Browse Topic: Fans

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PSYCHOACOUSTIC ANNOYANCE MODELS ASSESSMENT FOR AUTOMOTIVE FAN-SYSTEMS2026-01-0672To be published on 06/20/2026
Because of automotive electrification, fan systems previously hidden by internal combustion engines could become key contributors to the overall noise behavior. Metrics like overall Sound Pressure Level or Loudness are first order metrics enabling ranking. Yet, second order factors, that are relevant to assess annoyance, are not correctly described using a single criterion. This paper studies the applicability of various Psychoacoustic Annoyance (PA) models in an attempt to address subjective perception of sound quality. Based on pairwise comparison through a jury test with a set of 8 noises at a similar global level, the combined impact of several psychoacoustics metrics was previously determined. This computation includes a signal modulation metric, a frequency content balance and a tonal criterion. To assess this approach, the correlation for fan-system noise annoyance ranking based on its jury test is compared with several PA criteria, starting from initial Zwicker and Fastl model
Scouarnec, Denis, Bennouna, Saad
NVH Aspects of DC Charging2026-01-0703To be published on 06/20/2026
The deployment of high-power DC charging infrastructure for electric vehicles introduces new challenges in managing noise, particularly in public environments where acoustic comfort and regulatory compliance are essential. Noise emissions from both charging stations and vehicles during charging are a concern for operators of charging parks regarding customer experience and sound immission regulations. AVL employed a structured three-step approach to develop a non-expert tool for assessing the noise radiation of charging stations and vehicles during the charging phase. In a first step, AVL characterized the noise emissions with sound power measurements. Secondly, the measurement results were transferred to the virtual domain. To achieve this, the vehicles and charging station were characterized in the simulation with multiple monopole sources supported by transfer function measurements. This simulation model was validated against the sound power measurement results. After successful
Gojo, Josef, Polanz, Markus, Graf, Bernhard, Langjahr, Paco, Mehrgou, Mehdi
A Novel Looped-Freezing Mean Detached Eddy Simulation (DES) Based Approach to Evaluate Underhood Cooling Performance of Commercial Vehicles02-19-03-00186/9/2026
A novel looped-freezing mean approach based on Detached Eddy Simulation (DES) approach is developed in context of assessing underhood cooling performance in heavy-duty vehicles. The method involves computing a temporally averaged flow field from DES simulations, which is then frozen and used by the energy solver to predict temperature distributions. This process is iteratively repeated until a statistically steady-state temperature field is achieved. It is demonstrated that traditional DES approach demonstrates superior accuracy in capturing forced convection heat transfer compared to the Reynolds-Averaged Navier–Stokes (RANS) method. The validation against experimental data for flow over a heated sphere at a Reynolds number of 105 shows that DES yields Nusselt numbers with better correlation than RANS. However, it is observed that DES approach captures unsteady flow features that introduce temporal fluctuations in heat transfer. In the context of underhood cooling evaluations where
Holay, Sarang, Sankar, Hari, Dixit, Pritish, Singh, Ramanand
Multi-Objective Parameters Optimization of Centrifugal Fan Based on GA-BP Neural Network and NSGA- II2026-99-07015/15/2026
In order to achieve the research objective of simultaneously improving the air volume and reducing the noise of centrifugal fans, a combination of orthogonal experimental design, BP neural network modelling and multi-objective genetic algorithm (NSGA- II) was used to find the optimal method, and the worm tongue placement angle φ, worm tongue radius R, expansion angle θ and outlet expansion section height L of the worm casing were selected as optimization variables. The air volume and noise of the centrifugal fan under the design working condition were calculated by non-constant and constant calculations, and the air volume and noise were used as the optimization objectives. The results demonstrate that, compared to the initial design, the optimized fan model achieved a noise reduction of 10.99 dB and an airflow increase of 1.76%. Furthermore, the amplitude of the pressure pulsation coefficient at the blade passing frequency was significantly reduced at the monitoring point near the
Huang, Guoxing, Zhang, Weihong, Li, Weichang
Battery Cooling System Airborne Noise Correlation Using Statistical Based14-15-02-00084/16/2026
In a traditional electric vehicle, managing its battery thermal performance is of prime importance. A well-designed battery thermal management system helps in extending its life and avoids safety-related issues like thermal runaways. A critical part of this thermal management is the battery cooling system (BCS), which can be air- or liquid-cooled. Based on the vehicle battery pack size, location, and its design complexity, the original equipment manufacturer can opt for either of the previous two methods. An air-cooled type of BCS system usually involves an active ventilation fan to dissipate the battery heat in the surroundings, which brings symbiotic noise into the picture. In an air-cooled BCS system, the primary source of noise is the cooling airflow over the heat exchanger caused by the fan. The airflow and noise performance characteristics of this fan are typically measured by the supplier in a standalone condition. These performance parameters deviate greatly when the fan is
Nomani, Mustafa, Dupatti, Darshan, Nikam, Krishna, Sasikumar, R., Kajagar, Suresh, Panchare, Dattaji, Agalawe, Kiran
Engine Cooling Fan Structural AnalysisJ1390_202604 (Current)4/13/2026
Three levels of fan structural analysis are included in this practice: a. Initial structural integrity. b. In-vehicle testing. c. Durability (laboratory) test methods. The initial structural integrity section describes analytical and test methods used to predict potential resonance and, therefore, possible fatigue accumulation. The in-vehicle (or machine) section enumerates the general procedure used to conduct a fan strain gage test. Various considerations that may affect the outcome of strain gage data have been described for the user of this procedure to adapt/discard depending on the particular application. The durability test methods section describes the detailed test procedures for a laboratory environment that may be used depending on type of fan, equipment availability, and end objective. The second and third levels build upon information derived from the previous level. Engineering judgment is required as to the applicability of each level to a different vehicle environment
Cooling Systems Standards Committee
Multi-Stage Packaging and Routing Optimization for Automotive Component Layout, Wire Harness and Duct Route Design2026-01-05074/7/2026
Modern vehicle design involves complex considerations and tradeoffs between system integration and layout which have a direct impact on performance, efficiency, and cost. The placement of equipment including control boards, motors, and fans as well as the routing of ducts and wire harnesses poses a time-consuming and intricate problem for design engineers. This paper presents an automated methodology to determine the optimal component packaging configuration, duct routing, and wire harnessing layout to maximize component packing density and minimize the total routing length. A two-stage optimization framework has been developed where the first stage packages the components within the design space with considerations for space utilization, component overlap, proximity relationships, point-to-point accessibility, and component mounting. The second stage implements a custom A* path-finding algorithm and gradient based optimization to determine the optimal route layout between port points
LeFrancois, Richard, Kim, Il Yong
Research on the Working Characteristics of Thermal Management System of Refrigerant Direct Cooling for Battery2026-01-70242/27/2026
This paper focus on the direct cooling plate with serpentine flow channels, the effects of heat load power, compressor speed, fan speed, and types of heating plates on the temperature field of the cold plate were investigated respectively based on the direct cooling thermal management system.The experimental results show that as the heating power decreases, both the overall temperature and temperature difference of the cold plate decrease synchronously. The temperature distribution along the flow channel is non-monotonic, with the highest temperature at the first elbow (T2/T3) and the lowest temperature at the outlet (T12), which is lower than the inlet temperature.A study on the T4-T11 region reveals that when the fan speed is low, with the increase of compressor speed, both Tmax and Tmin first decrease and then increase, while ΔT decreases. When the fan speed is constant at medium or high levels, as the compressor speed increases from low to medium, Tmax and Tmin decrease and ΔT also
Chen, Sijian, Huo, Guojun, Chen, Jiyong, Wei, Shaoliang, Zhang, Guihao, Zhang, Jinglong, Ju, Xinze, Yang, Xiaoxia
Accelerating EV Thermal Controller Development Using Rapid Control Prototyping on Speedgoat2026-26-06851/16/2026
In the era of Software Defined Vehicles, the complexity and requirements of automotive systems have increased knowingly. EV Thermal management systems have become more complicated while having multiple functions and control strategies within software frameworks. This shift creates new challenges like increased development efforts and long lead time in creating an efficient thermal management system for Electric Vehicles (EV’s) due to battery charging and discharging cycles. For solving these challenges in the early stages of development makes it even more challenging due to the unavailability of key components such as fully developed ECU hardware, High voltage battery pack and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation at the same time, enabling the testing and validation of thermal control strategies without fully matured system and the ECU hardware. The framework uses the Speedgoat QNX machine as the
Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh
Thermal System Design of Inter-City Fuel Cell Electric Bus2026-26-04271/16/2026
In current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries working to achieve carbon neutrality by 2050. Hydrogen being a cleaner fuel, many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper, cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are designed considering overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done with the help of simulation models built using software KULI to predict
M S, Vignesh, Kiran, Nalavadath
Evaluating Thermal Control Strategies to Improve Electric Vehicle Range Using GT Suite2026-26-03621/16/2026
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating subsystems such as the high voltage battery (HVB), Electric powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant to cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and EPT thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, Abhijeet, Kumar, Dipesh, Gummadi, Gopakishore, Khan, Parvej, Thiyagarajan, Rajesh, Pandey, Rishabh, S, Ananth, Anugu, Anil, Mulamalla, Sarveshwar, Gangwar, Adarsh
Impact of Density in Simulation Model for Extreme Cold Ambient Conditions2026-26-03881/16/2026
Battery Electric Vehicles (BEVs) necessitate highly efficient thermal management strategies, as cabin heating directly consumes energy from the finite traction battery, potentially reducing driving range significantly. Early-stage design evaluations of warmup performance commonly rely on one-dimensional (1D) simulations due to their computational speed and efficiency. The accuracy and predictive capability of these models are critically dependent on how well they represent blower operation and account for temperature-induced variations in air density. This fidelity is essential because engineers depend on warmup simulations to set HVAC targets that will deliver real-world comfort and defrost performance within stringent range constraints. Earlier, warmup simulations employed a Constant Mass Flow (CMF) approach, which simplifies computations by assuming a fixed air density at a standard reference temperature. However, this approach contrasts with real-world blower behavior, where
Subramanian, Karthik
Advanced Thermal Management for High-Tonnage EVs: Increasing Coolant Flow and Reducing Energy Losses2026-26-01961/16/2026
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach of
Dixit, Sameer, Patil, Bhushan, Ghosh, Sandeep
Optimization of a Positive Displacement Type Supercharger Using Response Surface Modeling (RSM)2026-26-04291/16/2026
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, due to the lack of availability of continuous exhaust energy pulses, in a single or two-cylinder engine, the usage of turbocharger is not recommended. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model has been prepared in Creo, with three design parameters i.e. (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing. The optimum roots blower design is expected to fulfil the target boost pressure, power consumption and
Satre, Santosh Dadasaheb, Mukherjee, Nalini, Rajput, Surendra, Nene, Devendra
A Fluid-Structure- Interaction based Methodology to Evaluate Aero-Thermal Performance of Deformable Air Guides2026-26-03641/16/2026
The present work demonstrates a Fluid-Structure Interaction (FSI) based methodology that couples a Finite Volume Method (FVM) and Finite Element Method (FEM) based tools to estimate air guide deformation, thereby predicting accurate aerothermal performance. The method starts with a digital assembly step where the assembly shape and the induced stress due to assembly is predicted. A full vehicle Aerodynamic simulation is performed to extract the surface pressure on the air guide which is then used to estimate the extent of deformation of the air guides. Based on the extent a subsequent Aerodynamic simulation may be carried out to predict thermal efficiency. Comparison against pressure data and deflection data extracted from the wind tunnel experiments of vehicles has shown reasonable match demonstrating the accuracy and usefulness of the method.
Gadasu, Ravishastri, Choudhury, Satyajit, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
NVH Refinement on the Agriculture Tractor using Coupled Test and Simulation Approach2026-26-03161/16/2026
The Indian farmers choice of agriculture tractor brand is driven by the ease of operation and fuel efficiency. However, the customer preference for operator comfort is driving many tractor OEMs for improvement in noise and vibration at the operator location. Also, the compliance to CMVR regulation for noise at operator ear location and vibration at operator touch point location are mandatory for all the tractors in India. NVH refinement development of the tractor plays a critical role in achieving the regulated noise level and improved tactile vibration In presented work, the airborne sources such as exhaust tail pipe, intake snorkel and cooling fan are quantified by at tractor level through elimination method. The detailed engine level testing in engine noise test cell (hemi anechoic chamber) is carried out to estimate the contribution of engine components to overall noise. The outcome of Noise source identification (NSI) has revealed silencer, timing gear cover and oil sump to be
Gaikwad, Atul Annasaheb, Harishchandra Walke, Nagesh, Yadav, Prasad S, Bankar, Harshal
Low Idle Boom Noise Reduction on Light Weight Agricultural Cabin Tractor2026-26-01001/16/2026
In last two decades, Farm customer expectation on cabin comfort has been increased multifold. To provide the best-in-class customer experience in terms of comfort without adding cost and weight is bigger challenge for all NVH Engineers. It is evident from literature survey that cabin tractors with better comfort is well accepted by customers in US and European Market. Apart from engine excitation, customer has become more sensitive to customer-actuated-accessory noises due to overall reduction in cabin noise in last 2 decades. This paper presents the study conducted on HVAC blower noise in 30HP cabin tractor. Tactile vibrations and cabin noise is not acceptable when AC is switched on due to low frequency modulating nature in frequency range of ~65Hz and 130Hz. The investigation is carried out systematically considering each component of Source-Path-Receiver model. HVAC blower unit as source is diagnosed in detail to understand root cause. Strong dominance of first order of blower been
K, Somasundaram, Chavan, Amit
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-05791/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges—such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations—no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
Patra, Somnath, Hibare, Nikhil, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Design and Development of a Cost-Effective Reversible Cooling Fan for Agricultural Tractors2025-28-026111/6/2025
Agricultural tractors require self-cleaning and cooling technology, especially in hot and dusty environments. This study introduces a novel reversible fan system designed which is incorporating a manually operated lever-type connection mechanism as an alternative to conventional pneumatic systems. Traditional reversible fans often rely on pneumatic actuators for blade rotation control, which can introduce complexity, maintenance challenges, and energy inefficiency. The proposed design replaces pneumatic components with a mechanically optimized lever linkage system, enabling users to manually reverse the fan’s airflow direction with minimal effort. This innovation enhances operational simplicity, reduces dependency on compressed air systems, and low costs as compared to conventional type reversible fan. The lever mechanism, engineered for ergonomic usability, ensures rapid switching between sucker and pusher modes, optimizing the fan’s utility in applications such as dust removal
Debbarma, Respect, Parwal, Mahendra, Baghel, Anand
Electric Fan Arrangement and Cooling System Performance Predictions for Off Highway Vehicles2025-28-024111/6/2025
Traditionally, off-highway vehicles like tractors and construction machinery have relied on hydraulic, viscous, or fixed fans to meet the cooling demands of diesel engines. These fans draw power from the engine, impacting fuel consumption and contributing to noise levels that affect operator comfort. Recently, the adoption of electric fans in off-highway applications has increased due to their energy efficiency, lower noise, and flexible design. Electric fans can cool various components, such as radiators and condensers, and can be positioned for optimal performance. They are easily selected from established supplier catalogs based on application requirements like machine voltage, fan size, and type. This study explores various fan arrangements, including pusher and puller types, and multiple electrical fan banking based on cooler zones to improve cooling system performance without changing cooler size or specifications. A mathematical flow model was developed for both setups: the
Durairaj, Renganathan, Dewangan, Nitin, Anand, Ketan, Bhujbale, Sagar
Enhancing Energy Management through Machine Data Insights Using Leverage Fleet Intelligence Data Analysis2025-28-033011/6/2025
In the evolving landscape of energy efficiency and sustainability, understanding machine behavior in real-world operating conditions is essential. This solution introduces a data-driven Energy Management Dashboard designed to analyze and report critical machine parameters by leveraging LFI (Leverage Fleet Intelligence) and LFI Data (Local Field Intelligence Data). The tool serves as a robust solution for engineering and operations teams to gain actionable insights into machine performance and exposure. By tracking key parameters—such as engine fan speed, coolant temperature, and machine speed—across a fleet of machines (with support for over 1100 unique signals), the solution enables real-time monitoring and historical analysis. It helps identify when parameters go outside their specified limits and assesses the resulting impact on overall machine performance. The core functionality includes: Monitoring machine operating conditions under real field environments. Correlating parameter
Nandre, Ratnapratik, Joshi, Aaditya
Development of Vibration Fixtures for Automotive Testing: A Combined Analytical and FEA-Based Approach2025-28-025811/6/2025
Vibration testing is an essential component of automotive product development, ensuring that components such as engines, transmissions, and electronic systems perform reliably under various operating conditions. The adoption of electronics in the automotive industry, particularly during the 1950s and 1960s, marked a shift in vibration testing approaches, moving from primarily low-frequency tests to methods that could address high-frequency vibrations as well. This evolution highlights the need for effective vibration fixture designs that can simulate real-world conditions, enabling manufacturers to detect potential weaknesses before products are integrated into vehicles. A key aspect of vibration testing is the identification of resonant frequencies within components. The coupled mass-spring-damper system, for example, can exhibit multiple resonances characterized by a Bode Diagram, where the Q factor technique is utilized to assess damping levels. Accurate vibration analysis can be
Shinde, Pramodkumar, Shah, Viren
Advancing Vehicle-Level AC Thermal Management System Performance2025-28-043410/30/2025
Modern mobility solutions increasingly rely on HVAC systems due to growing transport demands, traffic congestion, and harsh environmental conditions. These systems, comprising a compressor, evaporator, condenser, and thermal expansion valve, require adequate airflow for optimal performance. Insufficient airflow, caused by factors like undersized ducts, improper fan settings, clogged filters, or high static pressures from duct restrictions, significantly hinders cooling capacity. The objective of this study is to develop a predictive model for passenger vehicle AC system performance under controlled environmental conditions. Discrepancies between predicted and desired performance will trigger a structured problem-solving process involving iterative testing, root cause analysis, and the development of corrective measures. The improvements will be focused on the vehicle-level HVAC design, adhering to customer specifications. This research will also establish an experimental validation
Meena, Avadhesh Kumar, Agarwal, Roopak, Sharma, Kamal, Kishore, Kamal
Study of Power Optimization Using Electrical Driven Fan in Off-Highway Diesel Engine Cooling System2025-28-042110/30/2025
Internal combustion (IC) engines experience several parasitic losses at the vehicle level, including those from cooling fans, hydraulic pumps, air compressors, and alternators. These losses limit the available output power for various applications. By replacing a conventional mechanical or hydraulic fan—typically driven by the engine crankshaft or hydraulic motor—with an electrically operated fan, engine frictional losses (fan drag) can be reduced, resulting in a gain in power. The fuel conserved due to the absence of fan drag contributes to usable power for applications. Mechanical fans operate at a fixed drive ratio that is directly proportional to engine speed, while hydraulic fans rely on a hydraulic motor, drawing power from the engine's alternator. In contrast, electric fans can run at constant speeds, independent of engine RPM, providing higher airflow at maximum torque speeds, which mechanical fans cannot achieve. The cooling performance of the engine remains uncompromised, as
Dewangan, Nitin, Kattula, Nitin, Kamal, Ankit
Noise Mitigation Techniques Off-Highway Vehicle HVAC Unit2025-28-037810/30/2025
Noise generated by a vehicle’s HVAC (Heating, Ventilation, and Air Conditioning) system can significantly affect passenger comfort and the overall driving experience. One of the main causes of this noise is resonance, which happens when the operating speed of rotating parts, such as fans or compressors, matches the natural frequency of the ducts or housing. This leads to unwanted noise inside the cabin. A Campbell diagram provides a systematic approach to identifying and analyzing resonance issues. By plotting natural frequencies of system components against their operating speeds, Test engineers can determine the specific points where resonance occurs. Once these points are known, design changes can be made to avoid them—for example, adjusting the blower speed, modifying duct stiffness, or adding damping materials such as foam. In our study, resonance was observed in the HVAC duct at a specific blower speed on the Campbell diagram. To address this, we opted to optimize the duct design
Trivedi, Arpita, Kumar, Ravi, Madaan, Ashish, Shrivastava, Pawan
Methodology for Underhood Air Prediction for Low Fidelity Computational Models2025-28-043110/30/2025
Thermal management is critical for modern vehicles, particularly for Zero Emission Vehicles (ZEVs), where maintaining optimal temperature ranges directly influences thermal system efficiency and vehicle range. Accurate prediction of underhood airflow behavior is essential for effective thermal management and also to estimate overall energy consumption by cooling system, with air-side dynamics playing a pivotal role in heat transfer over the heat exchangers of cooling package. Simulation tools like GT-Suite are indispensable for this purpose, enabling engineers to evaluate complex thermal interactions without the cost and time constraints of extensive physical testing. While 3D Computational Fluid Dynamics (CFD) models offer detailed insights into flow characteristics, they are computationally expensive and time consuming. In contrast, 1D models provide faster simulation times, making them ideal for system-level analysis and iterative design processes. However, 1D models inherently lack
Mutyala k, Akhil, Pudota, Praveen, Faseel, Ihsan, Gole, Pranali, Bashir, Murad
Study of Impact of Bumper Opening, Radiator Fan Capacity and Shroud Sealing on the Cabin Cooling Performance and MAC Power Consumption in ICE Vehicle2025-28-039210/30/2025
In automotive systems, efficient thermal management is essential for refining vehicle performance, enhancing passenger comfort, and reducing MAC Power Consumption. The performance of an air conditioning system is linked to the performance of its condenser, which in turn depends on critical parameters such as the opening area, radiator fan ability and shroud design sealing. The opening area decides the airflow rate through the condenser, directly affecting the heat exchange efficiency. A larger opening area typically allows for greater airflow, enhancing the condenser's ability to dissipate heat. The shroud, which guides the airflow through the condenser, plays a vital role in minimizing warm air recirculation. An optimally designed shroud can significantly improve the condenser's thermal performance by directing the airflow more effectively. Higher fan capacity can increase the airflow through the condenser, improving heat transfer rates. However, it is essential to balance fan
Nayak, Akash, lingampelly, Rajaprasad, Neupane, Manoj, Mittal, Sachin, Kumar, Mukesh, Umbarkar, Shriganesh
Automated Air Filter Clog Detection in Passenger Vehicles- Enhancing Cabin Air Quality2025-28-042010/30/2025
Air filters are critical to vehicle Heating, Ventilation, and Air Conditioning (HVAC) systems, ensuring cabin air quality by trapping dust particles that accumulate over time. However, conventional clogging diagnostics—such as physics-based simulations, empirical models or manual inspection—are often too complex or impractical for in-vehicle deployment. To address this, we present a simple and practical diagnostic approach for real-time detection of cabin filter clogging by continuously monitoring the pressure drop across the filter–evaporator assembly at five blower speed settings. Baseline pressure drop values were established for a clean filter in a production-spec Passenger car and the clogged filter threshold was defined by a 10% reduction in airflow. This corresponded to calibrated pressure drop values of 83, 108, 169, 212 and 256 Pa for blower speeds 1 to 5, respectively. These thresholds were programmed into the vehicle’s climate control ECU. During operation, when the measured
Raj, Rohit, Mohite, Yashwant, Naik, Niranjan, Ghate, Pravin
Enhancing Vehicle Performance by Integrated Cooling System Design for Front-End Air Flow2025-28-042210/30/2025
India, being one of the largest automotive markets has considered various policies affecting fuel efficiency to curb vehicle carbon emissions. In a typical light-duty vehicle (LDV), around 20% of the fuel's energy is used to power the wheels and overcome aerodynamic drag resistance. Aerodynamic drag resistance, influenced by the projected surface area, cooling drag and velocity refers to the resistive force encountered by the vehicle. Furthermore, cooling drag resistance is determined by the effective cooling system architecture and aerodynamic design of the front-end module (FEM), which has major impact on the vehicle's performance and ram curve. In the pursuit of enhancing cooling system architecture, this paper investigates thermal performance and structural integrity of using common fins for both the condenser and radiator to improve the inlet aerodynamic performance which lowers cooling fan power consumption. Preliminary results show a 12% notable reduction in motor power
K, Muthukrishnan, Vijayaraj, Jayanth Murali, N, Aswin, Narashimagounder, Thailappan, Mahobia, Tanmay
Numerical Simulation and Optimization of Engine Cooling System Based on One-Dimensional and Three-Dimensional Coupling Analysis Method03-18-07-004010/29/2025
The design of motorcycle engine cooling systems is often hampered by a trade-off between computational efficiency and simulation accuracy, making optimized design iterative and costly. A streamlined, coupled 1D–3D methodology, validated across diverse engine configurations, is needed to address this challenge. This study develops and validates an iterative simulation framework to efficiently optimize cooling systems for various motorcycle engines. The 1D system model defines the performance targets, while 3D CFD analysis enables detailed component optimization (water jackets, radiator airflow); an iterative process ensures the target fulfillment. The 1D–3D coupling analysis methodology is applied to single-, two-, and four-cylinder engines. Results show that the coolant flow velocity within the water jackets are sufficient to ensure effective heat removal of engines and confirms the rational layout design of water jackets. The radiator inlet coolant temperature for the original design
Tan, Libin, Yuan, Yuejin
Influence on Electric Vehicle Performance by Reproduced Real-World Driving Wind on a Chassis Dynamometer2025-01-041010/7/2025
The latest electric vehicles (EVs) have advanced thermal management systems to regulate heat distribution across the vehicle, thereby improving the driving range. the author thinks that a key factor, which is influencing thermal performance during driving, is the effect of the driving-wind. However, EVs performance is evaluated by using a chassis dynamometer (CHDY), where it remains unclear whether the driving-wind specifications, which defined in the Worldwide Harmonized Light Vehicles Test Procedure (WLTP), adequately replicate real-world conditions. This study investigates both internal combustion engine vehicles and several electrical vehicles to estimate the potential discrepancies in WLTP’s driving wind requirements. Specifically, the author modified the CHDY vehicle-cooling fan to more accurately simulate wind speed at the front and underside of the vehicle under real-world driving conditions, which drove at outside road. The author analyzed the impact of these modifications
Okui, Nobunori
Demand Reduction Through Electromagnetically Controlled Pitch (EMCP) of Fans, Propellers, and Turbines2025-01-05019/16/2025
Manufacturers of fans/propellers using hydraulically-actuated pitch control claim energy efficiency gains up to 75% over fixed-pitch solutions. Unfortunately, the added cost, weight, reliability and maintenance considerations of hydraulic solutions has limited the introduction of pitch control for small-to-medium fans and propellers leaving a large market unserved by the efficiency gains associated with changing the pitch of a blade when the blade shaft’s speed changes. Pilot Systems International and Cool Mechatronics are developing an electromagnetically controlled pitch (EMCP) fan/propeller that will produce a new pareto optimal in size, weight, power, cost and cooling (SWaP-C2). The technology will substantially improve the efficiency of military ground vehicle cooling fans which is typically the third greatest power draw (~20kW)1 in the entire vehicle and provide critical performance improvements during silent watch. It will be a key enabler for the electrification of aircraft.
McBain, Jordan
Effect of Pressure Losses and Reynolds Number on Active Grille Shutter Characteristics and Its Prediction2025-01-50599/10/2025
In the present article it is investigated why active grille shutters (AGS) can have very different aerodynamic characteristics, ranging from progressive to strongly degressive, and which factors influence them. For this purpose, the authority concept known from the field of heating, ventilation, and air-conditioning (HVAC) is referred to. According to this theory, the control characteristics of dampers depend primarily on the ratio of the pressure losses at the fully open damper to the pressure losses of the rest of the system. The adaptation of the concept to the automotive field shows that, in addition to the pressure losses, the geometry of the cooling air ducting plays a decisive role in motor vehicles. The effect of driving speed and fan operation on the characteristic curves is also being investigated. In addition, authority theory can also be used to derive the conditions under which the opening characteristic curve of an AGS provides a good prediction of the real characteristic
Wolf, Thomas
Simulation of Swirl and Discharge Coefficient Trade-off for Diesel Engine Intake Ports2025-24-00079/7/2025
In Diesel engines, charge motion usually consists of swirl and squish flow patterns. Traditionally, swirl generation is controlled through the design of the intake ports, presenting a trade-off between swirl and mass flow rate. An alternative approach to generate swirl is to use vortex-generating jets in the intake port. As a comparative basis for this approach a Pareto front was established between swirl and mass flow rate based solely on geometric variations. A new fully parametric geometry was deployed, with two intake ports per cylinder adhering to some constraints. Stationary flow-bench test setup was modeled, where a blower draws air through the intake ports at a constant pressure difference. The Pareto front was generated using semi-randomly selected geometries in combination with automated unsteady RANS (URANS) simulations, while scale adaptive simulations (SAS) were also employed on select geometries. These turbulence modeling approaches were explored using the OpenFOAM
Kahraman, Ali Berk, Ritter, Johann, Eilts, Peter, Scholz, Peter
Understanding the Aero-mechanical Behavior of a MGB Cooling FanF-0081-2025-02445/20/2025
The oil cooling fan of a Main Gearbox (MGB) is a mechanically-driven component whose purpose is to force an air flow through an air cooled oil cooler; its performance is crucial in ensuring that the MGB oil temperature does not exceed a predefined threshold, set to alert the crew in case of an abnormal situation. The design and the certification of a cooling fan is a process involving several steps and multiple disciplines; mechanical design, aerodynamic analysis, dedicated tests carried out both on rigs and at aircraft level need to be exploited as complementary tools to assess the correct aero-mechanical behavior of the system. The aerodynamic assessment is associated to performance, measured in terms of MGB oil temperature: considering a comparison between two cooling fans, one outperforms the other if the resultant MGB oil temperature is lower, keeping the same boundary conditions (engine torque, wind speed, ambient temperature, etc.). The correct mechanical behavior is instead
Sangiovanni, Andrea, Scaltritti, Diego, Podda, Daniele, Pisani, Paolo, Sartori, Sergio, Alari, Lorenzo
Simulation of Pass-by Fan Noise Emissions and Advancing Test Regulations for Heavy-Duty Electric Vehicles2025-01-00865/5/2025
The rapid adoption of electric vehicles (EVs) necessitates updates to the automotive testing standards, particularly for noise emission. This paper examines the vehicle-level noise emission testing of a Nikola Class 8 hydrogen fuel cell electric semi-truck and the component-level noise emission testing needed to create a predictive simulation model using Wave6 software. The physical, component-level noise emission testing focused on individual cooling fans in a semi-anechoic chamber to assess their isolated noise contributions. With this data, an initial model was developed using spatial gradient statistical energy analysis, which successfully predicted pass-by noise levels based on varying fan locations and speeds. Real-world pass-by testing confirmed the model's accuracy across different cooling fan speeds. By leveraging advanced simulation techniques, engineers aim to enhance the accuracy and reliability of pass-by noise predictions through cost-effective studies of architectural
Passador, Stephen, Woo, Sangbeom, Liu, Ting-Wei, De La Vega Alonso, Gerardo, Kim, James
Drilling Methods for Controlling Exit Burr Height in CRES Material Stacks2025-01-01695/2/2025
The Electroimpact Automatic Fan Cowl Riveter uses two novel drill processes to control exit burr height and achieve the required hole quality in CRES (Corrosion-Resistant Steel, also called stainless steel) material stacks. Both processes use piloted cutters on the OML (Outer Mold Line, referring to the exterior surface of an airframe) side, and two different tools are used in a backside spindle on the IML (Inner Mold Line, referring to the inside surface of an airframe) side of the component. The first process uses a shallow-angle shave tool in the IML spindle to directly control the exit burr height after it is produced by the OML spindle and is called the “burr shave” technique. The second process uses a countersink tool in the IML spindle and produces an “intermediate countersink” after the pilot hole is drilled by the OML spindle, but before the final hole diameter is drilled. These drill processes were able to achieve the required hole quality in a challenging CRES material stack
Schultz, Rich, Peterman, Randy, Luker, Zachary, Murakonda, Sai Krishna, Merluzzi, James
Performance Analysis of Commercial Vehicle Engine Cooling Fan Based on Fluid-Structure Interaction Method2025-01-86414/1/2025
When the cooling fan of the commercial vehicle engine is working, there is a strong fluid-structure interaction (FSI) between the airflow and the blades. If the effect of this interaction is not considered, significant errors may be caused in the prediction of fan performance. To analyze the effect of FSI on the aerodynamic and structural performance of the cooling fan, calculation models with and without considering FSI were established. The pressure and efficiency of the cooling fan were calculated using three methods: the Multiple Reference Frame (MRF) method, the Sliding Mesh (SM) method, and the bidirectional FSI method. These results were then compared with test data. Based on the FSI method, the aerodynamic and structural performance of the fan at different flow rates, rotational speeds and temperatures were calculated, and compared with results if FSI is ignored. The effect of flow rate, rotational speed and temperature on the fan performance was analyzed. The comparison and
Yu, Hui, Yin, Zhihong, Ying, Runhai, Wang, Xinling, Duan, Yaolong, Shangguan, Wenbin
Development and Performance Optimization of Formula SAE Racing Active Ground Effect System Based on Fan Drive2025-01-80014/1/2025
For Formula SAE cars, a significant increase in downforce can enable the car to score more points in the race and enhance the competitiveness of the vehicle. This paper focuses on the development of an active ground effect system driven by fans for the FSAE racing car. The system is designed to considerably increase the downforce of the racing car through the forced airflow generated by the fan, enable the dynamic adjustment of the aerodynamic balance of the racing car during the driving process, and achieve the vertical force control on the racing wheels, thereby improving the performance of the racing car. The Star-CCM+ software was employed to conduct CFD simulation to investigate the influence of different flow fans on downforce and optimize the layout and position of the fan. Due to the limited power that the car can carry, the paper will also simulate and calculate the range of pneumatic balance adjustment and vertical force control capability provided by the different openings
Yang, Chengyue
Flow Channel Optimization and Performance Analysis of Forced Air-Cooling Thermal Management for Lithium-Ion Battery Energy Storage Modules05-18-04-00273/5/2025
The maximum temperature and the maximum temperature difference of lithium battery energy storage systems are of great importance to their lifespan and safety. The energy storage module targeted in this research utilizes a forced air-cooling thermal management system. In this article, the maximum battery temperature, temperature difference, and cooling fan power are used as evaluation indicators. The thermal–fluid coupling simulation technology is utilized to restore the real structure of the module, ensuring the reliability of the simulation results. The P-Q curve is introduced for the boundary conditions of the heat dissipation fan to investigate the influence of the flow channel structure on the airflow volume and distribution. First, the thermal–fluid coupling simulation results of the original structure were compared with the measured parameters. Subsequently, the study on the airflow and temperature distribution of the original flow channel structure reveals that a significant
Guo, YuCheng, Bao, YiDong, Jiang, BingYun, Lu, FeiFei
Research on Engine Thermal Management System Modeling and the Control Strategies of an Extended-Range Hybrid Electric Vehicle2025-01-70631/31/2025
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, Shiyi, Zhang, Nan, Zheng, Junli, Sun, Tianfu, Zidi, Li
Numerical and Experimental Analysis of Tip Clearance Effect of Low-Speed Axial Flow Fan2024-01-600912/20/2024
The objective of the present study is to identify suitable tip clearances and volumetric flow rates for low-speed axial flow fans. The numerical analysis for this study is carried out using the Reynolds-averaged Navier–Stokes equation with the k-omega SST turbulence model to perform steady-state simulations. The results demonstrate that optimum performance is achieved with a tip clearance of 1 mm and a maximum volumetric flow rate of 10.74 m3/s. The novelty of this proposed work lies in enhancing the efficiency of axial flow fans with a circular arc cambered airfoil by using optimal tip clearance and volumetric flow rates through steady-state simulations. This method can be applied in the turbo machinery field and all types of jet engines to improve the performance of domestic and international flights, meeting future demands and expectations.
Vala, Jignesh R., Patel, D. K., Darji, Anand P., Balaji, K.
Integrated Vehicle Thermal Systems Simulation-Based Approach for Sizing of e-Truck Radiator and Fan2024-28-018612/5/2024
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, Shivakumar, Patel, Vedant, Challa, Krishna, Gurdak, Michael
Investigation of Automotive IC Engine Water Pump Housing Failure and Resolution through Experimental Modal Analysis and Study of Vibration Characteristics of the System2024-28-019412/5/2024
Cooling system for an IC engine, consisting of the Water pump (WP), Radiator and Fan, plays an important role in maintaining thermal efficiency of the engine and protects the engine from overheating. Based on the vehicle application requirement, Fan will be mounted directly either on Crankshaft or WP pulley. But wherever increase in Fan speed ratio are in demand, it is preferred to mount the Fan on WP pulley. So it important to understand the WP housing structural strength with respect to vibration loads contributed from Radiator Fan assembly. This paper presents investigation of Failure of WP Housing during engine validation at engine test bed with Electronic Viscous Fan, based on the different operating conditions of the engine and fan as per the validation cycle. While the accessories are loading and the corresponding stresses are high when the fan is engaged. But in the current case, the failure of WP housing happened only during Fan clutch disengaged condition. Experimental
R, Mahesh Bharathi
Cooling Module Fan Noise Simulation2024-28-00979/19/2024
Automotive cooling module system consists of condenser, radiator and intercooler which is used for thermal management of vehicle. Condenser helps to reject cabin heat, radiator to reject engine heat and intercooler rejects charged air heat to ambient. CRFM (Condenser, Radiator and Fan module) is conventionally packaged under the bonnet of passenger vehicle. Fan circulate airflow through heat exchangers and has primary role of airflow delivery. While performing vehicle level thermal management duty, fan noise is generated from CRFM and fan noise is considered as an important design attribute of CRFM. Many researchers have done fan noise simulation at component level and very limited literatures at vehicle (system) level simulation are available. Customer perceives noise from outside of the vehicle and it is important to predict fan noise at vehicle level at various operating speeds. Such simulations are transient in nature and modeling complexity demands high computational cost. Current
Kandekar, Ambadas Bhaguji, Duppati, Darshan, Borse, Harshal, Jain, Ayush, Patel, Kaushik, Baghel, Devesh
A Case Study of Engine Cooling System Simulation and Modelling for Air Conditioning Application in a Medium Duty Truck2024-28-01069/19/2024
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, Nalavadath, M S, Vignesh
Test Method for Measuring Performance of Engine Cooling FansJ1339_202409 (Current)9/18/2024
This SAE Recommended Practice is intended for use in testing and evaluating the approximate performance of engine-driven cooling fans. This performance would include flow, pressure, and power. This flow and pressure information is used to estimate the engine cooling performance. This power consumption is used to estimate net engine power per SAE J1349. The procedure also provides a general description of equipment necessary to measure the approximate fan performance. The test conditions in the procedure generally will not match those of the installation for which cooling and fuel consumption information is desired. The performance of a given fan depends on the geometric details of the installation, including the shroud and its clearance. These details should be duplicated in the test setup if accurate performance measurement is expected. The performance at a given air density and speed also depends on the volumetric flow rate, or the pressure rise across the fan, since these two
Cooling Systems Standards Committee
Fan Guard for Off-Road MachinesJ1308_202408 (Current)8/9/2024
This practice applies to guarding of engine cooling fans used on Off-Road Self-Propelled Work Machines defined in SAE J1116. It does not include guarding for belts, pulleys, or other rotating equipment used on these machines.
OPTC1, Personnel Protection (General)
A Finite-Element-Simulation Workflow and First Results of the Aero- and Vibro-Acoustic Signature of an Enclosed Centrifugal Fan2024-01-29406/12/2024
Centrifugal fans are applied in many industrial and civil applications, such as manufacturing processes and building HVAC systems. They can also be found in automotive applications. Noise-reduction measures for centrifugal fans are often challenging to establish, as acoustic performance may be considered a tertiary purchase criterion after energetic efficiency and price. Nonetheless, their versatile application raises the demand for noise control. In a low-Mach-number centrifugal fan, acoustic waves are predominantly excited by aerodynamic fluctuations in the flow field and transmit to the exterior via the housing and duct walls. The scientific literature documents numerous mechanisms that cause flow-induced sound generation, even though not all of them are considered well-understood. Numerical simulation methods are widely used to gather spatially high-resolved insights into physical fields. However, for a centrifugal fan, the numerical simulation of the coupled aero- and
Heidegger, Patrick, Czwielong, Felix, Schoder, Stefan, Becker, Stefan, Kaltenbacher, Manfred
Microneedle Patch Helps People Control Robotic ExoskeletonsTBMG-509156/1/2024
Hey superhero fans, meet the researchers making real life Iron Man technology possible. In a new study, engineers from Korea and the United States have developed a wearable, stretchy patch that could help to bridge the divide between people and machines — and with benefits for the health of humans around the world.
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