The rising demand for electric vehicles (EVs) has pushed automakers to prioritize visual brand consistency across both EVs and internal combustion engine (ICE) vehicles. A main design factor which is influenced by this trend is the front grille. In order to achieve uniform aesthetic looks, passenger car manufacturers often reduce the front grille openings and limit airflow. This closed grille style is common in electric vehicle. However, this creates challenges for internal combustion engine (ICE) vehicles with snorkel-type air intake systems, leading to reduced airflow and higher temperatures in the engine bay and intake air which eventually gets sucked in the engine resulting in low volumetric efficiency.
Maintaining a cooler intake air is vital for ICE performance. Adjusting snorkel position and airflow patterns in low temperature zones ensures the engine receives air at low temperatures. This improves the combustion efficiency, throttle response and eventually it reduces the risk of knock. This study emphasizes the need to control intake air temperature in such a way that the air intake system supports to meet performance and emissions targets.
In our study, we use simulation tools such as computation fluid dynamics (CFD) and experiments in order to demonstrate that the ICE vehicle grille design having restricted air flow which are similar to the electric vehicles, increases the air temperature that enters into the snorkel of air intake system. This pre-heated air that enters into engine reduces its efficiency, power output and also might eventually affect the emissions. The findings in our study quantifies the thermal penalty that are linked to this design standardization.
In order to overcome these issues, the study recommends tailored front-end module thermal management strategies for ICE vehicles particularly for air intake system. The approach optimizes airflow and minimizes heat gain in snorkel of air intakes and hence preserving engine performance without sacrificing the visual consistency between EV and ICE models.