A Noval methodology of compact cooling unit design for Truck applications by using CAE CFD simulation

The implementation of AC unit on truck as compulsory as per government guideline demands the AC supplier to design a compact and modular AC unit within the available package space. The installation of AC unit inside the vehicle helps the driver to drive safely due to better cabin comfort. This will reduce fatigue due to the long driving of the truck drivers. Thereby the safety of the truck and driver will be saved with the implementation. But there are challenges for AC manufactures to design the compact size AC unit. The challenges like performance, durability, cost and less noise to be met as per customer requirement. To overcome the issue of design at the early stage and compact AC unit within small space is possible with the support of simulation software. AE and CFD plays a major role in this regard. So first unit level CAE and CFD analysis conducted to predict the result. AE used for checking the strength of the mounting bracket of cooling unit and CFD used for verifying the air flow, air uniformity and air distribution through the Duct. The design feasibility further checked with tool room dept and final design been concluded based on simulation. The performance been met with the design changes on the cooling unit based on CAE and CFD result. After the simulation, proto of final design been tested and validated with simulation result. There is 5 % variation with actual test result. This way Cooling unit developed on faster pace with less cost and less time