Performance simulation

1D cycle simulation provides a rapid and cost effective mechanism for the investigation and optimisation of engine performance, giving valuable information on the gas dynamic and thermodynamic behaviour of the engine.

Our Approach


1D simulation allows the rapid investigation of new engine concepts before Computer Aided Design (CAD) data or hardware are available. It can be used to determine the specification of a new design and investigate, assess and optimise new engine components.

The performance simulation engineers work in conjunction with the design and thermodynamics teams to ensure that the optimal solution is developed taking into account project constraints such as cost, packaging and project timing.

Once test data is available, the models are correlated to further improve their accuracy and to enable them to be used in more detailed studies to provide additional support as the project develops.

Typical Projects include:

• Clean sheet engine design studies and performance optimisation
• Evaluation and optimisation of innovative new engine concepts
• Optimisation of intake and exhaust manifold geometries for full load performance
  
• Selection of valve profiles and timing for full load performance and part load fuel economy
• Turbocharger matching and optimisation
• Investigation and optimisation of innovative new engine components

Our Tools, Facilities and Services

MAHLE Powertrain use the 1D cycle simulation code ‘GTPower’ from Gamma Technologies. We have close ties with Gamma Technologies and collaborate to develop and improve the code when required.

Our team of performance simulation engineers have extensive experience of a broad range of engine projects with a wide range of engine configurations, fuels, performance targets and constraints.

1D simulation is used in conjunction with Design of Experiments techniques to investigate and optimise complex multidimensional problems. This enables the optimum solution to a problem to be found and allows prediction of the effect of practical constraints on that solution.


Customer Benefits

1D simulation provides a fast and effective method of investigating and optimising new engine concepts.

The models provide detailed information on gas dynamic effects within the engine, enabling an in-depth understanding of how the engine is operating and changes that can be made to further improve performance.


Project Examples

     Analysis of an Innovative New Engine Concept

GTPower was used to investigate an innovative new engine concept featuring variable compression and expansion ratios. The customer’s hand calculations were used as a starting point to construct a GTPower model that was used to determine the performance potential and cycle efficiency of the engine.

The model was used to optimise the gas flow through the engine and determine the key performance parameters to enable a first prototype to be designed.

     Development and Optimisation of the MAHLE Downsizing Engine

1D simulation was extensively used in the development of MAHLE’s downsizing engine. Key tasks included:

• Base engine concept investigation; bore, stroke, valve and port size etc.
• Optimisation of intake and exhaust manifold geometry
• Valve lift profile and timing optimisation
• Turbocharger matching, including optimisation and control of the twin turbocharger system
• EGR system investigation
  
• Compression ratio and alternative fuel investigations performed using advanced combustion models

     Variable Valve timing Optimisation for a Compression Ignition Engine

The MAHLE CamInCam® System allows the inlet valves of a 4-valve diesel engine to be individually controlled. This enables the engine to run with early or late inlet valve closing and also affects the charge motion.

GTPower was used to investigate the effect of cam timing on full load performance and part load fuel economy and emissions. The simulation gave an understanding of the effect of CamInCam® on charge motion and the benefits of the alternative cycles. Based on this information, appropriate valve lift profiles were developed and tested.


     Related Documents

The Design of Turbocharged Engines using 1D Simulation, SAE 2001-01-0576

Study of Cyclic Variation in and SI Engine Using Quasi-Dimensional Combustion Model, SAE 2007-01-0939

A New 3-Cylinder 1.2l Advanced Downsizing Technology Demonstrator Engine, SAE 2008-01-0611

Simulation and Optimisation of a Variable Valvetrain
System for a Compression Ignition Engine, VDI-Fachtagung