INTERNSHIP-PROTON BHD

Holiday

Cabin Comfort Project

1. Assuming the simulation of temperature analysis- Coldown

  - Run the simulation on server.

2. Internship Report Writing

  - Read about the company organization.

  - write about the company organization background.

Cabin Comfort Project

1. Temperature analysis - coldown.

  - Download the result of simulation from server.

  - Extract the temperature data from the simulation result.

  - Construct the graph to compare the CFD data with Experiment data.

  - Analyze the result.

2. Report writting.

  - Write about the internship experiences along internship program.

Cabin Comfort Project

1. Temperature Analysis-Coldown.

  -Extract the data from the simulation.

  -Construct the graph to compare the CFD with Experiment data.

  -Analyze the result.

2. Project presentation to CAE department.

Cabin Comfort Project

1. Temperature analysis- Coldown

  - Extract the data from simulation.

  - Construct a graph to compare simulation data with experiment data.

  - Analyze the data.

2. Files transfer.

  - Transfer the relevent files from PROTON'S workstation to external drive.

End of internship

  - Study how to import files from Hyperworks software to Solidworks and Ansys.

Holiday

Cabin comfort project.

1. Temperature analysis correlation.

  - download the simulation from the server and analyze the simulation model.

  - there is some error in the setting (inlet temp unit error).

  - do correction and re-run the model.

2. Report writting.

  - write the abstract.

  - write the intoduction.

   - background.

   - history.

Cabin comfort project

1. Correlation of temperature analysis (Cooldown).

  - change the templete of inlet temperature to Kelvin unit.

  - re-run the simulation.

2. Report writing.

  - create the timeline of PROTON history.

  - writing about the main activity in PROTON.

Holiday- Hari raya aidiladha

Holiday- Hari raya aidiladha

Holiday- Hari raya aidiladha

Holiday

Holiday

Cabin Comfort Project

1. Working on the slides for the final presentation.

  - Update the slide’s table of content, problem statement, objectives, etc.

  - Update the quality of slide’s content.

2. Submit the Presentation slide to the CFD lead to be checked.

  - Short briefing on the addition of slide’s content.

Cabin comfort project

1. Working on the slides for the final presentation.

  -Update the velocity contour for all four simulation cases.

  -Update the image numbering and its arrangement.

2. The slides are checked by the supervisor.

  - Update the slides.

3. The slides are checked by the CAE lead.

  - Update the slides.

Cabin comfort project.

1. Continue to update the Presentation slide.

  - Add the methodology workframe to the slide.

  -Add the experiment design process to the slide.

  -Add the design of experiment (DOE) to the slide.

Cabin comfort project.

1. Final revision and update to the Final presentation slide.

  - Touch up the slide to make it more presentable.

  - Update the important description that miss out from the slide.

2. Final Presentation.

  -  Present the Project to the lectures and PROTON'S engineers.

  - Q & A session from the lecturers.

Cabin comfort project.

1. Update the setting for temperature cooldown analysis.

  - set the inlet_temp to radiation at inlet.

  - set the body force at thermal shell to 'none'.

2. Internship report.

  - Read about the history and background of PROTON.

Holiday

Holiday

Cabin comfort project.

1. Temperature analysis- soaking.

  - update the geometry of grill and manikin (driver hand down).

  - setup the model.

  - setup all the settings at the acusolve.

  - Run the simulation.

2. Without manikin model setup.

  - update the geometry of grill and manikin (driver hand down).

  - setup the model.

  - setup all the settings at the acusolve.

  - Run the simulation.

Cabin comfort project.

1. Download the soaking analysis result.

  - analyze the result of the soaking simulation.

  - determine the error that effect the accuracy of simulation.

  - Plan to re-run the simulation.

2. Temperature analysis- soaking.

  - update the geometry of grill and manikin (driver hand down).

  - setup the model.

  - setup all the settings at the acusolve.

  - Run the simulation.

Cabin comfort project.

1. Download the soaking analysis result.

  - analyze the result of the soaking simulation.

  - determine the error that effect the accuracy of simulation.

  - addition on cabin thermal shell.

  - Plan to re-run the simulation.

2. Update the new geometry.

  - update the new grill angle and the driver's hand is put down.

  - Prepare the new updated model.

  - Setup all the settings at the acusolve accordingly.

  - Run the simulation.

3. Site visit to Multi Volume Factory (MVF).

  - Briefing about the background of MVF.

  - Visit the factory.

    - Consist of 3 main process.

     1. Body assembly.

     2. Painting.

     3. Trim assembly.

Cabin comfort project.

1. Download the updated simulation from Filezilla.

  - Record all the result in the table.

  - Simulate the airflow analysis.

  - Analyze the result.

Cabin comfort project.

1. Analyze the result of the new simulation (cont.)

  - Tabulated the data of velocity at the measured area for every position.

  - Compare the data with testing.

2. Prepare the slide for final presentation.

  - Screenshot the relevant diagram.

  - Analyze the velocity contour.

Holiday

Holiday

Cabin Comfort Project

1. Analyze the volume mesh correlation results of different volume intensity.

  - Fill in the table of results to compare the value of velocity among the correlations.

  - Compare the result with the given experimental data.

  - Calculate the differences between the simulation data against the experimental data.

  - Calculate the error between those two data.

2. Grid independence study.

  - Construct the velocity graph of the center cabin point of the four correlations.

Cabin comfort project

1. Working on the slides for the progress result presentation.

  - screenshot the relevent diagrams of result from the acufieldview(post processing software).

  - present the tabulated data of comparison between simulation and testing.

  - Present the airflow velocity contour inside the cabin.

  - Justify the expected sources of error that might happen.

2. Assist the testing department to run the Soaking-Cooldown test.

  - Role as the rear passangger.

  - Fill in the subjective feeling during the cool-down test.

Cabin comfort project.

1. Continue to update the Presentation slide.

  - 1st checked by SV for errors and to improve the quality of the slides.

  - 2nd checked by the CFD lead to improve the slides further.

  - Corrections and add-on to the slides.

2. Start with the soaking simulation.

  - Read through the tutorial of the simulation.

  - Use the most optimum model of surface/volume mesh to run the simulation.

  - Set up the model for the transient condition of the soaking simulation.

  - Run the simulation on the server but error has occured.

Cabin comfort project

1. Review the errors of the soaking simulation.

  - Re-check the overall settings.

  - Correct the possible errors.

  - Run on the server.

2. Presentation of simulation progress.

  - Present to En Sharum bin Man and Dr Nurulakmar.

  - Receive alot of constuctive comments to further improvement.

Cabin Comfort Project

1. Improve the presentation slide quality.

  - Re-take the value of airflow velocity by using the average value in the area method.

  - Re-calculate the percentage error.

  - Add table of content to the slide.

  - Add the airflow in the cabin Video to the slide.

  - Plan to re-confirm the points of anemometer and grill position with the testing department in order to improve the correlation of data.

2. Weekly meeting.

  - Explaination about the company's work culture.

  - Explaination about the format of work documentation.

Holiday

holiday

Cabin comfort project

1. Record the velocity reading into the excel file.

  - Construct the graph of all velocity points versus cases.

  - Compare the data to choose the best cases based on GIT.

2. Re-adjust the angle of center inlet grill based on the new data from testing to improve the accuracy of the correlation data.

  - Translate the aircond knob to the targetted position. 

  - Construct the axis to rotate the grill.

  - Repair the free edges/ T edges and interferences of the new meshes.

Cabin comfort project

1. Re-adjust the angle of center inlet grill based on the new data from testing to improve the accuracy of the correlation data.

  - Translate the aircond knob to the targetted position. 

  - Construct the axis to rotate the grill.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Renumber all the nodes and elements of the components.

  - Rescale the components.

  - Export the .nas file to the Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

Cabin comfort project

1. Prepare the 2nd model for the component with the new re-adjusted grill.

  - Remesh the component with the smaller minimum-maximum size.

  - Repair the surface mesh of the components with 'ruled' etc.

  - Export the model as a .nas file to be used in the acusolve for volume meshing.

  - set all the relevent setting accordingly.

  - Upload to the server the 'run'.

2. Analyze the airflow velocity at the outlet housing with different mesing size of the ducting.

  - The size of the grill was kept constant.

  - Record the data of the previous findings to be analyze.

Cabin comfort project

1. Analyze the result of the components with the new grill angle.

  - establish the bound of the components.

  - establish the airflow streamline in the cabin

  - establish the velocity contour in the cabin

 2. Disscussion about the GIT method.

  - Prepare the volume meshed components

  - Run on the server.

Cabin comfort project

1. Analyze the result of the components with the new grill angle (case 1&2).

  - establish the bound of the components.

  - establish the airflow streamline in the cabin

  - establish the velocity contour in the cabin

  - record the velocity reading on the point of interest.

  - compare the data with the experimental data

  - calculate the percentage error.

Holiday

holiday

Cabin comfort project

1. Surface cleaned up for the 1st model of iriz surface mesh (with_manikin).

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Study about the Grid Independence Test (GIT).

Cabin comfort project

1. Surface cleaned up for the 2st model of iriz surface mesh (with_manikin).

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Study about the Grid Independence Test (GIT).

Cabin comfort project

1. Surface cleaned up for the 3rd model of iriz surface mesh (with_manikin).

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Study about the Grid Independence Test (GIT).

Cabin comfort project

1. Surface cleaned up for the 4th model of iriz surface mesh (with_manikin).

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Establish the points to read the velocity value in the cabin based on points given by the testing department.

  - record the value from the AcuField View into the table in microsoft Excel.

Cabin comfort project

1. Repair the error from the 1st model with manikin.( The 2nd outlet at the back is was not deleted)

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Establish the points to read the velocity value in the cabin based on points given by the testing department(higher accuracy).

  - record the value from the AcuField View into the table in microsoft Excel.

3. Study about the anemometer and the influence of terbulence model to the sreamline.

holiday

Holiday

Cabin comfort project

1. Double the minimum and maximum element length to reduce the CPU time (Cabin parts only).

  - Remesh the required components to meet the new meshing size.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

Presentation 1

- Findings on the literature review.

  - The turbulent equations

   - Spalart allmaras, k-epsilon etc.

   - Mesh quality

   - Convergence creteria

   - Grid dependent test

Cabin comfort project

1. Delete the manikin for the without occupant situation.

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

Cabin comfort project

1. Surface cleaned up for the 2nd model of iriz surface mesh.

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

Cabin comfort project

1. Surface cleaned up for the 3nd model of iriz surface mesh.

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Prepare the slide show for progress meeting presentation with the head of departments and CFD engineers.

Cabin comfort project

1. Surface cleaned up for the 3rd model of iriz surface mesh.

  - Repair the holed seat with 'ruled' etc.

  - Repair the free edges/ T edges and interferences of the new meshes.

  - Export the file as .nas to be use in Acusolve.

  - Rename the components.

  - Set the boundary conditions etc.

  - Generate the volume mesh.

  - Set the problem descriptions etc.

  - Send the files to the server for the calculations of modelling.

2. Presentation of the project's progress to the head of departments and CFD engineers.

  - Receive a lot of good and constuctive comments for further improvement.

3. Break accessment of the benchmark cars (vios, iriz, axia and persona) on the test track.

holiday

holiday

Cabin Comfort Project

1. Continue to 'ruled' the front seats component to the manikins(driver and co-driver).

2. Surface cleaned up of the new Mannequin.

   - The unwanted elements on the components are removed.

  - The saperated parts of the components are 'ruled' to make it attached properly.

3. Study about the CFD and HVAC System for the lliterature riview from previous thesis and other resources.

Cabin Comfort Project

1. Continue to 'ruled' the seats component to the manikins (driver and co-driver).

2. Surface cleaned up of the overall cabin.

   - The unwanted elements on the components are removed.

  - The saperated parts of the components are 'ruled' to make it attached properly.

  - Checked the penetration and interferences on the components.

  - All the interferences are removed and repaired.

3. Study about the CFD and HVAC System for the lliterature riview from previous thesis and other resources.

  - Study about the Acusolve Software.

Meeting of Cabin Comfort Project

- Meeting with UTM lecturers testing department from PROTON.

- Discuss about the updates of the project.

- Presentation from Dr Haslinda about the project overview and schedule planning.

- Presentation about the findings data from testing department.

- Site visits to the testing area.

Cabin Comfort Project

1. Continue to 'ruled' the seats component to the manikins (driver and co-driver).

2. Surface cleaned up of the overall cabin.

   - The unwanted elements on the components are removed.

  - The saperated parts of the components are 'ruled' to make it attached properly.

  - Checked the penetration and interferences on the components.

  - All the interferences are removed and repaired.

3. Study about the CFD and HVAC System for the lliterature riview from previous thesis and other resources.

  - Study about the Acusolve Software.

Cabin Comfort Project

1. Continue to 'ruled' the seats component to the manikins (driver and co-driver).

2. Export the meshed component to Acusolve.

 - Acusolve detect the defects of the components that need to be cleaned. 

   Surface cleaned up of the overall cabin.

   - The unwanted elements on the components are removed.

  - The saperated parts of the components are 'ruled' to make it attached properly.

  - Checked the penetration and interferences on the components.

  - All the interferences are removed and repaired.

3. Study about the CFD and HVAC System for the lliterature riview from previous thesis and other resources.

  - Study about the Acusolve Software.

Cabin Comfort Project

1. Continue to 'ruled' the seats component to the manikins (driver and co-driver).

2. Export the meshed component to Acusolve.

 - Acusolve detect the defects of the components that need to be cleaned. 

   Surface cleaned up of the overall cabin.

   - The unwanted elements on the components are removed.

  - The saperated parts of the components are 'ruled' to make it attached properly.

  - Checked the penetration and interferences on the components.

  - All the interferences are removed and repaired.

3. Study about the CFD and HVAC System for the lliterature riview from previous thesis and other resources.

  - Study about the Acusolve Software.

4. Export the cleaned compnents from Hypermesh to Acusolve.

  - Renamed the components to be easily recognise.

  - Set the appropriate setting for the volume mesh.

  - Set the boundary conditions for the components.

  - Run the acusolve for the volume mesh on local workstation.

5. Hari Raya Aidilfitri Celebration.

Holiday

Holiday

Cabin Comfort Project

1.Surface Cleanup

- Change the component parts name to be easily recognise.

- Replace the current manikin from the IRIZ model to the new upgraded manikin.

- Export the HVAC Duct and duct extension to the PESONA model.

- Make the outlet hole at the PESONA cabin component.

- Used the ruled features to fixed the outlet on the PESONA cabin.

- Combined the doors and cabin back to form a cabin component.

- Cleaned up the seats component.

2. Meeting with the engineers of the CFD department to update the task's current status.

Cabin comfort project

1 surface meshing

- continue to cleanup the surface of the seats and floor component for PESONA model.

- Meshing the surfaces of the components.

- Checking the quality of the mesh on the components surface.

- Use 'ruled' features to combine/fixed the missing or holed surfaces.

- Components that has been done for today:

  - PERSONA'S floor

  - PERSONA'S seats

  - PERSONA'S outlet

  - PERSONA / IRIZ aircond inlet

Cabin comfort project.

1. Surface cleaned of components

- Cleaned up the surface of air inlet housing.

  - The solid of the component was removed.

  - Only the inner surfaces of the Inlet housing was choosen, other surfaces need to be removed.

  - The surfaces then meshed with a specific element size setting.

  - The quality of meshed surfaces was checked to make sure there is no free edges and any interferece.

2. The components then attached into the cabin.

  - The components need to be 'ruled' or 'node replace' to make it properly attached with other surfaces without any free edges or intersections.

3. The components that involve for today is :

- Air inlet housing

- Steering 

- Seats

- HVAC Ducting

Cabin Comfort Project

1. Continue to 'ruled' the seats component to the cabin.

2. Surface cleaned up of the new Mannequin.

   - The unwanted elements on the components are removed.

  - The saperated parts of the components are 'ruled' to make it attached properly.

3. Study about the CFD and HVAC System for the lliterature riview from previous thesis and other resources.

Cabin Comfort Project

1. Continue to cleaned up the surface of manikins component.

  - 'ruled' or replace the nodes the make sure the nodes are attached properly.

  - Checked the quality of meshed surface to make sure there is no free edges of interferences

2. Joined the meeting with all of the Computer Aided Engineering (CAE) department.

  - They discuss about the updates of their current projects with the head of department.

Holiday

Holiday

Hari Raya Aidilfitri

Hari Raya Aidilfitri

AcuSolve Training 1

Read the overview about the AcuSolve Software.

WORKSHOP 1 - Conjugate Heat Transfer

WORKSHOP 4 - Compressible Nozzle

WORKSHOP 5 - Rigid Body Motion

AcuSolve Training 2

1. Read about the solution strategy.

AcuSolve provides users with complete control over the solution process
•Equations that are solved
•Number of times that they are solved per step
•Order in which they are solved
•Linear solver to use for each equation
•Convergence tolerance for each equation
•Etc.

2. Workshop 6 - Flexible Ring

Purposes of the Workshop
•Learn the different types of Fluid Structure Interaction (FSI) that AcuSolve supports
•Set up a Practical FSI simulation (P-FSI)
•Set up a Direct Coupled FSI simulation (DC-FSI)
•Gain experience using ALE mesh motion
•Use Surface Manager to assign boundary condition types
•Use the “Propagate” feature to copy settings from one group to another
•Run AcuSolve
•Monitor solution with AcuProbe

3. Read about restarting simulations

Simulations can be restarted in two different ways.
•From AcuConsole GUI
•From the command line

4. Read about the Heat Transfer Modelling

AcuSolve supports many features for the modeling of heat transfer phenomena
•Conjugate heat transfer
•Heat transfer between solids and fluids.
•Radiant heat transfer
•Surface to surface radiation supported for applications having high temperature differences
•Solar Radiation
•AcuSolve supports solar radiation modeling on surfaces such as automotive windshields
•Many, many more
•Convective heat transfer from surfaces, thermal shells, etc.

Meeting with Testing Department

1. discuss about the work flow of the project.

2. Explaination about the details of the project from the representative of testing department.

3. Discussion about the data obtained from testing analysis.

4. Test drive(passanger)  the new model of car from PROTON on the test track.

AcuSolve Training

Workshop 7 – Natural Convection

Purposes of the Workshop
•Gain experience with the different heat transfer mechanisms simulated by AcuSolve
•Gain experience with simulations involving no inlet or outlet boundary conditions.
•Set up a heat transfer problem involving natural convection
•Load mesh by importing arm file
•Use the coupled Temperature/Flow solver
•Use Surface Manager to assign boundary condition types
•Monitor solution with AcuProbe
•Create an analysis template and use it to perform a mesh sensitivity study

Turbulence Modeling

AcuSolve supports various types of turbulence modeling
•Steady State Simulations
•Reynolds averaged Navier-Stokes equations solved to arrive directly at the time averaged flow field
•Transient Simulations
•Governing equations are integrated in time to yield a time accurate simulation of transient flows
•Many different turbulence closures are available for each type of simulation
•We will briefly discuss the closures that are available in AcuSolve in this presentation

Working with Expressions and Units

Changing the units
•This can be done in two different ways
•The first method is to type the number and units with a space in between and hit Enter.
•Next method is to click on the units next to the box for entering numbers. A list of units appears. Select the desired unit.
•When AcuConsole writes the input file all the data is converted to SI units.

Setting User Preferences

Preferences
•User can set the preferences by clicking on File > Preferences in the menu bar.
•Full control is provided to the user for adjusting the default settings.

Additional Workshops…

Workshop – Burner

Purposes of Workshop
•Gain Experience With
•Meshing with Zone Mesh Refinement
•Scalar Species tracking
•Periodic meshing and modeling
•Meshing to resolve a shear layer

Workshop – Rolling Ship

Purposes of Workshop
•Gain Experience With
•Guide Surface to Control Mesh Motion
•Free Surface
•Mesh Motion with a Multiplier Function

Workshop – Sensor UDF

Purposes of Workshop
•Gain Experience With
•Meshing with Zone Mesh Refinement
•User Defined Function
•Multiplier Function
•Volumetric Heat Source
•Restart from AcuConsole

Holiday

Holiday

1. Briefing more deeply about the assigned project.

2. Hypermesh Training 2

GEOMETRY

HM-2000 : importing and repairing CAD

HM-2020 : simplifiying Geometry

HM-2090 : Dimensioning

MESHING

2-D elements

HM-3100 : Automeshing

HM-3120 : 2-D Mesh in Curved Surface

QUALITY

HM-3300 : Checking and Editing Mesh

HM-3320 : Penetration

1. Morning Assembly.

2. Hypermesh Training 3

MORPHING

HM-3510 : Freehand Morphing

HM-3520 : Sculpting

HM-3530 : Changing a curvature using map to geometry

HM-3550 : Morph Volume

HM-3560 : Basics of domains and handles

HM-3630 : Morphing with Shapes

Hari Raya Aidilfitri

Hari Raya Aidilfiri

Holiday