ENGINE & TRANSMISSION DESIGN

Engine design

A lot of recent new engines have showed new variants and limits in every component and combustion type, which have motivated TENERGY to look into the relative merit of each engine.

The design philosophy of TENERGY is to develop well-researched and test-supported criteria to support the design decisions of future engine by investigating the key considerations of new engine design thoroughly and observing their trends carefully.

Experienced and highly motivated design engineers work on all types of design projects. And they are effectively supported by our experienced CAE, combustion system, mechanics and electronics teams. Furthermore TENERGY design details always take into account our clients'ﾕ manufacturing boundary conditions and facilities.

TENERGY mainly uses Pro-E or CATIA and carries out engine design based on 3D model. Theoretical and numerical analyses are also carried out for every optimization. We surely guarantee our design and development outputs after SOP.

 
 
 

Engine design

  • Gasoline engine
  • Diesel engine
  • Industrial engine
  • Hybridization
  • 2 - stroke engine
  • Wankel engine
  • Marine engine
  • Gen-set engine
 
 

Engine design process

Concept design

  • Performance definition
  • Packaging layout
  • Front & timing drive layout
  • Valve train layout
  • Intake & exhaust system layout
  • Cooling & lubrication circuit
  • Numeric analysis
    • 1D cycle simulation
    • 1D cooling & lubrication
    • Oil film thickness
    • Torsional vibration
    • Crankshaft, conrod
    • Piston & piston pin
    • Bolt tightening
    • Engine balancing

Definitive design

  • Parts & layout design(3D modeling)
  • Kinematic / Motion analysis
    • Valve & crank train
  • Structural FEA
    • Cylinder block & head
    • Crankshaft, connecting rod
    • Bulkhead & main bearing cap
    • Valve train
  • Modal analysis
    • Main structural parts
    • Covers & brackets
  • life calculation
    • High & low cycle fatigue
  • CFD
    • Intake & exhaust ports
    • In-cylinder flow(combustion)
    • Coolant flow
    • Intake & exhaust manifold

Detail design

  • Detail parts design(3D modeling)
  • 2D drawings
    • Tolerance
    • Roughness
    • Material
    • Machining
    • All information related to production
  • Reports
    • Design
    • Analysis

CAE ANALYSIS

TENERGY supports all CAE works required in every engine design stage.

In concept design stage, baseline simulations such as gas exchange calculation, numerical analysis of cranktrain and piston assembly including TV, 1-D cooling and lubrication analysis are carried out.

In detail design stage, structural and dynamic analysis of engine major components are carried out. In addition CFD of coolant and exhaust gas flow and NVH analysis of auxiliary parts are performed.

Highly specialized experts with many years of experience in the field of engine development are involved in all CAE works which simulate actual loading conditions as much as possible. Therefore they can offer the optimum solutions for all stages in development process.

TENERGY pays particular attention to CAE works in the scope of development process. CAE works support the whole development process efficiently and enable clients to produce highly qualified engines while achieving shorter development time and lower cost.

 
  • Gas exchange with T / C matching
  • 1-D cooling
  • 1-D lubrication
  • Valve train kinematics
  • Bearing load analysis
  • Torsional vibration
  • CFD In / Ex. port
  • CFD in-cylinder flow
  • CFD coolant flow
  • CFD intake manifold
  • CFD exhaust manifold
  • FEA cylinder head & block compound
  • FEA cylinder block
  • FEA cylinder head(LCF)
  • FEA crankshaft
  • FEA connecting rod
  • FEA exhaust manifold(HCF & LCF)
  • FEA brackets
  • FEA NVH & modal analysis
  • FEA intake manifold(plastic)
  • FEA cylinder head cover(plastic)
 
 

FE analysis of cylinder block & head compound

 

CFD analysis

TenergySoft

The company TenergySoft is a family of TENERGY providing comprehensive CAE consulting services to a variety of customers all over the world.

Business areas


Automotive

Defense

Rail

Shipbuilding & offshore

Aerospace etc.
 

CAE analysis of powertrain

  • Intake & exhaust flow
  • Structural & thermal
  • Noise & vibration
    - Normal mode & FRF of PT
    - Whine & rattle Noise of TM

CAE analysis of vehicle

  • Suspension K&C
  • Full vehicle R&H
  • Autonomous driving validation
  • Virtual test validation
  • Crash of bumper & hood

CAE analysis of shipbuilding

  • Structural & strength
  • Durability of ship
  • Performance estimation
  • Energy saving device
  • Propeller design

CAE analysis of others

  • Landing gear drop
  • Composite material
  • Railway derailment
  • Fluid-structure Interaction(FSI)
  • Heavy equipment

Application fields

  • Structure / Fatigue / Nonlinear
  • Multi body dynamics
  • NVH / Composite / Optimization
  • Fluid dynamics / 1D simulation
  • Vehicle driving simulator
  • Analysis & test process consulting

CAE analysis of chassis & vehicle

 

CAE Analysis of machinery

Aerospace analysis

 

Shipbuilding analysis

Development of energy saving device / Analysis for performance estimation

 
 

VI-GRADE H / W

HIL(Hardware In the Loop)

Accelerate your development process and prepare for subjective assessment on the driving simulator

STEERING RIG

Equipment
  • Steering rig (steering system not included)
  • Connection to the Driving Simulator
Applications
  • Steering system integration
  • EPS calibration
  • Steering feeling
  • Fault injection
  • Benchmarking
  • X-by-wire redundancy validation
  • ADAS development

*Possibility of connection with brake rig

BRAKE RIG

Equipment
  • Brake rig (brake system not included)
  • Connection to the Driving Simulator
Applications
  • Brake system integration & calibration
  • Brake pedal feeling
  • Fault injection
  • X-by-wire redundancy validation
  • Benchmark
  • ADAS development

AUTOHAWK

  1. Desktop (Offline + SiL + MiL)
    AutoHawk is used for off-line simulations, DoE, optimization loops
  2. In-lab (HiL + SiL + MiL)
    These are the typical HiL applications in which a device under test (DUT) is connected to AutoHawk running real-time software
  3. On-sim (HiL + DiL + SiL + MiL)
    These are HiL applications in which the driver sends inputs to AutoHawk through the simulator - useful to test corner cases and where the closed-loop inputs are essential
  4. On-vehicle (HiL + ViL + SiL + MiL)
    These are HiL applications where virtual vehicle model runs on the real vehicle with mutual influence
  5. Digital Twins (HiL + DiL + ViL + SiL + MiL)
    Driving simulator and real vehicle are fully synchronized and they affect each other

Transmission
Design & Develop.

Transmission development

  • Compact layout design of manual transmission and DCT
  • Multi-speed gearbox for electric vehicles
  • Cost-effective design of transfer case for 4WD
  • Development of compact AMT which has no torque interruption
  • HDT(Hydro-Dynamic Transmission) with Torque converter
  • TCU control logic development

Transmission calibration

  • Optimal results for dynamics, performance and fuel consumption

Prototype development, testing and validation

  • Rapid prototyping by 3D printing
  • Mechanical and functional rig tests
  • Transmission dynamometer for transaxle tests with engine

Transmission development process

We meet the requirements on the functionality and efficiency using an effective and start-to-finish process.
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