-speed pumps require a fully dedicated procedure, able to take into account of targets of different nature at the same time. On one side, high rotational speed (20.000 - 60.000 rpm) is necessary in order to fulfill the pneumatic performance. On the other side, such high speed may be challenging for the life of the bearings due to the loads generated by the dynamic response of the rotating system.
To support the pre-design phase of the new generation high-speed pumps the simulation approach has been widely employed. Specific tools have been introduced in order to sketch the pneumatic subsystem and to evaluate the dynamic loads acting on the bearings and consequently their life. Finally, all of these tools have been collected in one only workflow with the help of the modeFRONTIER ambient: the aim was both to integrate them in one only place and to link them through an optimization algorithm, obtaining a flexible tool able to deal with so different kind of applications.
The optimization procedure helps the engineer first to choose the optimum among all the possible layouts, exploring different relative positions of the impeller, the bearings and the magnetic rotor. Then, it helps to analyze a large number of variants, considering design constraints and limitations. Finally, it helps to detail and to keep under control possible trade-off between the pneumatic performance and the lifetime durability performance.

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Occupant safety is among the most important studies during a vehicle’s design process. To achieve the highest possible standards of occupant safety, engineers simulate a wide range of crash scenarios. In each scenario different factors affect the occupant injury results and the most effective way to identify these factors is to perform design of experiments (DOE) studies.
DOE studies can be used to optimize the vehicle's structure and the restraint systems. For the latter case many different properties of the seat-belt, the airbag, the seat and of the coupling between them and the occupant can be used as design variables to examine the occupant injury results.
In this paper a DOE studies how occupant injuries are affected from different seatbelt parameters. A THOR-50M ATD is used in a front impact sled test. The sled test was setup in ANSA, BETA CAE Systems’ pre- processor, the Optimization Tool of ANSA set up the DOE and LS-DYNA was used to calculate the results. META, BETA CAE Systems’ post- processor was used to extract automatically and evaluate all responses (injury peak values and time history curves).

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Ducati Corse | Stefano Rendina
Ducati Digital Process Innovation

Stefano Rendina, IT Manager, Ducati Racing, discusses how digital innovation is transforming the way we design, manufacture and service our products. Advanced simulations, data analytics, optimization are paving the road for a greener, safer and faster future. To maintain a technological advantage, a comprehensive approach to digital innovation has been put in place at Ducati.

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The present study involves the validation of the MPS meshless methodology for the simulation of oil piston cooling jets in a high performance engine application. A comparison between the approach using PARTICLEWORKS software implementing the MPS meshless method and the results obtained using STAR CCM+ software that implements the traditional finite volume calculation method with VOF multiphase model and Overset mesh will be presented. The MPS methodology makes it possible to quickly evaluate several different piston cooling configurations and geometries in early stage of engine design process.

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Flexible Printed Circuit Boards (PCBs) installed in complex shapes are increasingly being used in a wide variety of modern products ranging from smartwatches to automobiles. Their ability to survive high levels of shock and vibration along with the flexibility in connecting components and reduced package weights make them a desirable option. Given the complexity of PCB's, numerical modeling and analysis of such structures pose a major challenge and there is a need for clear, simple, and effective modelling techniques.
In this context, the Radial Basis Functions Mesh Morphing (RBF Morph) has been identified as a powerful mathematical tool to update the shape of a computational mesh by changing the nodal positions. In this work, a couple of different morph techniques have been developed and successfully applied to analyze flexible/curved PCBs. The methodology and the analysis results indicate that the morphing technology is arguably the simplest way to model flexible/curved PCBs.

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Endurica LLC | William Mars
Breaking the computational barrier to simulating full road load signals in fatigue of elastomers

Although modern computers are powerful and computing resources abundant, still, computing the impacts of full road load signals on durability of rubber parts has seemed to remain beyond the reach of even the largest industry players. The very large number of time steps involved, and the limited execution rate of typical finite element models has completely prevented the direct treatment of road load signals derived from track testing, from vehicle dynamical models or from a digital twin. In this work, we present the Endurica EIE nonlinear load mapping procedure, which provides a means by which the strain/stress histories resulting from full road load signals can now be rapidly generated. The procedure utilizes a series of pre-computed finite element solutions to populate a nonlinear map relating global load/displacement inputs to local strains/stresses within each finite element. For each time step of the full road load signal, the nonlinear map is used to obtain stress/strain results via interpolation. Examples are provided for 1-, 2- and 3-channel signal inputs, and applied to the following automotive components: a sway bar link, a control arm bushing, and a transmission mount. Input signals of several durations were studied as follows: 100, 1000, 10000 and 100000 time steps. The resulting analyses executed with as much as almost 4 orders of magnitude speed up relative to the alternative of a direct finite element solution, with error depending on map discretization (and therefore controllable up to an accuracy of about 10% in life). Importantly, the larger the number of time steps in the signal, the greater the relative analysis speed-up that is possible.

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Need to design, release and introduce a more affordable generation of battery electrical vehicles in the automotive market questions industry about efficiency of well established processes and traditional best practises. CAE discipline is no exception, most simulation environments and tools were developed to support internal combustion engine vehicle development and need some preliminary verification to be used for electric car applications too. This work assesses reliability of freeware softwares to estimate their performances, allowing thermal engineers priming their simulation models during early project develpment, saving time and improving risk management. Battery electrical vehicle heat generation and cooling capacity is sensitive to torque and speed profiles, then you have to explore many driving patterns to encompass all possible critical situations. Assuming freeware softwares provide fair enough simulation results, thermal CAE engineers can extract what they need by estimated vehicle performances, allowing performance expert concentrate their efforts to meet key customer requirements such as top speed, accelerations, driveability or range. A reliability assessment was performed estimating qualification lap times for electric cars attending official championships, relying on public available race results, regulations and vehicle specifications. All seasonal events were explored to introduce the largest possible variability due to different track layouts and environment conditions. Correlation between simulation and real results is encouraging, but in order to explore all selected freeware software features two additional investigations are planned for 2021,

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Dassault Systemes | Danilo Di Febo
EMC Simulation of an Electrical Vehicle Powertrain

This talk provides an overview of simulation solutions that address the challenges in the design of a three-phase inverter powertrain module , in particular, it addresses the EMC compliance, parasitic extraction aspects and impact of cables laid in to the vehicles. We start to evaluate the 3-phase system, limitation coming from the layout including the parasitic effect due to bond wire connection, this helps to reproduce the real scenario close to the prototype. The inverter will be integrate into the engine bay and connected to the electrical motor to estimate the emission. The engine bay will be integrate into full vehicles to evaluate the emission including the surrounding space.

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