Vehicle Engine Cooling System

Simulation (VECSS) Utilizing GT-Power

By
Brian J. Luptowski
Michigan Technological University
Department of Mechanical Engineering - Engineering Mechanics

Funding Provided by the Army Research Office

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Motivation
• Fuel economy
• System design, performance, and component sizing
• Simulation of advanced computer controlled (“smart”) cooling
systems in vehicles necessitates the coupling of commercially
available cycle analysis software (GT-Power) to vehicle and
engine fluid flow systems

Goals
• Develop a code capable of energy based cooling control and
multi-variable optimization
• Conduct advanced component analysis (electric fan, electric
coolant pump, actuators) to achieve reduced accessory power
and improved engine temperature control

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
The Vehicle Engine Cooling System Simulation (VECSS)
MTU’s VECSS is a engine cycle and cooling system simulation for a HD
truck with an emphasis on modeling all fluid and air handling components
and systems. Necessary inputs are shown below…

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 VECSS Schematic

Model Components
• engine
• turbocharger
• radiator
• charge air cooler
• coolant circuit
• oil cooler
• cab

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 VECSS - History
Funding…
1980 - 1998 - Kysor of Cadillac
1998 - 2000 - Engineered Machined Products (EMP)
2000 - Present - Army Research Office (ARO)

Students/Research Areas…
1980 - V.J. Ursini began development (Cummins NTC-350 Big Cam II in an
International Harvester COE-9670)

1995 - Kysor of Cadillac (collected field data with a Detroit Diesel Corp. Series 60
12.7L in a Freightliner FLD120)
1997 - K.V. Mohan (DDC S60 cycle analysis and comparison to experimental data)
1998 - A.J. Kulkarni (compressible airflow cooling model and comparison to field data)
1999 - C.W. Lehner (feedback controlled cooling with electric coolant pump and
actuator)
2000 - R.D. Chalgren (controlled EGR cooling with electric coolant pumps and actuator)
2002 - B.J. Luptowski (developing E-VECSS and 42-volt active cooling system model)
Michigan Technological University Research
Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
Current Project - Enhanced Vehicle and Engine Cooling
System Simulation (E-VECSS)

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Strengths of Software in E-VECSS

VECSS GT-Power
• Air flow across engine compartment • Graphical user interface (GUI)
• Detailed modeling of... • Flexible component configuration
• oil cooling system • Wave dynamics in air flow
• radiator • Multiple cylinder modeling
• charge-air-cooler
• Comprehensive combustion models
• EGR cooler
• Turbocharger modeling
• Established control strategies
• Accepts modules (user subroutines,
• Cab temperature control Simulink, etc.)
• Links to other GT-Suite™ components
(GT-Cool, GT-Drive, etc.)
• Commercial code accepted by industry

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
Validation Data for GT-Power Engine (DDC S60)
Pressure vs. Volume Comparison for VECSS Cycle Analysis
and GT-Power at 1500 rpm and full load

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
Validation Data for GT-Power Engine (cont.)
Pumping Loop Comparison for VECSS Cycle Analysis
and GT-Power at 1500 rpm and full load

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
Integration of GT-Power & VECSS via Simulink
Theoretical Aspects
• Fully coupled engine and cooling system
1. engine performance affects cooling system
2. cooling system performance affects engine

• Tool capable of concept evaluation and optimization

• Allows for concurrent design of an engine and cooling system to result in
complimentary, fully integrated systems

Technical Aspects
• GT-Power’s wiring harness allows output of engine data to external programs in
a vectorized form
• Wiring harness allows input of engine model parameters back to GT-Power
1. Coolant temperature
2. Loads placed on engine
3. …..
• Thermal systems (radiator, charge-air-cooler, and oil cooler) modeled in Matlab
files and “connected” to GT-Power via wiring harness in Simulink GUI

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
Schematic of Typical Engine/Cooling System Model

Engine vector signal vector signal

Engine Model
Maps

Engine Coolant
Charge Air Cooler, Engine Thermal
Temperature
Radiator, Model
Model
& Fan
Oil Circuit
& Cooler

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Schematic of Enhanced VECSS

wiring harness Engine Model wiring harness

(GT-Power)

Coupling of Engine
and
Cooling System Engine Coolant
Charge Air Cooler, Temperature
Radiator, Model
& Fan (VECSS)
Oil Circuit (VECSS)
& Cooler
(VECSS)

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Wiring Harness Information (Inputs/Outputs)
GT-Power Inputs GT-Power Outputs
How… How…
ActuatorConn SensorConn

PIDController RLTSensor

What…
• Coolant temperature into engine
• Coolant heat transfer coefficients
• Oil temperature
• Oil heat transfer coefficient
• Torque required by alternator
• Engine intake air temperature and
pressure after charge air cooler
What…
• Engine rpm
• Engine intake air mass flow,
temperature, and pressure before
charge air cooler
• Heat transfer rates to head,
cylinder wall, and piston
• Heat transfer rates to oil
• Crankshaft bearing loads

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Charge Air Cooler Model Integration Example
(Outputs) sensing temperature,
pressure, and flow rate

CAC

(Inputs) actuating pressure

loss coeff. & wall temperature

PID tracking
controller for
? P across CAC

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Problems Encountered and Solutions Developed
1. Linking external (VECSS) charge-air-cooler model to GT-Power and the need
to specify temperature and pressure drops of intake air in GT-Power
• Actuate wall temperature with large heat transfer multiplier to achieve specified ? T
• Tracking PID controller in GT-Power for pressure loss coeff. actuation to achieve
specified ? P
• Similar strategy to be used for linking external EGR cooler to GT-Power

2. Structure interface heat transfer data output unavailable for external model
• Examples - ring to cylinder wall heat transfer, valve to valve seat heat transfer
• Gamma Tech. staff modified code to make structure interface heat transfer data available
as an RLT quantity

3. E-VECSS has a significantly increased run time compared to VECSS

• Reason: modeling all cylinders w/ wave dynamics vs. one cylinder w/o waves dynamics
• Increased data & accuracy vs. run time increase (~100 fold increase in run time)
• Faster CPU as possible solution (currently use an ECS K7S5A motherboard w/ AMD
Athlon XP 1700, 256 MB RAM non-ECC)

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Overall Outputs From Enhanced VECSS

GT-Power Side VECSS Side

• Engine power • Charge-air-cooler outlet temperatures

for both air sides
• Fuel energy distribution
• Engine air pressure drop across
• Brake specific fuel consumption
charge-air-cooler
• Detail data on heat transfer rates
• Radiator outlet temperatures for
to components
coolant and air
• Engine component temperatures
• Oil temperatures
• FEA model of components’
• Fan speed, volumetric flow, and power
temperature distribution
• Coolant pump flow rate and power
• Air flow/wave dynamics summary
• Etc…
• Etc…

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
Enhanced VECSS Validation Data

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Application of Enhanced VECSS
42-volt Active Cooling System Modeling
System Components
• Two 42-volt fans
• Dedicated 42-volt high output alternator
• Efficient 42-volt pump(s)
• Actuators replace thermostats

Control Goals
• Reduced fan operation and power consumption
• Reduced coolant flow rate
• Reduced accessory power
• Decrease engine warm-up time
• Control of engine component temperatures to levels that provide
improved fuel economy and long term durability and reliability

Overall Goal
• Analyze technical advantage of 42-volt active cooling system in a heavy
duty diesel application
Michigan Technological University Research
Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 Summary
1. VECSS overview and history
2. Enhanced VECSS concept and components
3. Integration of GT-Power and VECSS
• Fully coupling engine and cooling system
• Wiring harness information
• Example: charge-air-cooler model integration
• Problems encountered and solutions developed

4. Enhanced VECSS outputs

5. Validation of Enhanced VECSS
6. Application to 42-volt active cooling system modeling
7. Linking GT-Power to VECSS has resulted in a modular, industry friendly,
simulation tool allowing for concurrent design, analysis, and optimization
of engines and cooling systems including controls for “smart” cooling
systems
Michigan Technological University Research
Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002
 VECSS – Recent Publications

Mohan, K.V., Arici, O., Yang, S., Johnson, J.H., ”A Computer Simulation of the
Turbocharged Diesel Engine as an Enhancement of the Vehicle Engine
Cooling System Simulation”, SAE Paper 971804, 1997.

Arici, O., Johnson, J.H., Kulkarni, A.J., “The Vehicle Engine Cooling System
Simulation . Part 1 – Model Development”, SAE Paper 1999-01-0240, 1999.

Arici, O., Johnson, J.H., Kulkarni, A.J., “The Vehicle Engine Cooling System
Simulation . Part 2 – Model Validation Using Transient Data”, SAE Paper
1999-01-0241, 1999.

Arici, O., Johnson, J.H., Lehner C.W. “Design and Development of a Model Based
Feedback Controlled Cooling System for Heavy Duty Truck Applications
Using a Vehicle Engine Cooling System Simulation”, SAE Paper 2001-01-
0336, 2001.

Chalgren, R.D., Parker, G.G., Arici, O., Johnson, J.H., “A Controlled EGR Cooling
System for Heavy Duty Diesel Applications Using the Vehicle Engine
Cooling System Simulation”, SAE Paper 2002-01-0076, 2002.

Michigan Technological University Research

Luptowski, Arici, Johnson, Parker
GT-Suite Users Conference Nov. 18, 2002