Beruflich Dokumente
Kultur Dokumente
rd
of the 3 International Modelica Conference,
Linköping, November 3-4, 2003,
Peter Fritzson (editor)
Paper presented at the 3rd International Modelica Conference, November 3-4, 2003,
Linköpings Universitet, Linköping, Sweden, organized by The Modelica Association
and Institutionen för datavetenskap, Linköpings universitet
Program Committee
Peter Fritzson, PELAB, Department of Computer and Information Science,
Linköping University, Sweden (Chairman of the committee).
Bernhard Bachmann, Fachhochschule Bielefeld, Bielefeld, Germany.
Hilding Elmqvist, Dynasim AB, Sweden.
Martin Otter, Institute of Robotics and Mechatronics at DLR Research Center,
Oberpfaffenhofen, Germany.
Michael Tiller, Ford Motor Company, Dearborn, USA.
Hubertus Tummescheit, UTRC, Hartford, USA, and PELAB, Department of
Computer and Information Science, Linköping University, Sweden.
Abstract
Models that can be used to analyse the fuel
consumption of auxiliary units in heavy vehicles are
presented. With the purpose of evaluating the
influence from various drive concepts and control
principals, a model library is developed in the
modelling language Modelica. The library contains
a mixture of models developed from physical
principles and models fitted to collected data.
Modelling of the cooling system is described in
some detail. Simulation results are compared with
measurement data from tests in a wind tunnel.
SML SML
Engine
Radiator
In heavy vehicles, these units normally are the components: The parameters of the flow models,
mechanically driven. The model corresponds to the however, typically have to be estimated from
current design of a Scania truck where the water experimental data.
pump is directly driven from the crankshaft while
the cooling fan is connected to the shaft via a
viscous clutch enabling a passive speed control. 3.2 Dynamics of the cooling system
However, the basic structure allows for changing the For the control volumes it is possible to select which
model to describe other ways of driving and state representation that should be used. The
controlling these auxiliaries. transformation of state variables from the primary
mass and energy balances to the selected states is
3.1 Cooling system components dependent on the properties of the media inside the
volume. The modelling of the control volumes is
The main parts of the cooling system are modelled, rather standard. Here it essentially follows the
using the thermodynamic and hydraulic base principles used in ThermoFluid (Tummescheit et al.
classes. In figure 4 the structure of the cooling 2000).
system is depicted. The model mainly consists of
two adjoining flows of mass and energy: the flow of
coolant fluid and the airflow. For the airflow, pressure, p, and temperature, T, are
chosen as state variables. The transformed balance
The pump drives the flow of coolant fluid through equations then become
the engine and the retarder. The retarder is a
hydraulic brake mounted on the secondary side of
∂u ∂u & &
the gearbox. When used to brake the vehicle, it m p& + m T =U
produces heat that is emitted to the cooling system. ∂p ∂T
(1)
∂ρ ∂ρ &
The temperature of the coolant is controlled with the V p& + V T + ρV& = m&
thermostat by splitting up the coolant flow into one ∂p ∂T
part passing the radiator and one part flowing in a
by-pass pipe. The air enters the cooling system in
the air intake at the front of the truck cab and exits Here U& and m& denote the net flow of energy and
at the air outlet at the rear. The airflow is partly mass into the control volume while m and V are the
driven by the fan and partly by the pressure build up mass trapped in the volume and the size of the
caused by the wind speed at the intake and outlet. volume, respectively. Additionally, the air is
The air is used to cool down both the turbo charged regarded as an ideal gas yielding the following
intake air to the engine, and the coolant fluid. The expressions for the density, ρ, and the partial
charge air cooler, or intercooler, and the radiator are derivatives in equation (1)
connected in series so that the cooling air first
passes the charge air cooler and then the radiator. pM
Both charge air cooler and the radiator is cross ρ=
TR
directional heat exchangers, i.e., the hot and cool ∂u ∂ρ M
media streams are perpendicular to each other. = 0, = (2)
∂p ∂p TR
∂u ∂ρ pM
= cv , =− 2
∂T ∂T T R
The models of the coolant and the air streams are
built up with alternating control volumes and flow
models. In the control volumes, mass and energy where M denotes the molar mass and cv the specific
balances are defined, while in the flow models, heat capacity at constant volume, respectively, while
relations between the pressure drop and the flow are R is the molar gas constant.
determined. The control volumes describe the
dynamic behaviour and are parameterised purely
with geometrical quantities and properties of the Similar expressions are used for the state derivatives
contained media. The flow models describe pressure of the coolant media, although only the temperature
drops, heat transfer and consumed power based on is chosen as state variable. The pressure of the
empirical relations. No explicit identification of the coolant is determined purely from static hydraulic
parameters of the control volumes is needed, since relationships.
they could be found in the technical specification of
3.3 Parameters of the flow models Table 1 Summary of model components in the
cooling module.
For the airflow, pressure drops in the components
Component Characteristic Data Slack
along the flow path are modelled as an exponential source
friction loss
Pump - Pressure rise Rig test s
- Power Rig test
consumption
∆p = c | q | m& e (3) Engine - Flow Rig test
resistance
- Heat Data s
The frictional pressure losses in the components capacitance sheet
coolant path is modelled with a second order - Heat emission Rig test
polynomial to coolant
- Heat emission Rig test
from charge
∆p = c2 | q | q + c1q ( 4) air
Retarder - Flow Rig test
resistance
The pressure rise in the pump and the fan depend on - Heat Data s
the flow through the components and the angular capacitance sheet
velocity of the shaft. In the model the following - Heat emission None
equations are used to describe the operation of the Thermostat - Opening Rig test
pump and the fan, respectively characteristic
- Flow Rig test
resistance
∆p = R1 | ω | ω + 2 R2ωq − R3 | q | q (5) - Dynamic Rig test
response
Radiator - Flow Rig test
∆p = R1 ρ | ω | ω + 2 R2ωm& − R3 | q | m& (6) resistance
coolant
- Flow Rig test
In equation (3)–(6), q and m& denotes volume flow resistance air
- Operating Rig test
rate and mass flow rate, respectively, while ω characteristics
denotes the angular velocity of the pump or the fan. - Heat Data
capacitance sheet
Air intake - Pressure None s
The wind speed gives rise to a differential pressure build-up
at the air intake and outlet relative the ambient Charge air - Flow Rig test s
pressure. In the model, the pressure difference cooler resistance
depends on the wind speed, v, the air density, ρ, and Fan - Pressure rise Rig test
the non-dimensional coefficient CD according to - Power Rig test
consumption
Fan clutch - Slip Rig test
ρ characteristics
∆p = CD v2 (7 ) Engine - Flow Rig test
2
compartment resistance
Air outlet - Pressure None s
In order to find the parameter values of the sub- build-up
models, experimental data is collected from tests on
individual components in a laboratory environment. Input from other parts of the total model is primarily
Essentially parameters of equation (3)–(7) and other heat losses that need to be cooled away. The engine
characteristics are identified for each component emits heat to the cooling system both directly into
depicted in the overview of the cooling module in the engine block, which is heated up by the
figure 4. Table 1 summarises which parameters that combustion, and through the cooling of the charge
are identified and what data that are used. air. The amount of heat depends on the current
torque and speed of the engine.
In the model this is calculated from a look-up table. 4 Assembling the total model
The table is obtained from measurements done in
test cells. The heat emitted to the cooling system The modelling errors in the sub-models are very
from the retarder is directly proportional to the small. However, when they are assembled to a full
braking power. In some sub-models, the parameters model, effects that are not handled in the sub-
solely represent basic quantities such as mass or models may play an important role. It may be
volume that are found from the data sheet of the effects from the installation the truck cab such as the
corresponding component. The tests are performed piping between the components. Non-linearities
in the laboratory under well-controlled conditions. may amplify small errors in the sub-models when
As a result the obtained prediction errors are very these are connected and new feedback paths are
small as can be seen by the example in figure 5, closed. It can be shown, using a simplified model of
showing the pressure drops in the airflow path. the cooling system, that the change of temperature
900
of the coolant in steady state due to a small
perturbation of the airflow is proportional to the
800
squared inverse of the airflow. Thus, the simulated
700 temperature will be very sensitive to modelling
600 errors influencing the airflow. Further, for the
Pressure [Pa]
500
pressure build-up due to the wind speed there exists
no practicable experiment on a component level.
400
Therefore, the result of the total model is verified
300 through comparison with experimental data
200 collected in a wind tunnel. In the wind tunnel, the
100
vehicle is driven on a dynamometer with a defined
load and speed of the engine. Fans are used to
0
0 1 2 3 4 5 6 7 simulate the wind speed. Results from nine steady-
Mass flow [kg/s]
state tests and two step-response tests are used to
Fig. 5. Pressure drop as a function of airflow for the tune the model parameters. A number of the
charge air cooler model (solid) compared with parameters in the sub-models are assigned as slack
measurements (stars). Corresponding drops parameters that are adjusted to fit the behaviour of
for radiator (dashed and triangles), and engine the total model to the measurements. In table 1 the
compartment (dash-dotted and circles). choice of slack parameters is indicated in the last
Pressure rise of the fan model (dotted) at 1400 column. In figures 6 and 7 the cooling temperature
rpm compared with measurements (squares). obtained with the tuned model are compared with
measurements.
92
80
90
75
Temperature, coolant [deg C]
88
Temperature, coolant [deg C]
70
86
65
84
60
82
55
80
50
78
45
76
1100 1200 1300 1400 1500 1600 1700 40
Engine speed [rpm] 0 500 1000 1500 2000
Time [s]
Fig. 6. Simulated temperature of the coolant in Fig. 7. Simulated response of the coolant
steady state at 80 km/h with full load and temperature on a step in the engine load at 60
different speeds on the engine (solid) km/h with engine speed 1400 rpm (dashed),
compared with measurements (stars). compared with measurements (triangles).
Corresponding at 60 km/h (dashed and Corresponding at 40 km/h (dash-dotted and
triangles) and at 40 km/h (dash-dotted and circles).
circles).
85
80
75
0 500 1000 1500 2000
Time [s]