Simulating cooling speeds 40 percent faster while reducing performance lead times by 6 percent

Manufacturing HVAC systems more efficiently

As the only air conditioning (AC) manufacturer in Malaysia, Daikin Malaysia Sdn. Bhd. produces a variety of heating, ventilation and air conditioning (HVAC) equipment locally and globally. This includes systems from residential AC units to high tech commercial heat pumps, air-cooled and water-cooled chillers.

Established in 1998, Daikin Malaysia’s state-of-the-art research and development (R&D) center, Daikin R&D Malaysia Sdn. Bhd. (DRDM), drives advances in energy efficiency and improves its customer’s in-home comfort. As one of the largest R&D centers in Southeast Asia, the center’s core activities include product design and development, part qualification, reliability testing, product certification and researching advanced technology innovations.

Since 2007, the center has been using various simulation software for product development and structural simulation, like piping stress and fan fatigue analysis. However, to continue ensuring these activities are effective and efficient, DRDM needed to stay on the cutting edge of simulation. For this, the center uses Siemens Digital Industries Software’s Simcenter™ software, which is part of the Siemens Xcelerator business platform of software, hardware and services.

Using Siemens solutions to improve HVAC systems

To stay competitive and innovative, DRDM used Simcenter STAR-CCM+™ software for computation fluid dynamics (CFD) simulations, which enabled the center to optimize the airflow and energy efficiency of its HVAC products.

To improve the cooling experience for customers, Daikin evaluates cooling speeds during testing to ensure optimal performance. It is crucial to determine the best parameters, such as the startup compressor speed and electronic expansion valve (EXV) settings, to achieve the target air-leaving temperature within the desired timeframe. For this, the center leveraged Simcenter Amesim™ software.

“By investing in Simcenter, we further advanced our simulation capabilities for transient simulation, allowing for more precise modeling of dynamic systems and improving overall product performance,” says Dr. Chng Ming Hui, senior lead engineer at DRDM.

DRDM used Simcenter Amesim to fine-tune the modeling of the compressor startup frequency and the EXV opening and duration while determining startup control parameters. When adjusting these parameters, the center found the air-leaving temperature decreased as the startup compressor frequency or EXV opening increased. This resulted in higher startup compressor frequency-boosting cooling capacity, reducing the air-leaving temperature. Another way to increase cooling capacity was to increase the EXV opening, which lowers the superheat at the evaporator. This allowed for more precise dynamic system modeling and improved overall product performance.

“DRDM is using Simcenter Amesim software, which has significantly shortened our development lead times by accurately predicting liquid and system behavior during transient states,” says Hui.

Improving lead times and cooling speeds

Leveraging Simcenter Amesim for cooling speed simulations, DRDM shortened lead time by enabling virtual testing before physical trials. This method allowed the center to optimize parameters, reducing iterations and enhancing efficiency. The simulation-driven approach streamlined the design and development process, delivering accurate, reliable results faster while minimizing costs and improving overall design and testing productivity. This way, DRDM reduced performance testing lead time by 6 percent, accelerating product development and delivery of new products to customers. Additionally, by eliminating physical testing, DRDM lowered their electricity consumption and greenhouse gas emissions, improving sustainability.

“By leveraging Simcenter Amesim advanced simulation capabilities, we can model complex fluid dynamics and system interactions in real time,” says Hui. “This enables our engineering teams to identify potential issues early in the design process, optimize performance and ensure reliability, all while reducing time-to-market.”

Another benefit was that DRDM could simulate cooling speeds 40 percent faster. This was important because traditional methods were insufficient with customer demands for products that were colder. With simulation, it is easier to fine-tune parameters to deliver faster cooling.

Expanding Simcenter integration

Daikin plans to expand their use of Simcenter Amesim to test items and integrate them with CFD tools. The company hopes to achieve shorter testing lead times (for example, fine-tuning software parameters to optimize the system while maintaining product quality).