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System simulation is used to reproduce technical systems in mathematical models in order to predict their behavior on the computer by means of numerical simulation. In this way, it is possible to identify problems at an early stage and to carry out extensive variant studies.
In contrast to detailed fluid dynamics simulation (CFD) or thermal analysis in solids (FEM), system simulation uses coarser spatial resolutions. The focus is on the interactions between different system components and physical effects. Therefore, the terms 0D/1D simulation and multiphysics simulation have become established. Both can be seen as synonymous to system simulation.
Both steady-state and dynamic problems can be investigated. Widely used tools for system simulation are Simulink and Dymola, although there are many other general and application-specific tools. We are well versed in both the theory and practice of systems simulation technology. We are happy to share this knowledge with you!
Products can be tested virtually. This helps to detect errors even before prototypes are built.
Individual simulations calculate in minutes. A large number of variants can be calculated and evaluated in a short time.
Integrated into the development process, system simulation replaces part of the test bench experiments. This saves time as well as the budget.
We are well versed in the fundamentals of thermodynamics and model almost any thermal system.
For many applications, we have ready-to-use simulation models in our TIL model library and can deliver results very quickly. For example for refrigeration cycles, heat pumps, battery thermal management and hydrogen refueling stations.
In individual projects we adapt existing models or develop new simulation models to answer your specific questions.
We may be experts in thermal systems, but we know that the world is not just pressure, temperature and enthalpy. For example, to develop the optimal refrigerant compressor, mechanical and electrical engineering must be taken into account.
In most projects, we use the Modelica modeling language. This equation-oriented language is a perfect tool to model systems across domains.
For many technical areas, there are model libraries and experts who are familiar with them. We are happy to work with them on your tasks.
...and if we couldn't find one, we made it ourselves.
Lack of engine waste heat and temperature-sensitive batteries make thermal management a challenge.
Reliability is one thing, energy efficiency is another. With system simulation you will find the best configuration.
The easiest way to enter the world of system simulation is in a project. Especially if there is no simulation competence in your company yet, it makes sense that we take over the model building and the simulation.
With simulation competence in your own company, you can carry out simulations independently. We can provide you with the necessary software and consulting services. You can learn how to use the software in our training courses.
Emerson develops components and systems for supermarket refrigeration. Due to its environmental benefits CO2 as refrigerant is becoming more and more important in this sector. But compared to traditional refrigerants the thermodynamic properties of CO2 are totally different (high pressures and low critical temperature). Designing efficient CO2 cycles is challenging and there are many different cycle concepts proposed. Together with Emerson experts we have developed simulation models for a number of different concepts and run a simulation study to compare the seasonal efficiency of these cycles.
Eric Winandy et al.: Assessment of the seasonal efficiency of different CO2 booster architectures for different climates. DKV Jahrestagung, 2018
In their development process of heat pump controllers Vaillant has established a comprehensive testing strategy. Before they connect developed controllers to real heat pumps in their lab, they are connected to virtual heat pumps running on special real time simulation hardware and software from dSPACE. Crucial ingredients for this so-called Hardware-in-the-Loop (HiL) tests are simulation models of the heat pumps, that are accurate, fast and robust. We developed these models for Vaillant using our Modelica library TIL Suite and set up a reliable tool chain to export these models to dSPACE platform. The models include a full dynamic physical model of the refrigeration cycle. It can handle switching of refrigerant flow direction caused by different modes for defrost, heating and cooling. Vaillant is now able to detect issues in control code much earlier and saves with this virtual testing a considerable amount of expensive lab experiments.
Manuel Gräber et al.: Physical Modeling of Heat Pumps for Hardware-in-the-Loop Testing. 13th International Modelica Conference, 2019
Together with Volkswagen we have developed simulation models for battery thermal management systems. Geometry of cooling plates and its flow patterns are taken into account by discretization with finite volumes. Compared to detailed CFD simulations the spatial resolution is much lower but still high enough to achieve confident results. This approach reduces the computation time dramatically enabling usage of numerical optimization algorithms or large-scale simulation studies. Cooling systems can be designed with less pressure loss and increased energy efficiency.
Robert Wendland et al.: Dynamic Optimization of Thermal Management and Cooling Plate Design for Battery Systems. 27th Aachen Colloquium Automobile and Engine Technology, 2018