Assignment 7

• Explore tutorial number 9 and write a detailed report (50 marks)
• Build FRM Model for following configuration using FRM builder approach (50 marks)
• Bore 102 mm stroke 115 mm CR 17
• No of cylinder 6
• CI engine
• Twin Scroll Turbine
• GT Controller
• Run all cases

FRM Builder:

select frm builder from the tools section ,

choose create new engine model and ok

We need to select the type of engine , he choose CI engine and click next

Note here CI engine comes with a turbocharger which is also to be selected

Provide the cylinder geometry details here

Bore = 102 mm

stroke = 115mm

Compression ratio=17

Now select the no. of cylinders for the engine

hhere choose 6 cylinder engine

Select the twin scroll turbocharger

for the controller logic select the GT-SUITE Controller

the finished model will look as below

The intake system:

it has a intake pipe , air box for filter and intake pipe exit

End environment:

pressure = 1bar

Temp = 298k

Air box:

the volume of the box is specified

Thermal components of the box

an imposed wall temperature of 298k is imposed

FRM builder engine model:

it has a simplified intake manifold and 2 exhaust manifolds

Intake manifold:

main attributes

thermal attributes

wall temperature = 330k

cylinder geometry

as we specified

firing order:

1-5-3-6-2-4

cylinder:

main attributes:

combustion object is DI pulse which is a non predictive combustion

Profiles :

injected mass of fuel profile , injection timing and other profiles are specified

Exhaust manifold:

main attributes

Thermal attributes

Scroll turbocharger:

EGR controller

FRM outlet

End environment outlet:

outlet conditions

Diesel injector controller:

main attributes

controller inputs:

air flow rate , engine speed ,BMEP

output signal :

injected mass rate

EGR controller configuration:

Input signals:

EGR Mass flow , Air flow rate ,

output signals:

EGR Valve diameter and EGR throttle angle

waste gate controller:

main attributes

waste gate controller:

input signals:

boost pressure

Output signals:

wastegate diameter

all reciever signals

all output/send signals:

cases:

Run control:

max duration = 1000 cyles

flow simulation :

Time elapsed

Monitors:

Engine operating conditions for all cases:

Engine perfromance predicitions all cases:

the air flow rate decreses when the bmep target is reduced

this also helps in reducing the bsfc ,

the volumetric efficiency increases with decrease in bmep target and air flow rate

FRM CONVERTER:

from the tools , select the FRM converter

select the baseline model whhich needs to be reduced here it is 4cylinder -GDI-Turbo-WOT

and clcik next

for checking the accuracy we need to identify the important parameters which are crucial hence select those parameters

all the variable are identified for checking the accuracy once done , select click next

Model reduction step1 :

this template will be opened

choose exhaust manifold , give step name and clikc on simplify for accuracy

exhaust manifold will be simplified

go to run setup - explicit control and

max time step = 720

this is simplified exhaust manifold

click on exhaust manifold port run

main attributes

initial conditions:

pressure = 2.8bar

temperature = 1000k

burned gas components

thermal conditions:

imposed wall temp = 550k

heat transfer multiplier is added in cases as parameter

check in cases a value of 1 is specified

after cchecking all those click on calibrate

this template will araise

click on configure calibration

design optimizer will be opened

in response rlt : select trb-tla:Turbine

in factors select the lower and upper limit

lower limit=0.95

upper limit = 2.8

resolution = 2.0%

then click on run calibaration after calibration is over , this window will be openend

click on open key RLT plots in GT-POST

in GT post

click on the simulation runtime to view the factors

factors of real time vs engine speed graph is generated

calibration check for the exhaust manifold:

got to tge simplified exhaust manifold

select the flow split template of EP1_PDROP1-1 right click and select combine flow volume wizard

combine flow volumes wizard is opened:

leave everything as default and clikc on next , next and finish

in combine flow volume wizard this window will be opened

select the EP1_Pipe1 and name object as EPFS and finish

click on EPFS-1

main attributes :

thermal attributes:

imposed wall temperature : choose GasT

GasT attributes:

for catalytic converter:

the wireless signal or RLT(x) is average temeprature

similarly for EP1_PDrop1

the RLT selector is average temperature

in case setup , the exhaust pipe diamter is taken as a parameter , the value is arbitarily fixed at 40mm

after checking case setup , run the model by click on run model

after the first step where exhaust manifold is reduced , calibrated and run , step2 model reduction window will automatically be directed ,

here select the exhaust pipe(which is to be reduced) give the step name as Exhasut pipes , after that click on simplify for accuracy , the exhaust pipes will be reduced and the reduced model can be checked by collapsing the window

after that , click on calibrate will take us to the calibration window

here we can click on select case for calibration/open case setup and check the cases in case setup

after that, clcik om configure calibration

design optimizer will be opened

change respnse RLT to trb-poa:Turbine

in factors,

set lower limit=35

upper limit=45

after that click on run calibration

Results window will be opened after calibartion

click on run model

After running the model , it will redirect to step3

select intake manifold and name step as intake manifold

click on simiplify for accuracy

this is the simplified main model after intake manifold is reduced

go to the simplified intake manifold plenum

IM1_Plenum1-1

main attributes:

Thermal attributes:

initial wall temperature = 350k

Boundary data:

cases setup:

heat transfer multiplier for intake manifold is taken as 1.0

once the intake manifold is simplified some of the components will be deleted hence we need to replace them

so replace the missing parts with the present for accuracy checking

then click on ok

then click next calibrate

open case setup and check the cases and parameter set.

go to configure calibration , design optimizer will be opened

change response RLT to cmp-poa:compressor

in factors:

lower limit = 0

upper limit = 1.1

resolution = 2%

run calibration

after that results window is opened

click on Run model and close

step4 :

model reduction window for step4 will be opened

choose subsytem as boost pipes and give name for step as compressor outlet pipe

click on simplify accuracy

reduced model:

here note that the intercooler effectiveness template is not connected via signals

click on the intercooler pipe

BP1_CAC1

imposed wall temperature is 300k

heat transfer multiplier = 8.984505

since the effectivenss template is not connected via signals we need to connect it as shown below

click on heat exchanger connection :

diamter is taken as a parameter

boost pipe diameter is taken as 35mm

click on next calibrate

calibration (optional) window will be opened click on configure calibration:

design optimizer is opened

Response RLT = cmp-poa:compressor

factors:

upper limit=40

lower limit=30

then click on run calibration and next

then click on run model and close

step5 window will be opened

select intake pipes and give step name as intake pipes

then click on simplify for accuracy

simplified model:

cases:

intake pipe diam is taken as a parameter

click on pipe round template and make sure all discretization length is DXI and DXE

only exhaust and intake

expand and click on next calibrate

this window is opened

click on configure calibration:

design optimizer

response RLT = cmp-pia:compressor

factors:

lower limit = 40

upper limit = 50

click on run calibration and next

in results window , click on Run model and finish

step6

give name as additional changes and click on simplify for speed

click on open case setup and check the cases setup

click on configure calibration

design optimizer:

Response RLT = trb-tia:Turbine

Factors:

lowerlimit = 0

upper limit=2

resolution = 1%

click on run calibration

in results window , click on Run model and finish

step7:

give name as cylinder slaving and click on collapse

go to engine cylinder template

click on cylinder-01 and cylinder-01 overide

change cylinder slaving option to master in overide

go to run setup

in flow , improved solution for large flow through cylinders as v2017

then click on expand and click on next calibrate

results window will be enabled , here click on run model and finish

final main model:

cases setup:

results:

Turbine speed monitor:

waste gate controller monitor: