Effective thermal management in internal combustion engines is essential for meeting increasingly stringent global emissions regulations and fuel efficiency standards. This paper presents a comprehensive solution to enhance engine thermal management performance by addressing key system aspects, including coolant circuit architecture, Integrated Thermal Management Module (ITM) control strategies, port-specific flow management, zero-flow operation, and standardization of HVAC (Heating, Ventilation, and Air Conditioning) settings.
The research was conducted on a newly developed engine platform, where a suite of advanced thermal management measures was applied and verified through both vehicle and bench testing. Key improvements included reducing the thermal mass of the coolant circuit to enable faster warm-up of the engine and major components, as well as refining ITM control logic through linear mapping and signal filtering for more precise target coolant temperature regulation. Enhanced zero-flow management allowed for optimal control of coolant flow, especially during engine start-up and under low ambient conditions, effectively reducing heat loss and minimizing lubrication oil dilution. Further optimizations, such as adjusting port opening strategies and radiator flow distribution, contributed to improved system responsiveness and fuel economy. Standardizing HVAC operational settings ensured reproducibility and reliability of warm-up behavior during testing.
These integrated improvements were successfully applied to the new engine and demonstrated their technological effectiveness and commercial viability in practical applications. The approach proved capable of delivering substantial benefits in terms of warm-up performance, control stability, and energy efficiency—all while supporting regulatory compliance requirements.
Overall, this study demonstrates practical and widely applicable strategies for optimizing thermal management systems in modern spark-ignition engines. The applied solutions can be readily implemented in both new engine development and the enhancement of existing vehicles, helping automakers achieve regulatory compliance, improve market competitiveness, and adapt effectively to evolving environmental standards.