design optimization of a refrigeration compressor
TRANSCRIPT
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Design Optimization of a Refrigeration Compressor
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2/282 November 2021, CFturbo, Inc.
• Conceptual design of a centrifugal compressor R134a
• Software: CFturbo, integrated into Ansys Workbench
• One initial design + one manual design variation, “Design2”
• Mathematical optimization using CFturbo/Ansys Workbench/Design Explorer o 8 geometry parameters, 141 different designs in totalo All design points meet the performance requirements at selected rpm
• Substantial stage efficiency improvement at design speedo Initial design: η=56% o Manual “Design2”: η= 59% o Optimized “Design107”: η= 73%
• Total project time: 10 days• Next steps
o Adjustments and fine-tuning, for example blade loading variation and volute parameters o 360° impeller model and transient simulations for final check of steady-state results
Summary
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3/282 November 2021, CFturbo, Inc.
1 Design target points
Speed Pt Tt Mass flow rate
Pressure ratio Πts
rpm psi F lb/s -
44000 50 60 4.1 3.9
Design target 36000 50 60 2.7 2.8
32000 50 60 1.7 2.4
30000 50 60 0.8 2.0
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1.5
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2.5
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3.5
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4.5
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5Pr
essu
re ra
tio [-
]Mass flow rate [lb/s]
Inlet Total pressure p = 50 psiOutlet Mass flow or static pressure
Fluid R134a (Real Gas)
Rotational speed numbers for off-design points were determined during the project
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4/282 November 2021, CFturbo, Inc.
Mesh statistics Nodes Elements
Impeller (Segment) ≈ 750k ≈ 700k
Volute ≈ 875k ≈ 2.02m
Overall (with Pipe,in + Pipe,out) ≈ 1.76m ≈ 3.10m
2 Computational Mesh
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5/282 November 2021, CFturbo, Inc.
Inlet
Outlet
Rotor-Stator-Interface (RSI) RSI1
Periodic boundaries
2 CFD Setup, Boundaries conditions and control sections
ANSYS CFX 2020 R2Steady state, Mixing Plane, Total Energy,SST-Turbulenzmodel, High-Resolution-Differencing-Scheme, viscose work term
Inlet Total pressure p = 50 psiOutlet Mass flow rate or static pressure
Rotor-Stator-Interface (RSI) RSI2
Discharge Diffuser Outlet (DDO)
Pressure ratio Πstage = P DDO / P INLET
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6/282 November 2021, CFturbo, Inc.
3 Initial Design
Impeller Main DimensionsDS=62 mm,D2=122 mmB2= 4mm
Impeller Blade Anglesβ,B1= 43 ... 16 β,B2= 60
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7/282 November 2021, CFturbo, Inc. Design & Optimization HVAC Compressor
1
1.5
2
2.5
3
3.5
1.5 2 2.5 3 3.5 4 4.5 5
Pres
sure
ratio
Sta
ge [-
]
Mass flow [lb/s]
Design point
Initial Design Stage (t-t)
Initial Design Stage (t-s)
3 Initial Design, Pressure ratio (Stage)@36000rpm
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8/282 November 2021, CFturbo, Inc.
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0.55
0.6
1.5 2 2.5 3 3.5 4 4.5 5
η ise
ntro
pic
(tota
l -st
atic
) [-]
Mass flow rate [lb/s]
Initial Design Stage
Design & Optimization HVAC Compressor
Initial design meets the pressure ratio however the peak efficiency occurs at a higher mass flow rate.
Targets -> Increase efficiency and shift peak efficiency to lower mass flow rates.
3 Initial Design, Efficiency ηisentropic (Stage)@36000rpm
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9/282 November 2021, CFturbo, Inc.
4mm
3mm
4 Design2 – Manual modification, reduced outlet width b2Outlet width B2= 3 mm (previoulsy 4mm)
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10/282 November 2021, CFturbo, Inc.
1
1.5
2
2.5
3
3.5
1.5 2 2.5 3 3.5 4 4.5 5
Pres
sure
ratio
Sta
ge [-
]
Mass flow [lb/s]
Initial Design Stage (t-t)
Initial Design Stage (t-s)
Design2 Stage (t-t)
Design2 Stage (t-s)
4 Design2 – Pressure ratio (Stage)@36000rpm
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11/282 November 2021, CFturbo, Inc.
4 Design2 – ηisentropic@36000rpm
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.5 2 2.5 3 3.5 4 4.5 5
η ise
ntro
pic
(tota
l -to
tal)
[-]
Mass flow [lb/s]
Initial Design Impeller
Initial Design Stage
Design2 Impeller
Design2 Stage
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12/282 November 2021, CFturbo, Inc.
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0.55
0.6
0.65
1.5 2 2.5 3 3.5 4 4.5 5
η ise
ntro
pic
(tota
l -st
atic
) [-]
Mass flow rate [lb/s]
Initial Design Stage
Design2 Stage
Design2 meets required the pressure ratio at design point; theisentropic stage efficiency has been increased by 7 points at the design flow rate (at 2.7 lb/s).
4 Design2, Efficiency ηisentropic (Stage)@36000rpm
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13/282 November 2021, CFturbo, Inc.
1
1.5
2
2.5
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3.5
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4.5
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0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Pres
sure
ratio
Sta
ge [-
]
Mass flow rate [lb/s]
Design2 Stage (t-t)
Design2 Stage (t-s)
CFD n44000rpm
CFD n33000rpm
CFD n30000rpmDP0
DP1
DP2
DP3
Design2, select rpm, all other operating points meet or exceed the target pressure ratios.
4 Design2, Other operating points
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14/282 November 2021, CFturbo, Inc.
Bi-directional Integration for Automated Simulation, Design Space Exploration, Optimization
5 CFturbo in Ansys Workbench
Design Parameter Exchange
Connected parameter sets in CFturbo and Workbench!
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5 Mathematical optimizationStart optimization from „Design2“8 geometry parameters were selected for optimization
Optimization methodMISQP (ANSYS Design Explorer, default setting)
Objectives and Constraints
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16/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, design parameters D2, b2 , β2
tm
Mean lines
Leading edge
βB2
βB1
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17/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, design parameter „Wrap Angle φ“
tm
Mean lines
tLE,S tTE,H
tTE,S
Leading edge
φ
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18/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, design parameter „Radial Offset“
Offset
The radial offset between impeller outlet and volute inlet is used to add a non-rotating component between impeller and volute. Technically it workd as a short lenght radial diffuser.
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19/282 November 2021, CFturbo, Inc.
5 Mathematical optimization „Volute Radius and Diffusor Height“
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20/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, Results
Computational effort:Approx. 1 hour per design on a 12 core AMD Ryzen Threadripper PRO 3945WX 4.00 GHz workstation
• Optimization process 141 designs• Three ecxellent design proposals
Selected best fit „Design107“ • Peak efficiency η(t-s) > 73% • Π (t-s) ≈ 3.0
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5 Mathematical optimization – Comparision
Design2
Design107
Impeller Main Dimensions
DS [mm] 62.0 62.0D2 [mm] 122.0 115.0B2 [mm] 3.0 3.0
Mean Blade AnglesL.E. β,B1 [°] 43/16 43/16T.E. β,B2 [°] 60 55
Blade Wrap Angle φ [°] 99/70 108/79
Number Blades Z [-] 14 (7/7) 12 (6/6)
Radial Diffuser L [mm] 2.0 6.6
Discharge Diffuser H [mm] 120.0 116.6
Design2 Design107
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22/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, Results Design 107
n=36000 rpmṁ=2.7 lb/s
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23/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, Results Design 107
n=36000 rpmṁ=2.7 lb/s
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24/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, Results Design 107
n=36000 rpmṁ=2.7 lb/s
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25/282 November 2021, CFturbo, Inc.
5 Mathematical optimization, Results Design 107
Span = 50%
n=36000 rpmṁ=2.7 lb/s
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26/282 November 2021, CFturbo, Inc.
5 Mathematical optimization – Pressure ratio (Stage)@36000rpm
1
1.5
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2.5
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3.5
4
4.5
5
5.5
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Pres
sure
ratio
Sta
ge [-
]
Mass flow rate [lb/s]
DP 0 DP 1
DP 2 DP 3
n30000rpm (t-t) n30000rpm (t-s)
n32000rpm (t-t) n32000rpm (t-s)
n36000rpm (t-t) n36000rpm (t-s)
n44000rpm (t-t) n44000rpm (t-s)
„Design 107“
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27/282 November 2021, CFturbo, Inc.
5 Mathematical optimization – ηisentropic (Stage)@36000rpm
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
η ise
ntro
pic
(tota
l -st
atic
) [-]
Mass flow rate [lb/s]
Stage@n30000rpm
Stage@n32000rpm
Stage@n36000rpm
Stage@n44000rpm
„Design 107“
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