CD-adapco STAR European Conference 2011

Automatic HVAC Workflow with STAR-CCM+

Georgios Apostolopoulos, Dr. Christian Merkle, Dr. Wolfram Kühnel

Behr GmbH & Co. KG, Germany

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G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Outline

  Behr

•  Products

•  CFD at Behr

  Simulation of HVACs

•  Computation of temperature control curves

•  Former approach: STAR-CD v3.26 + Harpoon

•  Automatic HVAC workflow with STAR-CCM+

  Conclusions

•  Advantages and potential

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G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Behr: Products Behr – systems partner for total thermal management

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G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Behr: CFD at Behr Typical examples

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs

  Meaning of “Temperature Control Curve” (TCC) •  Typical air temperatures: 5°C after evaporator, 80°C after heater •  The position of the mixing flap defines the mass flux fractions of hot and cold air •  For computing the temperature control curve, only the mixing flap position is changed

Computation of temperature control curves

for the four outlets, the temperature should vary between 5°C and 80°C

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G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs Former approach: STAR-CD v3.26 + Harpoon

manual preparation

automated part

CAD

fixed part(template): heat exchangers, ducts, solver settings

variable part: housing, flaps, (+deflectors)

initial model (coupled, pro-STAR

panels)

Simulation + Postprocessing

------------ Blower: pt1 [Pa] (PTBL) 251.588 ps1 [Pa] (PSBL) 148.607 dp Filter1 zu klein 0.000 0.000 dp Filter2 zu klein 0.000 0.000 ------------ Evap.: T [mm] (DEEV) 39.500 unif. index (UIEV) 0.890 pt1 [Pa] (PEV1) 220.581 pt2 [Pa] (PEV2) 159.756 dpt [Pa] 60.825 m [kg/s ] (MEV) 1.046e-01 m [ % ] (REV) 100.0 ps1 [Pa] (PEV3) 213.246

new flap positions or geometric changes e.g. deflectors)

batch meshing

automatic coupling to template model

„shortcut“ add baffles

+ restart

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G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs Former approach: STAR-CD v3.26 + Harpoon

  Typical Postprocessing of HVAC Simulations •  Scalar scenes •  Bar pressure drop graphs •  Residual plots •  User defined quantities •  Advanced postprocessing in Fieldview •  Automatic report in MS-Word

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs Automatic HVAC workflow with STAR-CCM+: Overview

  One time work for a specific project •  Manual preparation -  Template sim file -  Import CAD in template sim file -  Organize/rename parts/surfaces

•  Start HVAC Wizard Java automation plugin

  Repetitive work for every TCC point -  Rotate flaps panel -  Meshing -  Solving

•  Automatic MS-Powerpoint report plugin

Geometry

Physics

Meshing

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G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs

  Extrusions representing real duct geometry   Offset Parts Panel

•  Selection of outlet part surface •  Selection of LCS •  Desired extrusion lengths •  Automatic “extrusion” and generation of new parts

Automatic HVAC workflow with STAR-CCM+: HVAC Wizard plugin

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs Automatic HVAC workflow with STAR-CCM+: HVAC Wizard plugin

  Rotate Flaps Panel •  Selection of flap •  Selection of percentage of rotation – direction of rotation •  Automatic rotation of the respective part

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Simulation of HVACs Automatic HVAC workflow with STAR-CCM+: MS-Powerpoint report plugin

  Automatic MS-Powerpoint report generation •  Scalar scenes •  Bar pressure drop graphs •  Residual plots •  User defined quantities

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

G-TC4 Georgios Apostolopoulos, March 2011, Apostolopoulos_STARConference2011.pptx

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Automatic HVAC Workflow with STAR-CCM+ STAR European Conference 2011

Conclusions

  The whole workflow is now done in one environment (from CAD import to MS-Powerpoint report generation)

  High usability of automatic HVAC workflow tool, but difficult to maintain over different STAR-CCM+ releases

•  Automatic java macro update tool highly appreciated

  Total process time

•  Temperature Control Curve: comparable

•  Geometry optimization: slower due to meshing time

  Meshing time is considerably longer with STAR-CCM+ compared to Harpoon

  High memory requirement of STAR-CCM+ in comparison with STAR-CD workflow

  Modifications of the geometry require the remeshing of the whole HVAC geometry

•  Parallel meshing, local remeshing, overlapping grids

  Different porosity model compared to STAR-CD (Darcy’s-Law announced for v6.04)

Advantages and potential