Advanced Engine System Integration
12% Efficiency Gain & 88% Packaging Optimization
[ BUSINESS CONTEXT ]
A performance vehicle manufacturer was risking delays on a flagship product launch due to severe packaging constraints and thermal issues in their new engine bay design.
[ PROJECT CHALLENGE ]
They needed to integrate a high-output turbocharging system into their 2.0L inline-four engine bay with only 147mm clearance. Previous attempts compromised air filter size and routed coolant lines too close to exhaust manifolds, causing heat soak.
[ STRATEGIC SOLUTION ]
Our approach combined 1D system-level simulation (Ricardo WAVE) with 3D CFD (Star CCM+) in an integrated workflow to optimize the entire air intake system and validate critical thermal areas.
Engineering Methodology
1D Air-Path Simulation
Used Ricardo WAVE to optimize plenum volume and intake runner lengths.
Transient CFD Analysis
Simulated turbulent kinetic energy to eliminate air-pockets and reduce pressure drop.
Conjugate Heat Transfer
Coupled fluid and solid solvers to design a heat shield, maintaining ECU temps below 65°C.
Kinematic Routing
Developed complex 5-axis coolant pipe geometries in Creo.
Quantified Engineering Impact
Optimized intake geometry reduced manifold pressure loss.
New shielding prevented sensor drift and limp-mode triggers.
Achieved full system integration within the 147mm envelope.
Regained power lost in previous designs by optimizing the air filter box.