Browse Topic: Coolants

Items (1,366)
A great number of performances of an electric vehicle such as driving range, powering performance, and the like are affected by its configured batteries. Having a good grasp of the electrical and thermal behavior of the battery before the detailed design stage is indispensable. This paper introduces an experiment characterization method of a lithium-ion battery with a coolant system from cell level to pack level in different ambient conditions. Corresponding cell and pack simulation models established in AMESim that aimed to capture the electrical and thermal features of the battery were also illustrated, respectively. First, the capacity test and hybrid pulse power characterization (HPPC) test were conducted in a thermotank to acquire basic data about the battery cell. Next, based on acquired data, first-order equivalent circuit model (1C-ECM) was built for the battery cell and further combined with environmental boundary conditions to check the simulation accuracy. Then, hybrid
Zhou, ShuaiLiu, HuaijuYu, HuiliYan, XuYan, Junjie
A method for performance calculation and experimental method of a high voltage heater system in electric vehicles is proposed. Firstly, heater outlet temperature and pressure drop of the heater are used as metrics to compare simulation results with experimental data, thereby validating the established model. Then, simulations are performed on two heater flow channel configurations: a cavity flow channel and a cooling fin flow channel. It is observed that the latter significantly reduces the heating plate temperature. This reduction enhances the protection of heating elements and extends their operational lifespan, demonstrating the advantages of incorporating cooling fins into the flow channel structure. The optimization variables for multi-objective optimization include the fin unit length, fin height, fin thickness, fin width, and spacing between two adjacent rows of fins. The optimization objectives include pressure drop, heat transfer efficiency, and heating plate temperature
Gong, MingWang, XihuiWang, DongdongShangguan, Wen-Bin
This study investigates the impact of thermal imbalances on energy delivery and Battery State of Power (SoP) in immersion-cooled battery cells. It explores how these imbalances, which arise when cells within a module operate at different temperatures, lead to variations in internal resistance and inefficiencies in energy storage and discharge. Such imbalances critically affect the battery's SoP, representing the maximum charge or discharge power the system can support over specific time intervals. By analyzing SoP over 10-second durations and continuous, we assess how thermal imbalances influence both short-term and medium-term power capabilities. Temperature significantly impacts cell aging, and imbalances can accelerate degradation in some cells, ultimately affecting serviceability. To address these issues, we employ a high-level simulation framework that integrates advanced tools. GT-SUITE software optimizes thermal performance by adjusting coolant temperature and flow rate to
Meshginqalam, AtaNegro, SergioAtluri, PrasadTyagi, RamavtarSuzuki, JorgeK B, AnjushaCao, Yuyuan
Lithium-ion batteries (LIBs) are critical components in electric vehicles (EVs) and renewable energy systems. However, conventional cooling techniques for LIBs often struggle to efficiently dissipate heat during fast charging and discharging, potentially compromising performance and safety. This study investigates the thermal performance of immersion cooling applied to an Electric Vehicle (EV) battery module comprised of NCA-chemistry-based cylindrical 21700 format Lithium-ion cells. The effectiveness of immersion cooling in reducing maximum cell temperature, temperature gradient, cell-to-cell temperature differential, and pressure drop within the battery module is evaluated on a detailed 3D model of a 360-cell immersion-cooled battery module that was developed, incorporating a well-established heat generation model based on theoretical analysis and experimental data to simulate the thermal characteristics of the battery system. The effects of the different fluid properties are first
Garcia, AntonioMicó, CarlosMarco-Gimeno, JavierElkourchi, Imad
The operating temperature of lithium-ion battery (LIB) cells significantly influences their degradation behavior. In indirect liquid cooling systems, temperature variations within a Battery Electric Vehicle (BEV) LIB module are inevitable due to the increasing downstream temperature of the cooling medium as it absorbs heat. This leads to reduced temperature differentials between the cooling medium and the LIB cells. As a result, LIB cells located further along the flow path experience higher average temperatures than those at the front. Typically, a maximum average cell temperature difference of 5 K within LIB modules is considered acceptable. However, results from a conventional cooling system indicate that, when fast charging is exclusively used, this can lead to a 15.5 % difference in the total ampere-hours passed before the End-of-Life (EOL) is reached for the front and back LIB cells. To address this issue, a switchable thermal management system for the traction battery is
Auch, MarcusWeyershäuser, KonstantinKuthada, TimoWagner, Andreas
Efficient thermal management is essential for maintaining the performance and safety of large-capacity battery packs. To overcome the limitations of traditional standalone air or liquid cooling methods, which often result in inadequate cooling and uneven temperature distribution, a hybrid air-liquid cooling structure was designed. A three-dimensional model was developed, and heat transfer and fluid flow characteristics were analyzed using computational fluid dynamics (CFD) simulations. Experimental validation was carried out through discharge temperature rise tests on individual battery cells and flow resistance tests on the liquid cooling plate. The thermal performance of the hybrid system was compared to that of standalone cooling methods under various discharge rates. The results indicated that the hybrid system significantly enhanced cooling performance, reducing the maximum temperature difference by 5.54°C and 3.37°C, and the peak temperature by 11.66°C and 4.5°C, compared to air
Li, HaoGuo, YimingZhou, FupengLi, KunyuanShangguan, Wen-Bin
A tested method of data presentation and use is described herein. The method shown is a useful guide, to be used with care and to be improved with use.
S-12 Powered Lift Propulsion Committee
Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed
Birgül, Çağrı EmreMeydan, Ömer
This paper addresses a series of issues in the thermal management system of proton exchange membrane fuel cells (PEMFC) during power fluctuations, such as slow system response, insufficient stability, significant temperature fluctuations, and the complexity of coupled control between coolant flow and air flow. A solution is proposed by designing separate Linear Active Disturbance Rejection Controllers (LADRC) for the coolant flow and air flow control loops. A one-dimensional model of the PEMFC thermal management system was established on the LMS AMESIM simulation platform, combined with a hydrogen fuel cell vehicle model and a driver model, fully considering various influencing factors such as vehicle power fluctuations and driver demands. Subsequently, the LADRC control algorithm was developed on the Matlab-Simulink platform, and a co-simulation analysis was performed to compare the control effects of PID control and LADRC under both custom operating conditions and the New European
Zhu, ShaopengMei, JingYang, LangZong, YajingLiu, YunmeiZhang, BoChen, Huipeng
With the rapid adoption of new energy vehicles (NEVs), effective thermal management has become a crucial factor for enhancing performance, safety, and efficiency. This study investigates the steady-state and dynamic characteristics of a secondary loop CO₂ (R744) thermal management system designed for electric vehicles. The secondary loop system presents several benefits, such as improved safety through reduced refrigerant leakage and enhanced integration capabilities with existing vehicle subsystems. However, these advantages often come at the cost of decreased thermodynamic efficiency compared to direct systems. Experimental evaluations were conducted to understand the effects of varying coolant flow rates, discharge pressure, and dynamic startup behaviors. Results indicate that while the indirect system generally shows a lower coefficient of performance (COP) than direct systems, optimization of key parameters like coolant flow rate and discharge pressure can significantly enhance
Zong, ShuoHe, YifanGuan, YanDong, QiqiYin, XiangCao, Feng
A mathematical model of the thermal management system (TMS) for an extended-range hybrid electric vehicle is developed. The variation in engine coolant temperature is examined under different water pump and fan control strategies, and its subsequent impact on engine TMS energy consumption is analyzed. Based on the simulation results of energy consumption under various control parameters, machine learning regression models are constructed, and four different regression algorithms are applied. By incorporating temperature-based optimization into the water pump and fan control strategy, system energy consumption can be effectively reduced. The machine learning regression results indicate that the mathematical model of TMS cannot be simply regarded as a linear model. ANN and SVM regression show high degree of agreement with the mathematical model. This study provides a theoretical foundation for the development of data-driven tool for optimizing real-time TMS control strategies.
Pan, ShiyiZhang, NanZheng, JunliSun, TianfuZidi, Li
Magnesium oxide (MgO) nanofluids are of great interest for enhancing the performance in thermal management especially in automotive applications, where efforts have been made to reduce parasitic losses from traditional cooling systems. These findings highlight the effects of Water–ethylene glycol and MgO nanofluids on viscosity and thermal conductivity in specific filling a gap in research that allows to clarify how these states behave at different temperature (T) and concentration (C) conditions. Test results demonstrate that the thermal conductivity of MgO nanofluids improved adequately /while its corresponding change in viscosity remained under control, affirming a significant improvement for energy savings by means heat transfer enhancement using new generation coolants based on this nano-additive. The results also provide useful information for design and development of automotive cooling systems, including real numbers on performance improvements that lead to more efficient and
Jeyanthi, P.
The aim of the article is to evaluate the effect of the cooling system on the NVH behavior of traction permanent magnets synchronous motors (PMSMs). An effective numerical method is proposed for modeling the fluid–structure interaction in the cooling system of PMSMs. A simplified physical prototype of a cooling jacket of a PMSM is realized by welding two concentric tubes with an internal cavity filled by coolant. A finite element model of the structure is realized. The coolant is modeled as an acoustic domain to account for the fluid–structure interaction in the cavity and a coupled acoustic–structural dynamic problem is solved. The model is validated by experimental modal tests conducted on the prototype of the cooling jacket both with and without the presence of coolant. The validated model is employed to quantify the effect of the cooling system on a real PMSM. The structure of a 10-poles, 12-slots electric machine is modeled by means of finite element method. The model includes the
Barri, DarioSoresini, FedericoBallo, FedericoLucà, FrancescantonioManzoni, StefanoGobbi, MassimilianoMastinu, Giampiero
The research introduces the thermal properties of silicon dioxide (SiO2) nanofluids and the promising application of these fluids in hybrid vehicle cooling systems. How to make fluids is simply to disperse a 50-50 mixture of both Ethylene Glycol and Water; into this solution add SiO2 nanoparticles concentration ranges from 0.1% up to 0.5% volume according desired properties or material characteristics etc. When viscosities and thermal conductivities of nanofluid were measured over the temperature range from 25 to 120 °C using Brookfield viscometer and transient hot-wire method; results were as follows: Viscosity of SiO2 nanofluids at 120°C higher concentrations 0.5%, more viscous fluids, thermal conductivity also rose with results, although there was a plateau at around 40% increase compared to that of water-based slurries. At 0.5% concentration, thermal conductivity increased by up to 20% at 120 °C, compared with the value of pure ethylene glycol. These results suggest that SiO2
Sundaram, V.Madhu, S.Vidhyalakshmi, S.Saravanan, A.Manikandan, S.
In this study, we investigate the thermal conductivity optimization of nanodiamond nanofluids for application in high-performance automotive engines. Nanodiamond particles, known for their superior thermal properties and stability, are dispersed in a base fluid composed of ethylene glycol and water. Various concentrations of nanodiamonds are prepared to evaluate their impact on thermal conductivity and viscosity. The experimental setup includes precise measurements of thermal conductivity using the transient hot-wire method and viscosity using a rotational viscometer over a temperature range of 25°C to 100°C. The results demonstrate significant enhancements in thermal conductivity with acceptable increases in viscosity, suggesting the potential of nanodiamond nanofluids in improving engine cooling efficiency. The study concludes with recommendations for future research to explore the long-term stability and performance of these nanofluids in real-world automotive applications.
Jeyanthi, P.Gulothungan, G.
In this study, the viscosity and thermal performance of nanofluids based on ZnO-MgO mixed oxide nanoparticles added in different concentrations to ethylene glycol-water mixture are characterized with potential applications in engine cooling. The work began with two needs: the increasing importance of better heat removal in automotive engines, where traditional coolants struggle to adequately maintain good thermal conductivity but at low viscosity to acceptable levels; and a chance opportunity for exploration provided by MMD/MILab Engineer Andrew Cricee. The work wants to improve the cooling properties, but still keeping good fluidity by integrating ZnO-MgO nanoparticles. Preparation method the preparation of ZnO-MgO nanofluids was done using volume concentrations of 0.1%, 0.3% and 0.5%. To determine chemical properties, viscosity measurements were made on the Dragonfly using a Brookfield viscometer at temperatures ranging from 25 ° C to 80 ° C while varying the nanoparticle
Manikandan, S.Vickram, A. S.Madhu, S.Saravanan, A.
Nanofluids have emerged as effective alternatives to traditional coolants for enhancing thermal performance in automotive applications. This study conducts a comparative analysis of the viscosity and thermal conductivity of ZnO and Cu hybrid nanofluids. Nanofluids were prepared with ZnO and Cu nanoparticle concentrations of 0.1%, 0.3%, and 0.5% by volume and were characterized over temperatures ranging from 25°C to 100°C. The results demonstrate that ZnO and Cu hybrid nanofluids achieve an increase in thermal conductivity by up to 22% and 28%, respectively, compared to the base fluid. Concurrently, the viscosity of these nanofluids increases by up to 12% at the highest concentration and temperature. This study addresses a critical research gap by investigating the combined effects of ZnO and Cu nanoparticles in hybrid nanofluids, an area that has been underexplored. By providing new insights into optimizing both thermal conductivity and viscosity, this research contributes to the
Sivasubramanian, M.Sundaram, V.Madhu, S.Saravanan, A.Vidhyalakshmi, S.
Properly sized under hood components in an electric vehicle is important for effective thermal cooling at different load conditions. Powertrain aggregate loop plays significant role in generating heat with heat sources like eMotor, inverter, variable frequency drivers, on board charger and so on. Radiator being the most critical part in electric vehicle which acts as a heat sink for these powertrain components. Radiator with the help of coolant removes heat generated by different components in powertrain loop. It becomes important to understand the heat generated by the powertrain components at different drive/load scenarios and decide on the correctly sized radiator and fan. Rightly sized radiator and fan combination helps to balance the tradeoff of precise thermal needs in eTruck to an oversized/undersized component. Main objective of this study is to estimate heat loads from system model representing powertrain aggregate components to study the existing radiator capacity and propose
Koti, ShivakumarPatel, VedantChalla, KrishnaGurdak, Michael
The lithium-ion battery is the most common type of batteries in modern electric vehicles. During vehicle operation and battery charging, the temperature of the battery cells increases. The temperature of any battery must be controlled and maintained within a specified range to ensure maximum efficiency. Considering the overall thermal effect on the battery, a battery cooling system is of great importance in electric vehicles to maintain the temperature of the battery cells inside the battery pack. There are different types of systems for battery cooling, out of which the water cooled systems are very popular. They use a mixture of water and ethylene glycol to absorb heat from the battery cells. The coolant circulates through the tubes or cold plates surrounded by the cells to absorb the heat. The paper involves the study of variation on temperature and pressure drop including overall thermal performance on the batteries by changing the internal structure. The temperature of battery
Parayil, PaulsonAhmad, TaufeeqDagar, AakashGoel, Arunkumar
Balancing low conductivity, corrosion resistance and optimum heat transfer in next-generation EV coolants while meeting new EV safety regulations. Managing the heating and cooling of electric vehicle propulsion systems may seem to be an easy task compared with combustion engines. After all, ICEs run much hotter-the thermal optimum for a gasoline engine is around 212 F (100 C). By comparison, EV batteries normally generate (as a function of current during charge/discharge cycles) a relatively cool 59-86 F (15-30 C). And while motors and power electronics operate hotter, typically 140-176 F (60-80 C), they still run cooler than ICEs. But among the myriad complexities of EV thermal management are batteries' dislike for temperature extremes, new cell chemistries, heat-generating high-voltage electrical architectures and 800V fast charging. All are putting greater focus on maintaining stable EV battery thermal performance and safety. Experts note that compatibility among the cell chemistry
Brooke, Lindsay
Innovators at NASA Johnson Space Center have developed an adjustable thermal control ball valve (TCBV) assembly which utilizes a unique geometric ball valve design to facilitate precise thermal control within a spacesuit. The technology meters the coolant flow going to the cooling and ventilation garment, worn by an astronaut in the next generation space suit, that expels waste heat during extra vehicular activities (EVAs) or spacewalks.
This test method provides a standardized procedure for evaluating the electrochemical resistance of automotive coolant hose and materials. Electrochemical degradation has been determined to be a major cause of EPDM coolant system hose failures. The test method consists of a procedure which induces voltage to a test specimen while it is exposed to a water/coolant solution. Method #1, referred to as a “Brabolyzer” test, is a whole hose test. Method #2, referred to as a “U” tube test, uses cured plate samples or plates prepared from tube material removed from hose (Method No. 2 is intended as a screening test only). Any test parameters other than those specified in this SAE Recommended Practice, are to be agreed to by the tester and the requester.
Non-Hydraulic Hose Committee
The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075
Premkumar, R.Ramesh Babu, R.Saiyathibrahim, A.Murali Krishnan, R.Vivek, R.Jatti, Vijaykumar S.Rane, Vivek S.Balaji, K.
Climate across India varies from extreme Cold to extreme hot. As an objective to improve comfort to drivers during summer, it is mandate by Indian Government to introduce Air Conditioning in Trucks from June 2025. Air Conditioning system includes Evaporator, compressor, Condenser and expansion units. Condenser needs continuous air flow to reject the absorbed heat from driver cabin to surrounding air. This is possible by directing air through condenser by an external fan. For this condenser is remotely mounted with an electric driven fan or directly to the radiator-fan system. In this paper a case study is presented where Cooling system of a Non AC Intermediate Commercial Truck is modified for Air Conditioning application. Condenser is mounted on the radiator and the additional heat load is managed by a minor change in the system. Fan is operated based on coolant temperature and with additional controls for Air Conditioning. Simulations are done in a Thermal management software “KULI
Kiran, NalavadathM S, Vignesh
Electric Trucks offer one of the most promising alternatives to vehicles in the field of transport of goods. In battery electric trucks, heat is generated by components present in the electric truck such as battery of the electric vehicle, electric drive system, Endurance Brake System etc. which require cooling and Thermal management system to control and monitor the cooling system. The thermal management system considered here includes two coolant tanks. The first coolant tank performs thermal management for the battery and Electric-Drive(e-Drive) components which can heat up to 600C and the second coolant tank performs thermal management for HPR circuit, and it is used to break the charging circuit to protect the battery getting charged beyond 100% using regenerative braking concept. HPR (High performance resistor) is the component which can heat up to ~950C and make sure the battery is not getting charged beyond the safe limits. Since HPR is a critical component and operates at high
Pekala, Sagar MohanaZacharias, NevinKulkarni, Krathika
The present study develops and analyses a novel thermal management system that utilizes a serpentine cooling plate with fluid flow channels to regulate the temperature of cylindrical lithium-ion batteries in an electric vehicle battery module. The research investigates the impact of many variables affecting the cooling efficiency during discharge processes, including C-rate, number of cooling channels in the cooling plate, inlet fluid velocity and aluminium nanoparticle concentration in the fluid. The study includes 49 lithium-ion batteries with a capacity of 4.9 Ah each using NMC chemistry and a form factor of 21700 connected in series and parallel. A coolant made of water-glycol combination in 70:30 ratio is considered to disperse the thermal energy generated in the batteries. With the increase in the number of cooling channels, the maximum temperature of the batteries is reduced significantly. Increasing the cooling fluid's velocity reduces the batteries' maximum temperature
Yogeshwar, DasariRepaka, Ramjee
Motor temperature plays a critical role in controlling pump speed and regulating coolant flow to prevent overheating during motor operation. Presently, negative temperature coefficient (NTC) sensors are commonly used for motor temperature measurement, typically installed at the motor winding’s end for ease of installation. However, in oil spray-cooled motors, the temperature distribution is uneven due to the spray pipe, leading to lower temperatures near the pipe compared to other areas. This results in a challenge where relying solely on NTC measurements at the winding end may not meet the motor’s cooling requirements. To address this issue and improve temperature signal accuracy, a novel approach has been developed that utilizes four signals derived from the motor controller: motor speed, motor torque, along with oil pump speed, oil temperature. Employing the lumped parameter method, a model established in Simulink aims to estimate the average temperature in the motor’s high
Lu, JunjieLi, QiangChen, BinglinZhu, LunzhiWu, JianYan, Pingtao
In the face of the world’s population growth and ensuing demands, the industrial sector assumes a crucial role in the management of limited energy supplies. Superalloys based on nickel, which are well-known for their remarkable mechanical qualities and resilience to corrosion, are now essential in vital applications like rocket engines, gas turbines, and aviation. However, these metals’ toughness presents a number of difficulties during machining operations, especially with regard to power consumption. This abstract explores the variables that affect power consumption during the machining of superalloys based on nickel in great detail and suggests ways to improve energy efficiency in this area. The effects of important variables on power consumption are extensively investigated, including cutting speed, feed rate, depth of cut, tool geometry, and cooling/lubrication techniques. A careful balance between these factors is necessary to maximize machining efficiency and reduce power usage
Başaran, AlperÖzer, MahmutKazan, Hakan
Within this work a compact automotive heat pump module prototype with the natural refrigerant R290 (propane) is presented. R290 is non-toxic, has a low global warming potential (GWP) of 3, is environmentally friendly and is not affected by PFAS restrictions. Furthermore, R290 has a superior efficiency compared to refrigerants like R1234yf & R134a, which makes it a promising alternative. A test setup is built to evaluate the performance of the prototype HP-module, which is charged with approx. 190g of refrigerant and reaches a cooling/heating capacity of approx. 11kW/16kW at the investigated conditions. In addition, a 1-D numerical tool for the calculation of steady state conditions is implemented in MATLAB/Simscape and validated by time-averaged test data. The objective of the numerical tool is to be able to quickly predict the pressure levels within the refrigerant loop in advance to testing, as the pressure levels of the HP-module are not directly controlled, but result from the
Pogorelov, AlexejReimers, Thorsten
Hypersonic flight vehicles have potential applications in strategic defence, space missions, and future civilian high-speed transportation systems. However, structural integration has significant challenges due to extreme aero-thermo-mechanical coupled effects. Scramjet-powered air-breathing hypersonic vehicles experience extreme heat loads induced by combustion, shock waves and viscous heat dissipation. An active cooling thermal protection system for scramjet applications has the highest potential for thermal load management, especially for long-duration flights, considering the weight penalty associated with the heavier passive thermal insulation structures. We consider the case of active cooling of scramjet engine structural walls with endothermic hydrocarbon fuel. We have developed a semi-analytical quasi-2D heat transfer model considering a prismatic core single cooling channel segment as a representative volume element (RVE) to analyse larger-scale problems. The model includes
Mukherjee, RaginiRoy Mahapatra, Debiprosad
In recent years, swift changes in market demands toward achieving carbon neutrality have driven significant developments within the automotive industry. Consequently, employing computer simulations in the early stages of vehicle development has become imperative for a comprehensive understanding of performance characteristics. Of particular importance is the cooling performance of vehicles, which plays a vital role in ensuring safety and overall performance. It is crucial to predict optimal cooling performance, particularly about the heat generated by the powertrain during the initial phases of vehicle development. However, the utilization of thermal analysis models for assessing vehicle cooling performance demands substantial computational resources, rendering them less practical for evaluating performance associated with design changes in the planning phase. This paper introduces a method for constructing a low-dimensional model capable of predicting the time series response of
Sugai, TomotakaShintani, KoheiHonda, TakumuSakamoto, HironobuTsuchiyama, Minoru
In this paper, we present a novel algorithm designed to accurately trigger the engine coolant flow at the optimal moment, thereby safeguarding gas-engines from catastrophic failures such as engine boil. To achieve this objective, we derive models for crucial temperatures within a gas-engine, including the engine combustion wall temperature, engine coolant-out temperature, engine block temperature, and engine oil temperature. To overcome the challenge of measuring hard-to-measure signals such as engine combustion gas temperature, we propose the use of new intermediate parameters. Our approach utilizes a lumped parameter concept with a mean-value approach, enabling precise temperature prediction and rapid simulation. The proposed engine thermal model is capable of estimating temperatures under various conditions, including steady-state or transient engine performance, without the need for extra sensors. Moreover, it exhibits greater robustness compared to temperature estimation systems
Chang, InsuSun, MinEdwards, David
The hybrid system's thermal strategy is centered around controlling the cooling of the motor, inverter, DCDC and evaporator. In this electric drive circuit system, the water temperature sensor is positioned at the radiator outlet rather than within it. Consequently, when determining the required air volume for radiator cooling and water demand for sub-components of the electric drive circuit, an estimation of the inlet water temperature becomes necessary. This estimation relies on a heat transfer formula that converts heat released by circuit sub-components into their contribution to temperature rise within the circuit plus the outlet temperature from the previous round through the radiator to determine inlet water temperature. The inverter's heat transfer power depends on voltage and current levels. Adjusting motor torque leads to rapid changes in current flow while maintaining a low speed for optimal flow rate through the electric drive pump. As a result, there should be a
Jing, JunchaoWang, ZhentaoLiu, YiqiangHuang, WeishanDai, Zhengxing
In order to study the influence of engine silicone oil fan clutch on the performances of engine cooling system under different control strategies, a model of engine cooling system for light truck is established. The working characteristics of the silicone oil clutch and the measured performance parameters of the cooling system components are taken into account in our proposed model. Modeling methods for different silicone oil fan control strategies are also given. Using the established model, the performance parameters under different vehicle speeds, such as coolant temperature of engine outlet and power consumption of cooling fan, are calculated and analyzed. The in-suite measurement of the engine cooling system is carried out to get the temperatures of engine coolant inlet and outlet from engine ECU. The model is validated by the comparison between the calculation and the measured results. Based on the established model, the working characteristics of different control forms of
Jiang, Chun-HongWang, XihuiWang, XinlingDuan, YaolongShangguan, Wen-Bin
The influence of the channels of a liquid-cooled plate on the heat dissipation performance of battery module is investigated in this paper. A topology optimization method for obtaining channel configurations of the liquid cooled plate is presented. Firstly, the battery pack cooling system test platform is built to test the flow resistance of the liquid-cooled plate under different flow rates and the maximum temperature and temperature difference of the battery under different working conditions. Secondly, the geometric model of the battery pack is established, and CFD software is used to simulate according to the test conditions. The test results validate the correctness of the model. Then, taking the average surface temperature of the liquid-cooled plate as the optimization objective, the topology optimization structure of the liquid-cooled plate is obtained by variable density method. The influence of different inlet flow rate and inlet coolant temperature on the heat dissipation
Zhou, QingLi, MinLi, Zai-huaLu, Shi-pingShangguan, Wen-Bin
A ban on Per- and Polyfluorinated Substances (PFAS) has enforced automobile companies to find alternatives to current R1234yf refrigerant. One such natural substitute, R290 (propane), is becoming popular with automotive manufacturers and suppliers due to its high performance and efficiency. However, due to its high flammability, R290 is not allowed in the cabin evaporator/condenser in order to ensure the safety of the driver and passenger. This requires the design of a novel indirect Heat Flux Management System (HFMS) with coolant as a working fluid to transfer heating to cabin and powertrain cooling components. The design of the heat pump system confines flammable R290 refrigerant to a hermitic compact box to avoid leakages. This paper aims to investigate the performance and efficiency of a new R290 refrigerant-based indirect heat pump system. The system is tested on a test bench, and the results are compared to an indirect heat pump system with R1234yf refrigerant. The study and
Gupta, RaghavSaraswat, RohanGravelle, Aled
The existing FCEV have been developed with only a few vehicle models. With the diversification of both passenger and commercial FCEV lineups, as well as the increasing demand for vehicle trailer towing, there is a growing need for high-capacity fuel cell stacks to be applied in vehicles. However, at the current level, there are limitations and issues that arise, such as insufficient power output and reduced driving speed. As a results, the importance of thermal energy management has been increasing along with the increase in required power. Traditional cooling performance enhancement methods have mainly focused on developing increased hardware specifications, but even this approach has reached its limitation due to package, cost and weight problem. Therefore, it is essential to develop a new cooling system to solve the increases in heat dissipation. This study aims to develop an evaporative cooling system using water as a by-product of the stacks, and to identify the effects of
PARK, Ui JoonKwon, Soon BeomChoi, Kyung JunLee, Gil WooOh, Dong Seok
Environmental Protection Agency (EPA) study indicates that a typical passenger vehicle emits about 4.6 metric tons of carbon dioxide per year. The Automotive industry facing a challenge of meeting stringent CO2 emission targets of 95g per kilometer for passenger car application. Thermal efficiency of internal combustion engine is one of the crucial technical parameters, which plays an important role in meeting CO2 emission targets. Global Automotive industry tends to achieve for cleaner, lower emission, low noise & improved performance for automotive products. Engine Overheating is affecting thermal efficiency & thus brake specific fuel consumption of the vehicle. Radiator is one of the critical components in Engine cooling system, which will ensure optimum operating range of internal combustion engine through precise control on coolant flow rate by Thermostat valve. Heat dissipation through radiator is directly proportional to volumetric mass flow rate of atmospheric air. The demand
Palve, ChandrakantThakur, PaurnimaChavan, VishalAher, Amit
The increasing demand for higher specific power, fuel economy, Operating Costs as well as meeting global emission norms have become the driving factors of today’s product development in the automotive market. Substitution of high-density materials and more precise adjustment of material parameters help in significant weight decrease, but it is accompanied by undesirable cost increase and manufacturing complexity. This becomes a challenge for every automotive engineer to balance the above parameters to make a highly competitive design. This work is a part of the Design and Development of 2.2 L, 4 Cylinder TCIC Diesel Engine for a whole new vehicle platform, concentrated on automotive passenger car operation. This paper explains the selection of a suitable cylinder head gasket technology for a lightweight engine that acts as a sealing interface between the cylinder block and cylinder head. The decision to select aluminium alloy for both the cylinder block and head still allows the design
Dhadse, AshishDharan R, BharaniVellandi, VikramanSasikumar, MLoganathan, S.
As emissions standards become more stringent, OEMs are pushing engines to run on leaner fuel mixtures, which puts increased thermal stress on components, particularly pistons, causing them to operate at higher temperatures. This requires more robust design and rigorous testing of components. Telemetry methods offer accurate and real-time feedback, allowing designers to test components at various operating conditions, providing more flexibility than other traditional methods. Piston temperature measurement is a critical aspect of engine development because it directly affects engine performance and durability. Among the various techniques available for this purpose, telemetry methods have gained considerable attention in recent years. This method involves integrating temperature sensors and transmitter on the piston, which transmit temperature data wirelessly to a receiver outside the engine. In this paper, we evaluate the impact of coolant temperatures, valve timing, ignition timing
Pandey, Ram KrishanKumar, AtulJangra, Sumit
In the automotive industry, thermal management plays a very important role to solve the problems of energy saving and emission. The under hood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts
P V, NavaneethPrasad, Suryanarayana A NML, Sankar
This paper presents investigation study done on improvement in coolant pump hydraulic efficiency by proposing novel design of impeller blade for internal combustion engine. In typical coolant pump design, hydraulic efficiency plays a very important role in defining performance characteristics of coolant pump. Hydraulic efficiency is inversely proportional to drag imposed on impeller blades. In current investigation, coolant pump’s impeller blade design is optimized by taking inspiration from Biomimicry. Tubercles design is adopted on tip of impeller blades. Considerable literature study indicates tubercle design has never been tested in IC Engines in automotive industry. Design calculations along with CFD work has been carried out in order to adopt tubercles design on impeller blade tip. The virtual results are encouraging, with efficiency improvement in range of 1% to 4% by means of analytical & CFD calculations at coolant pump component level. Though investigation is carried out on
Barve, AmolRoy Pratihar, SudeshnaMokashi, OnkarPatil, Naveen
The thermal performance of an engine coolant system is efficient when the engine head temperature is maintained within its optimum working range. For this, it is desired that air should not be entrapped in the coolant system which can lead to localized hot spots at critical locations. However, it is difficult to eliminate the trapped air pockets completely. So, the target is to minimize the entrapped air as much as possible during the coolant filling and deaeration processes, especially in major components such as the radiator, engine head, pump etc. The filling processes and duration are typically optimized in an engine test stand along with design changes for augmenting the coolant filling efficiency. However, it is expensive and time consuming to identify air entrapped locations in tests, decide on the filling strategy and make the design changes in the piping accordingly. In the current effort, a simulation-based testing method for coolant filling and deaeration processes is
Khandagale, VitthalPasunurthi, Shyam SundarMaiti, DipakBollu, ThejaSaha, Rohit
This SAE Recommended Practice defines the minimum performance and dimensional requirements for quick connect couplings between flexible tubing or hose and rigid tubing or tubular fittings used in coolant systems. This document applies to automotive and light duty truck applications under the following conditions: a Gasoline, diesel, hybrid, and electrical propulsion cooling systems. b Operating pressure up to 206 kPa (30 psi). c Operating temperatures from -40 °C (-40 °F) to 125 °C (260 °F). Quick connect couplings function by joining the connector to a mating end form, typically without the use of tools. The requirements stated in this document apply to new connectors in assembly operations unless otherwise indicated. For modern powertrain applications, the interconnection of the following devices is typically the design responsibility of the cooling group: coolant control valve, water-to-air charge air cooler (CAC), radiator (high and low temperature variants), and remote
Cooling Systems Standards Committee
One of the key components in engine cooling system design in internal combustion vehicles is the radiator, which is responsible not only for regulating the engine coolant temperature but also for the required airflow crossing the grille openings. Considering different construction techniques and materials, the radiator design and its characteristics influence the overall vehicle performance. This work proposes a study on the influences of the radiator in the overall performance of a conceptual vehicle design, when considering different parameters. The main radiator characteristics evaluate in this study are the construction type, heat exchange thin number and tube number in different configuration arrays. Virtual cfd simulations are used to perform this study, where the drag influence in verified in three velocities: 40, 60 and 80 kph and compared with a baseline vehicle. The water flow rate is also evaluated and compared with same baseline model, in order to provide the best radiator
Buscariolo, Filipe FabianGonzales, José Fernando PazAlves, Julio Cesar Lelis
The performance standards of Li-ion batteries used in EVs have skyrocketed, owing to their rapid commercialization in recent years. This has made Li-ion battery thermal management more vital than ever before, as optimum performance is achieved only when the batteries are within the narrow temperature range of 25° to 40°C. However, the operating temperatures in a lot of EVs go way beyond 40°C, leading to a reduction in the battery performance and lifetime. This study aims to solve this problem by improving the battery packing and maintaining the battery temperature via a hybrid cooling system which involves both air-cooling and liquid cooling. The aim is achieved by varying the liquid coolant used in the system and the cell arrangement in the battery module which has 32 cells in an 8x4 arrangement. Water-ethylene glycol solution and two other nanofluids, namely cu-nanofluid (1% vol) and CNT-nanofluid (0.1% vol) have been used as the coolants while the cell arrangements considered are
Selvan, V. Arul MozhiS, PalanisamyBharadwaj, Hari
Heat transfer optimization is a crucial aspect of the design process for Formula Student race cars, particularly for the radiator, usually housed in a side pod. For the car to operate at peak performance, a well-designed radiator-sidepod system is essential such that it can dissipate heat generated by the engine faster, for the car to run in optimal performance. Testing the car physically for various radiator-sidepod design iterations is a very difficult task, also considering the costs to manufacture the radiator-sidepod setup. The objective of this study is to develop a comprehensive methodology for analysing heat transfer through radiator setup using Computational Fluid Dynamics and to validate it through experimental investigations, to enhance performance and efficiency of the radiator setup. It further explains how to find out its heat transfer efficiency, and to choose the right radiator-sidepod setup, giving optimal performance. The flow of coolant inside the radiator, as well
Suresh, SankarSundar, MahimaBhaskara Rao, Lokavarapu
Considering the advancements in manufacturing industries, which are crucial for economic growth, there is a substantial demand for exploration and analysis of advanced materials, especially alloy materials, to enable efficient utilization of new technologies. Lightweight and high-strength materials, like aluminium alloys, are highly recommended for various applications that necessitate both strength and resistance to corrosion, such as automobile, marine and high-temperature applications. Therefore, there is a significant need to investigate and analyse these materials to facilitate their effective application in manufacturing sectors. This study investigates the machinability of drilling AA6061 using a micro-textured tool and proposes an Adaptive Neuro Fuzzy Inference System (ANFIS) model for investigating the machinability of drilling AA6061 aluminium alloy with a micro-textured uncoated tool. The ANFIS model considers various input parameters such as spindle speed, feed rate, and
Katta, Lakshmi NarasimhamuNatarajan, ManikandanPasupuleti, ThejasreeSiva Rami Reddy, NarapureddySivaiah, Potta
This work for the Coordinating Research Council (CRC) explores dependencies on the opportunity for fuel to impinge on internal engine surfaces (i.e., fuel–wall impingement) as a function of fuel properties and engine operating conditions and correlates these data with measurements of stochastic preignition (SPI) propensity. SPI rates are directly coupled with laser–induced florescence measurements of dye-doped fuel dilution measurements of the engine lubricant, which provides a surrogate for fuel–wall impingement. Literature suggests that SPI may have several dependencies, one being fuel–wall impingement. However, it remains unknown if fuel-wall impingement is a fundamental predictor and source of SPI or is simply a causational factor of SPI. In this study, these relationships on SPI and fuel-wall impingement are explored using 4 fuels at 8 operating conditions per fuel, for 32 total test points. The fuels were directly injected at two different injection timings: an earlier injection
Splitter, DerekBoronat Colomer, VicenteNeupane, SnehaPartridge, William
Items per page:
1 – 50 of 1366