During the development process, it is common for drivetrain subsystems and components to be designed and optimized separately. However, in the real vehicle, these subsystems have diverse interactions. The goal must always be the best possible design of the overall system, as well as optimizing each individual component within this system.
Here FKFS is able to offer our customers a helpful and effective combination of overall system expertise and in-depth detailed knowledge about the individual components. We carry out concept studies, take on tasks from our customers’ everyday business, or are available as a research partner for scientific investigations.
It is important to us to understand and validate the simulation results with regard to the interrelationships concerned. This is the only way we can generate trust in our simulation results and recognize the limits of the model sufficiently early on.
What will the combustion engine look like in ten years? Which combustion processes will be used? What requirements will there be on EGR routes, valve train variabilities, cooling performance, oil supply, exhaust aftertreatment and sensors? Questions which drivetrain developers and suppliers are asking in equal measure. Our wealth of experience in combustion process development, our UserCylinder and our digital engine construction kit help describe future scenarios.
Important: during the development process, it is common for the drivetrain, air path, combustion process, oil circuit and cooling circuit to be designed and optimized separately. However, in the real vehicle, these subsystems have diverse interactions. The goal must be the optimization of the overall system. Using virtual test vehicles, the 0D/1D simulation provides tools which can be used early on in the development process to depict the interactions of the subsystems in transient operation.
It can be used to determine the boundary conditions, requirements and efficiency potential of possible future drive components.
3D-CFD simulations allow a "virtual view" into the engine.
For this purpose, QuickSim only uses StarCD® as a solver and allows:
- … the extent of the simulation domain from one individual cylinder up to the full engine (to increase the predictability and reduce the influence of boundary conditions)
- the simulation of several successive cycles (to reduce/eliminate the influence of initial conditions)
- an efficient and reliable computation within short CPU-times
- a clear and concise evaluation of the simulation results (virtual testbench)
An integrated working-process calculation supports the analysis of the engine processes and also enables a continuous comparison with testbench measurements and/or other simulation programs (controlling function). In addition to standard fuels like gasoline and diesel, also gas engines (CNG and hydrogen) and bio-fuels can be simulated. Here, the virtual analyses of all engine operating strategies, as well as any kind of design adjustments are possible.
The battery plays a key role in the electrification of the drivetrain. Its performance largely determines the range as well as the thermal management requirements for a vehicle. Therefore, prediction of the electrical and thermal behavior of a battery – aided by simulations – is vital during the early stages of development. FKFS uses our own in-house-developed 1D models based on Thevenin models for this, as well as commercial 3D simulation tools. We are able to acquire the data we need to validate the model from our in-house battery cell test bench.
To simulate cooling systems, we use system simulation tools which depict the cooling system and its numerous components as a network. The overall thermal management of the vehicle can be modeled by incorporating further models, e.g. for the interior. Customer-specific driving cycles and the relevant environmental conditions can be taken into consideration here.
This simulation can be used either to optimize and evaluate the overall system, or to check the performance of an individual component.