Browse Topic: Thermodynamics

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Thermal Model of a Traction Inverter for an Automotive Application including DC-link capacitor, power modules and electrical connections2025-01-0519To be published on 11/25/2025
In automotive applications a traction inverter is used for energy conversion between battery and electrical machine. For high performance drives lightweight design is demanded. Additionally, higher efficiency of the inverter results in lower cooling requirements but is often achieved by increasing component weight. Hence, thermal modelling of the components and their interactions is essential to determine the best compromise between weight, efficiency and cooling requirements. In traction inverters the DC-link capacitors, power modules, high voltage electrical connections and low voltage devices dissipate power. In this paper the focus is on the thermal modelling of the DC-link capacitor, power modules and high voltage electrical connections and their system, as the performance of the inverter is defined by these components. The thermal models are derived based on geometries and physical properties. First, the DC-link capacitor thermal model is presented and considers the anisotropic
Blaschke, Wolfgang Maximilian, Mengoni, Leonard, Pflüger, Robin, Kulzer, André Casal
Cooling System Design Approach for Off-Road Vehicles Using 3D CFD and 1D Tools2025-28-0260To be published on 11/06/2025
The average product development cycle spans 3-5 years, involving extensive virtual and physical testing of the machine. Advances in simulation tools have significantly enhanced our ability to identify product solutions early in the design phase. Tools like 1D KULI and Creo Flow simulations offer faster solutions in less time, thereby accelerating the product development cycle. Cooling systems are crucial components of off-highway hybrid vehicles, directly affecting engine efficiency and overall machine functionality. An optimized cooling system ensures the engine operates within safe temperature ranges, preventing overheating and potential damage. Thus, designing an effective cooling system is a vital aspect of machine engineering. 3D Computational Fluid Dynamics (CFD) simulations are essential for evaluating cooling system performance. These high-fidelity simulations provide detailed insights into fluid flow and heat transfer, enabling engineers to predict and enhance cooling
Ukey, Snehal, Tirumala, Bhaskar, Nukala, Ramakrishna
Thermal Management Control Strategy for Hybrid Electric Tractor2025-28-0318To be published on 11/06/2025
Global emission norms are getting stringent due to combat the harmful effluent of the internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is used
K, Sunil, Makana, Mohan, K, MALA, Natarajan, Saravanan, D, Mari
E-Motor thermal management using 2D-3D coupling2025-28-0225To be published on 11/06/2025
In the electrical machines, detrimental effects are resulted often due to the overheating, such as insulation material degradation, demagnetization, decreased lifetime and efficiency of the motor and Joule losses. Hence, it is vital to optimize the reliability and performance of the electric motors (E-Motor) and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an E-Motor powering on E-Machines. With the aggressive focus on electrification across automotive industry, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of motors. With this study using Ansys Fluent - Maxwell coupling, a complete 3D CFD with CHT modeling of an Electric Motor, including all the key components like the windings, rotor
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Challenges in Transitioning from 400V to 800V Off-Highway Power Electronics2025-28-0281To be published on 11/06/2025
Electrification applications are increasingly moving towards higher voltage systems to enable greater power delivery and faster battery charging. This trend is particularly evident in the shift from 400V to 800V systems, which offers several benefits and poses unique technical challenges. Higher voltage systems reduce current flow, minimizing energy losses and improving overall efficiency. This is crucial for applications like electric vehicles and off-highway machinery, where efficient power management is essential. One of the primary benefits of increasing the DC link voltage beyond the 400V is the ability to support higher power levels Additionally, higher voltage systems can reduce the size and weight of power components, contributing to more compact and lightweight designs. However, transitioning to 800V systems introduces several technical challenges in power electronics design. Key components such as power components (IGBT , MOSFET etc) must be optimized to handle higher
Hatkar, Chetan Manohar, Pipaliya, Akash
A Measurement method to correlate CFD prediction of air flow velocities across cooling pack for Farm Tractor2025-28-0273To be published on 11/06/2025
An agricultural tractor is a sophisticated machine with a densely packed underhood compartment, presenting unique challenges in airflow management through its heat exchangers. The complexity of the design leads to non-uniform airflow patterns, as the fan-driven system draws air from front, top, and side openings. This variability makes it essential to establish a reliable correlation between test airflow and simulated airflow values. Our investigation has revealed notable differences in the velocity values obtained from the Power Take-Off (PTO) test using various instrumentation. The handheld vane-type anemometer is widely utilized due to its accessibility, affordability, and simplicity. However, it is worth noting that this device can demonstrate discrepancies ranging from 70% to 90% when compared to Computational Fluid Dynamics (CFD) predictions, especially in heavy duty applications. In this study, we have established a robust correlation between the airflow through the heat
A, Boopalshanmugam, Ganesan, Thanigaivel, Reddy, Lakku, Sateesh, Tadi, Gopinathan, Nagarajan
Virtual Reality Application in CFD Data Analysis for After Treatment Systems2025-28-0329To be published on 11/06/2025
Virtual reality (VR), Augmented Reality (AR) and Mixed reality (MR) are advanced engineering techniques that coalesces physical and digital world to show case better perceiving. There are various complex physics which may not be feasible to visualize using conventional postprocessing methods. Various industrial experts are already exploring implementation of VR for product development. Traditional computational power is improving day-by-day with new additional features to reduce the discrepancy between test and CFD. There has been increase in demand to replace actual test by accurate simulation approaches. Post processing and data analysis is key to understand complex physics and resolve critical failure modes. Analysts spend considerable amount of time to analyze results and provide directions, design changes and recommendation. There is a scope to utilize advanced features of VR, AR and MR in CFD post-process to find out the root cause of any failures occurred with advanced
Savitha, Bhuduri, Sharma, Sachin
Temperature effect on the static and fatigue performance of thermoset and thermoplastic composites2025-32-0006To be published on 11/03/2025
The growing demand for lightweight, durable, and high-performance materials in industries such as aerospace, automotive, and energy has driven the development and evaluation of thermoset and thermoplastic composites. This study investigates the static and fatigue behavior of one thermoset material and two thermoplastic composites at varying temperatures (-30°C, 22°C, and 120°C) to simulate extreme environmental conditions. Experimental tests were conducted to evaluate mechanical performance and fatigue strength, focusing on the influence of temperature on strength and life cycles. The results highlight the significant impact of temperature on static properties and fatigue behavior, offering critical insights into their application in temperature-sensitive environments. A numerical modeling approach was applied to predict fatigue behavior by incorporating the effects of mean stress and temperature. Different fatigue damage models, including temperature-dependent formulations, were
Chiocca, Andrea, Sgamma, Michele, Franceschini, Alessandro, Vestri, Alessio, mancini, Simone, Bucchi, Francesco, Frendo, Francesco, Squarcini, Raffaele
Impacts of enhanced physics-based estimation modeling for trapped air and EGR estimation in real-time control of hydrogen injection in a PFI internal combustion engine2025-32-0047To be published on 11/03/2025
Hydrogen PFI engines face abnormal combustion issues, especially during transient operation. The air-to-fuel ratio and trapped exhaust gas significantly affect combustion stability and NOx emissions, requiring continuous monitoring. Real-time estimation of the trapped gas composition and thermodynamic state is therefore crucial but challenging. This work introduces a real-time, physics-based Multi-Input-Multi-Output (MIMO) model for accurately estimating trapped air and exhaust gas mass at the intake valve closing (IVC) event. In detail, the estimation model makes use of dynamic in-cylinder and exhaust pressure measurements to accurately model mass flows and heat exchange equations with 0.5 CAD resolution. This allows an extremely high fidelity when modelling the physical properties of the various chemical species along the engine cycle. Moreover, the model calibration appears only in the form of two coefficients implemented on a lookup table for twelve different operating points
Galli, Claudio, Ferrara, Giovanni, Grilli, Niccolò, Balduzzi, Francesco, Romani, Luca, Vichi, Giovanni
Optimum Bore-to-Stroke Ratio for a Flathead Uniflow Two-Stroke SI Engine and its Impact on Different Fuels2025-32-0024To be published on 11/03/2025
This numerical study investigates a spark-ignited, two-stroke engine employing uniflow scavenging, flathead cylinder head design, and an exhaust valve system to identify the optimal bore-to-stroke (B/S) ratio for maximizing brake efficiency at fixed displacement. A single-cylinder prototype engine was constructed, and its experimental data validated a 1D GT-SUITE simulation model. This validated model was then utilized to simulate a full-scale, 1.5-liter displacement, horizontally opposed four-cylinder engine with supercharger-assisted boosting, intended for small aircraft propulsion. The simulations explored a range of B/S ratios from undersquare (0.7) to oversquare (1.5), maintaining a consistent brake power output of 60 kW at 3000 rpm and lambda 0.9. Results showed that increasing the B/S ratio enhanced brake efficiency from 26.0% at B/S=0.7 to 27.0% at B/S=1.5, largely due to reduced frictional losses attributed to shorter stroke and lower piston speeds, decreased heat transfer
Zanchin, Guilherme, Hausen, Roberto, Fagundez, Jean Lucca, Lanzanova, Thompson, Martins, Mario
Machine Learning-Enhanced Electrical Circuit Model Parametrization for Battery Cells: Reducing Experimental Workload Through GITT Testing with Altair RapidMiner®2025-32-0097To be published on 11/03/2025
This study addresses the challenge of reducing the experimental workload involved in characterizing battery cell behavior as a function of state of charge and temperature. Galvanostatic Intermittent Titration Technique tests were carried out in a climate chamber across a wide temperature range, from -20 °C to 70 °C, with 10 °C intervals. The voltage and current response data collected from these tests were used to train several machine learning algorithms. The trained models could then be used to predict the cell voltage response every 5 °C from -15 °C to 55 °C. While the models were experimentally validated at 15 °C, 25 °C, and 35 °C, the predicted voltages across this range contribute to enhancing the characterization process. In particular, the inclusion of these predicted voltage profiles—combined with the experimental data collected every 10 °C from -20 °C to 70 °C—allows for the creation of more accurate lookup tables for the parameters of the equivalent circuit model. These
Giuliano, Luca, Peretto, Lorenzo, Canella, Nicholas, Nefat, Damir
Quantitative Analysis for Optimizing Thermal Management in Fuel Cell Vehicles2025-28-0358To be published on 10/30/2025
Zero emission vehicles are essential for achieving sustainable and clean transportation. Hybrid vehicles such as Fuel Cell Electric Vehicles (FCEVs) use multiple energy sources like batteries and fuel cell stacks to offer extended driving range without emitting greenhouse gases. Optimal performance and extended life of the important components like the high voltage battery and fuel-cell stack go a long way in achieving cost benefits as well as environmental safety. For this, energy management in FCEVs, particularly thermal management, is crucial for maintaining the temperature of these components within their specified range. The fuel cell stack generates a significant amount of waste heat, which needs to be dissipated to maintain optimal performance and prevent degradation, whereas the battery system needs to be operated within an optimal temperature range for its better performance and longevity. Overheating of batteries can lead to reduced efficiency and potential safety hazards
BHOWMICK, SAIKAT, Churi, Chetana
Investigation on Flow pattern architecture design on thermal plate for Battery electric vehicles.2025-28-0406To be published on 10/30/2025
Liquid cooling systems are a widely used method for cooling lithium-ion batteries in modern electric vehicles. Battery thermal plate (BTP) is a key component of the liquid-cooled thermal management system, which regulates battery temperature to prevent thermal runaway and fire accidents. Designing an energy efficient flow pattern with uniform velocity and temperature distribution is a major challenge for the BTP. In this paper, the effect of flow patterns in cooling performance of the BTP is examined. Battery temperature can be efficiently controlled by varying direction, number of flow channels and structure of the BTP. Complex flow pattern networks are modeled and compared based on the computational fluid dynamics results. The channel flow resistance, pressure drop, and temperature distribution are key parameters which are evaluated for varying mass flow rate conditions. From the study, the flow pattern which satisfies the temperature requirement and have 10% less pumping power
K, Muthukrishnan, S, Saikrishna, K, Keshavbalaje, Gutte, Ashish
Structural and thermal behavior prediction of chiller by using CAE simulation2025-28-0396To be published on 10/30/2025
Heat exchangers are critical components in various industrial applications, enabling efficient energy transfer between fluids. Chiller (Plate-type heat exchanger), with its compact design and high thermal performance, have gained significant attention in industries such as HVAC, power generation, and chemical processing. This study presents a comprehensive thermo-structural analysis of a chiller generated due to varying fluctuating temperatures and vehicle vibrations using Computer-Aided Engineering (CAE) tools. The analysis involves modeling the heat exchanger geometry, including the alternate chiller plates, to capture the complex geometries. Advanced simulation techniques such as Computer- Aided engineering (CAE) and Finite Element Analysis (FEA) are employed to investigate the thermal behavior under varying operating conditions, including flow rates, inlet temperatures, and pressure drops. Key parameters like pulsation pressure test, temperature distribution, dynamic stress
Jaiswal, Ankit, Parayil, Paulson
A Critical Assessment of Alternative Refrigerants and Waste Heat Recovery for Sustainable Thermal Systems2025-28-0356To be published on 10/30/2025
The increasing demand for heating and cooling, coupled with growing environmental concerns, necessitates a paradigm shift towards sustainable thermal management practices. This paper presents a rigorous and scholarly investigation into innovative heating and cooling concepts, with a specific focus on the development and implementation of alternative refrigerants and waste heat recovery systems. The transition away from conventional refrigerants, with their detrimental impact on the environment, is explored through a comprehensive analysis of promising alternatives. Hydrofluoroolefins (HFOs), natural refrigerants (e.g., CO2, hydrocarbons, ammonia), and their blends are critically evaluated, considering their thermodynamic properties, environmental impact (GWP, ODP), safety considerations (flammability, toxicity), and application-specific performance. The paper delves into the intricacies of advanced cooling technologies, including absorption cooling, adsorption cooling, and
K, Neelima, Ch, Kavya, C, Somasundar, B, Harichandana, Satyam, Satyam, P, Geetha
Probabilistic Thermal Modelling of AdBlue System Using Bayesian Networks2025-28-0370To be published on 10/30/2025
In Diesel engine exhaust after treatment system (ATS), Nitrogen Oxides (NOx) emissions control is achieved via Selective Catalytic Reduction (SCR) in which AdBlue or Diesel Exhaust Fluid (DEF) plays vital role. But AdBlue freezes below -11°C due to which in cold climate conditions system performance becomes critical as it affects efficiency as well as overall performance leading to safety and compliance with emission standards issue. So, it is essential to have a dynamic thermal management system which can predict the potential hazards to AdBlue system especially in cold ambient temperature conditions. Present paper focuses on developing Bayesian Network (BN) based algorithm for improving thermal management of AdBlue system by modelling probability of key factors influencing on its performance including AdBlue temperature, ambient temperature, coolant temperature & its flow, vehicle operating conditions, heater performance etc. The BN model can predict real time AdBlue freezing
Thakur, Shivam, Salunke, Omkar
Automotive AC System Design and Validation Methodology at Vehicle-Level2025-28-0434To be published on 10/30/2025
Abstract: 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
Meena, Avadhesh Kumar, Agarwal, Roopak, Sharma, Kamal, Kishore, Kamal
IHX technology and its Effectiveness in Automotive AC performance2025-28-0430To be published on 10/30/2025
The Internal Heat Exchanger (IHX) is an important component in modern car air conditioning (AC) systems particularly in AC Lines. It increases cooling efficiency by transferring heat from the high-pressure liquid refrigerant to the low-pressure vapour. By using this technology improves refrigerant sub-cooling and superheating, As a result higher cooling performance, lower energy usage, and less strain on the compressor. It improves vehicle fuel economy and a longer lifespan for AC components. Also, IHX prevents liquid refrigerant from entering the compressor, reducing the danger of damage and increasing system reliability. This optimization helps maintain consistent refrigerant flow, reduces energy consumption, and improves the overall Coefficient of Performance (COP). The implementation of IHX technology in AC lines results in more compact, streamlined system designs, which allow for better temperature management, faster response times, and lesser cooling loads. IHX can boost cooling
Dudeja, Kailash, Singh, Saniya
Temperature and State of Charge Equalization through Passive and Active Thermal Management System Techniques for Electric Vehicles2025-28-0363To be published on 10/30/2025
Electric vehicles commonly employ lithium-based batteries owing to their elevated energy density, long lifespan, and flexible design. Currently, thermal safety is the focus of research, especially in high-power and dense packing applications. A battery thermal management system is critical for equalization of temperature control, data management, voltage and current estimation, battery safety, performance, and durability. To produce a balanced and efficient thermal management solution, passive and active thermal management strategies address thermal challenges. This paper provides a review on impact of temperature on battery performance along with a thorough comparison between passive and active thermal management strategies, with an emphasis on temperature equalization and state-of-charge equalization in battery systems. In addition, a Simulink model is developed to simulate the active and passive thermal management strategies. A passive strategy is analysed to equalise temperatures
Shaik, Amjad
Effect of Bumper shroud and condenser sealing on the cabin cooling performance and the Fuel efficiency in ICE vehicle2025-28-0392To be published on 10/30/2025
In automotive systems, efficient thermal management is essential for optimizing vehicle performance, enhancing passenger comfort, and reducing fuel consumption. The performance of an air conditioning system is closely linked to the performance of its condenser, which in turn depends on critical parameters such as the opening area, shroud design, and radiator fan capacity. The opening area determines the airflow rate through the condenser, directly impacting 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 air recirculation and ensuring uniform air distribution across the condenser surface. 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
Nayak, Akash, lingampelly, Rajaprasad, Neupane, Manoj, Mittal, Sachin, Kumar, Mukesh, Umbarkar, Shriganesh
DEVELOPMENT OF TEMPERATURE SENSOR FOR AUTOMOTIVES2025-28-0394To be published on 10/30/2025
The paper presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It can measure temperatures ranging from -200°C to 600°C. It clearly shows the variation of resistance with temperature. For this design, copper material is used because of some advantages: high electrical conductivity, thermal conductivity, and mechanical strength, which help in withstanding harsh climate conditions in the stratosphere. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature.
P, Geetha
Methodology for underhood air prediction for low fidelity computational models2025-28-0431To be published on 10/30/2025
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
Numerical Investigation of Novel Hybrid Battery Thermal Management system Integrating angular Fins for Lithium Ion batteries2025-28-0351To be published on 10/30/2025
To address the challenges of thermal management in lithium-ion batteries associated with safety scenarios, real-world driving conditions, and operating cycles, particularly at high discharge rates and extreme ambient conditions, it is necessary to maintain the battery temperature within its optimal operating range. This research introduces a novel hybrid Battery Thermal Management System (BTMS) integrating different cooling techniques, namely phase change material (PCM) and air cooling with fins in the air channel. Unlike conventional approaches that utilize standard rectangular fins, this study employs angular Cantor fins with varying angles and different numbers of fin segments to enhance heat dissipation. The hybrid system aims to exploit PCM's high latent heat storage capability while ensuring efficient convective heat removal via air cooling. The airflow through the cooling channel may accelerates heat dissipation from PCM, thereby increasing PCM's effectiveness. The angular
Kalvankar, Tejas, Lam, Prasanth Anand Kumar, ARURI, PRANUSHAA
A Smart Multi-disciplinary Approach to Evaluate Thermal Insulation Impact on Automotive Mobile Air Conditioning System Performance2025-28-0425To be published on 10/30/2025
Automotive mobile air conditioning (MAC) systems rely on effective thermal insulation to maintain cabin comfort and energy efficiency. However, insulation materials degrade over time due to thermal cycling and environmental exposure, impacting overall system performance. This study investigates the effects of reducing insulation material density (GSM) in critical areas such as the engine firewall, plenum, roof, and door panels on MAC system efficiency. A multi-disciplinary approach combining basic engineering calculations, frontloading CAE simulations, and targeted experimental testing was employed. Initial calculations provided directional input for cabin heat load analysis, guiding early-stage design decisions. Simulation models were used to predict the impact of insulation reduction on cooling performance, energy consumption, and component durability, reducing reliance on iterative physical testing. Experimental validation was then conducted selectively, focusing on critical areas
Kulkarni, Shridhar, Deshmukh, Ganesh, Joshi, Gaurav, Nayakawadi, Uttam, Shah, Geet, Jaybhay, Sambhaji
Optimization of Coolant Circuit Layout to Prevent Cavitation in Battery Electric Trucks Using Simulations.2025-28-0354To be published on 10/30/2025
In the design of battery electric trucks, efficient thermal management is crucial to ensure optimal performance and longevity of the vehicle’s components. This study focuses on the layout optimization of the coolant circuit to avoid cavitation issues in the coolant pump of a battery electric truck. Initially, we designed the electric truck's coolant circuit layout and conducted preliminary simulations to predict flow behavior and thermal efficiency. However, during prototype testing, cavitation was identified at the inlet of the coolant pump, affecting the system’s performance. To diagnose the issue, we performed several rounds of simulations, analyzing flow dynamics and pressure drops within the circuit. Based on the simulation results, we optimized the coolant layout, adjusting component positioning and flow paths to reduce the risk of cavitation. Subsequent tests confirmed that the optimized layout resolved the cavitation problem, leading to improved pump performance and enhanced
Garg, Ravi
Heat Pipes for PEM Fuel Cell Cooling – A Numerical Study2025-28-0355To be published on 10/30/2025
The principle of Proton Exchange Membrane (PEM) fuel cell technology involves reaction of hydrogen and oxygen near the membrane to produce electricity, and PEM fuel cells are being adopted to drive automobiles carrying wide range of loads. Some heat is also generated along with electricity due to the reaction in PEM fuel cell, and it must be dissipated to surroundings to maintain required operating temperature which is vital for efficient operation of the PEM fuel cell. Conventionally, liquid coolants are used to cool the PEM fuel cells, which require considerable pumping power. It is crucial to reduce the pumping power, and one way is to rely on passive cooling technologies like heat pipes. Heat pipes are widely used to dissipate heat from narrow heat generating spaces by working on the principles of phase change and capillary forces. The working fluid in the heat pipe, evaporates by taking the heat in the evaporator section, and condenses by rejecting heat to surroundings in the
Karlapalem, Vidyadhar, Bansode, Annasaheb
Integration and Evaluation of Different Thermal Loops through Simulation for Improved Defrost and Range of an Electric Truck2025-28-0417To be published on 10/30/2025
The rapid advancement in thermal management for electric vehicles (EVs) is driven by the need to reduce battery load and enhance EV range. Unlike conventional platforms, EV thermal management is complex due to temperature sensitivity and the numerous components involved. Powertrain components, such as the motor and transmission, operate at higher temperatures, while the battery and passenger cabin require distinct thermal conditions. This necessitates a carefully modelled thermal layouts that considers the diverse thermal needs of each component. The primary objective of this study is to improve the existing thermal layout of EVs, aiming for a more efficient design and evaluating its benefits through simulation. Utilizing the 1D commercial software GT-SUITE, the research integrates different layouts of EV’s and study the hydraulic and thermal feasibility. Integrations are based on operating temperatures, flow, and pressure requirements, while ensuring thermal comfort in the cabin and
Patel, Vedant Umang, Koti, Shivakumar, Gurdak, Michael, singh, Ramanand
Development of Thermal Management Strategies for Refrigerant Boilers in Organic Rankine Cycle for Solar Electric Energy Conversion2025-28-0414To be published on 10/30/2025
Electricity is a fundamental requirement for individuals worldwide, driving technological advancements that were once unimaginable. Various methods are employed for electricity generation, depending on the availability of raw materials in different regions. Traditional sources such as thermal power (coal and natural gas), hydropower (water), solar power (sunlight), wind power, and nuclear power are widely used, with thermal and hydropower plants being the primary contributors. Approximately 70% of global electricity is produced from thermal power plants, but these methods contribute to environmental pollution, greenhouse gas emissions, and acid rain. Thermal power plants typically operate on the Rankine cycle, consisting of a boiler, turbine, condenser, and pump. A similar approach can be applied to the Organic Rankine Cycle (ORC) using solar energy, where heat is transferred to the working fluid in the boiler through a heat pipe, a passive heat exchanger system. This closed-loop
Deepan Kumar, Sadhasivam, Kumar, V, Dhayaneethi, Sivaji, Mahendran, M, Saminathan, Sathiskumar, R, Karthick, A, Vikasraj
Cabin Thermal Management Analysis using Alternative refrigerants through 1D Simulation model2025-28-0390To be published on 10/30/2025
At present, all the major Automobile industries are working on sustainability to reduce environmental degradation, conserve resources, and promote the health of ecosystems. As a result, these industries are transitioning to refrigerants with lower Global Warming Potential (GWP) .With growing concerns over climate change, R134a's high Global Warming Potential (GWP of 1400) presents a major environmental challenge. R1234yf, with its substantially lower GWP, presents a more sustainable alternative that aligns with stricter global regulations. This shift not only helps mitigate climate impact but also demonstrates the automotive industry’s commitment to adopting greener technologies. Refrigerant properties like Latent heat, density, Thermal conductivity, e.t.c changes with respect to refrigerants hence cabin thermal management will be affected. In this paper, we will discuss the system level comparison of R134a and R1234yf by developing 1D simulation model. This paper will focus on 1D
Mudaliar, Devarajan, Wanjare, Amol, Rai, Amit, Ghate, Pravin
Design and analysis on integrated thermal management solution for electric vehicles2025-28-0418To be published on 10/30/2025
Thermal management system (TMS) for battery electric vehicles (BEV) incorporates maintaining optimum temperature for cabin, battery and e-powertrain subsystems under different charging and discharging conditions at various ambient temperatures. Current methods of thermal management are inefficient, complex and lead to wastage of energy and battery capacity loss due to inability of energy transfer between subsystems. In this paper, the energy consumption of an electric vehicle's thermal management system is reduced by a novel approach for integration of various subsystems. Integrated thermal management system (ITMS) integrates air conditioning system, battery thermal management and e-powertrain system. Characteristics of existing integration strategies are studied, compared and classified based on their energy efficiency for different operating conditions. A new integrated system is proposed with a heat pump system for cabin and waste heat recovery from e-powertrain. Various cooling and
K, Muthukrishnan, S, Saikrishna, Mahobia, Tanmay, Vijayaraj, Jayanth Murali
3D CFD Analysis on Flow and Thermal Dynamics of PEM Water Electrolyzer2025-28-0350To be published on 10/30/2025
The proton exchange membrane (PEM) water electrolyzer is an emerging technology to produce green hydrogen due to its compactness and producing high purity hydrogen. This study presents a numerical investigation of multiphase flow dynamics and heat transfer within the anode side of a PEM water electrolyzer, focusing on the anode plate and porous transport layer (PTL). Different channel configurations, i.e., rectangular, semicircular, and wavy channels are considered while varying the PTL thickness within the commercially available ranges. Simulations are conducted under varying oxygen generation rates (corresponding to different current densities) and different inlet water flow rates. The effects of channel configuration and PTL thickness on pressure drop, flow uniformity, and temperature distribution within the cell are illustrated pictorially and graphically. Additionally, impact of PTL thickness on crucial cell performance parameters are reported. The impact of varying water flow
Dash, Manoj Kumar, Bansode PhD, Annasaheb
Thermodynamic Exergy Analysis of PEMFC Systems for System Efficiency and Waste Heat Recovery2025-28-0352To be published on 10/30/2025
Proton Exchange Membrane Fuel Cell (PEMFC) vehicles are emerging as a promising green alternative to fossil fuel and battery-operated electric vehicles. Fuel cells convert the chemical energy of fuel to direct current (DC) through electrochemical reactions, rejecting some heat in the process. This study aims to minimize heat generated during these reactions within the fuel cell stack and utilize it to enhance stack efficiency. Through thermodynamic modeling and exergy analysis, the research focuses on reducing waste heat from exothermic reactions in PEMFC stacks. It investigates using low-temperature waste heat for heating hydrogen and inlet air also examining into how stoichiometry and current density influence heat reduction. Analytical studies were carried out using air stoichiometry ranging from 1.5 to 2 and ambient temperatures typical of Bangalore's climate (15°C to 35°C). The results show that increasing the current density from 1 A/cm² to 1.5 A/cm² significantly raises the
Sahu, Tomesh Kumar, Bansode, Annasaheb
Evaluation of Alternative Cooling method for High Performance Resistors in zero-emission trucks.2025-28-0359To be published on 10/30/2025
High Performance Resistors (HPR), also known as brake resistors are used in zero emission vehicles (ZEVs) to dissipate excess electrical energy produced during regenerative braking, as heat energy. It is necessary to use a suitable cooling technique to release this heat energy into the atmosphere in a regulated manner. Currently in ZEVs, liquid cooled HPR with its dedicated heat exchanger and other auxiliaries such as pump, surge tank, Coolant and coolant lines, is used which increases the cost, packaging space and assembly time. This paper presents air cooling as a substitute heat-exchanging technique for high-performance resistors which eliminates the need of auxiliaries mentioned above, resulting in space optimization and reduction in assembly time. An air cooled HPR, designed for this study consists of a heat exchanger, which accommodates a resistor wire within its tubes. The design was made to fit commercial vehicle use, specific to trucks, due to packaging constraints in vehicle
MENARIYA, PRAVIN GANESH, KUMAR, VISHNU, Arhanth, Mahima, Umesha, Sathwik, Jagadish, Harshitha
A Scalable GUI-Based Approach for Developing Thermal Management Software in Electric and Hybrid Vehicles2025-28-0410To be published on 10/30/2025
The increasing complexity of thermal management systems in electric and hybrid electric vehicles presents significant challenges in software development, particularly in accommodating diverse thermal layouts across various vehicle models. Current solutions rely heavily on calibration processes, which are not only cumbersome but also lack scalability, as they are designed for a fixed number of components. This paper presents a novel method for developing thermal control software that addresses these limitations by leveraging a user-friendly graphical user interface (GUI) configurator.. This configurator allows users to intuitively design thermal layouts, including the arrangement of components, sensor locations, and mixing valves. The configurator generates a comprehensive configuration file that serves as the foundation for automated source code generation, ensuring that the software aligns precisely with the unique thermal requirements of each vehicle. By utilizing parameterized
Dhanasekar, Hemanth Sidhartha, T P, Lithin Raj
Energy-Efficient Thermal Management in Electric Vehicles using Fuzzy Logic Control2025-28-0415To be published on 10/30/2025
The increasing adoption of electric vehicles (EVs) necessitates innovative solutions for efficient thermal management to enhance both battery performance and passenger comfort. This paper presents a novel control strategy for simultaneous battery and cabin cooling in EVs, leveraging a two-stage fuzzy logic controller. The proposed system integrates a comprehensive plant model to simulate real-world conditions and optimize compressor speed dynamically, ensuring energy-efficient thermal management. The first stage of the fuzzy controller determines the initial compressor speed based on primary input parameters, including battery and cabin temperatures. The second stage refines this speed by considering secondary parameters such as condenser and chiller pressures, along with the power output ratio derived from the plant model. This multi-stage approach ensures that the cooling demands of both the battery and cabin are met efficiently while maintaining safe operating conditions. This
PONANGI, BABU RAO, Meduri, Sunil, Pudota, Praveen, J, Anandu
Multi-Phase Analysis of Oil-Air Cavitation and Its Impact on Heat Generation and Wear in High-Speed Automatic Transmission Lubrication2025-28-0403To be published on 10/30/2025
Automatic transmissions operate under high-speed and high-load conditions, where effective lubrication and cooling are critical for durability and efficiency. One of the key challenges in such systems is oil-air cavitation, which arises due to rapid pressure fluctuations and shear forces within the Automatic Transmission Fluid (ATF). This phenomenon leads to bubble formation and collapse, generating localized thermal spikes, increasing viscous dissipation, and accelerating component wear. This study employs Computational Fluid Dynamics (CFD) simulations using ANSYS Fluent to investigate cavitation effects in the automatic transmissions. A Volume of Fluid (VOF) multiphase model is used to simulate oil-air interactions, while the Schnerr-Sauer cavitation model captures bubble dynamics under varying operating conditions. Key parameters, including gear rotational velocity, ATF viscosity-temperature characteristics, oil jet injection angles, and pressure gradients, are evaluated to quantify
Wadkar, Swapnil P., Kanna, Rajesh Deepak
ML-Based System Level Optimization of EV Cooling Circuit2025-01-0376To be published on 10/07/2025
Efficient thermal management is vital for electric vehicles (EVs) to maintain optimal operating temperatures and enhance energy efficiency. Traditional simulation-based design approaches, while accurate, are often computationally expensive and limited in their ability to explore large design spaces. This study introduces a machine learning (ML)-based optimization framework for the design of an EV cooling circuit, targeting a 5°C reduction in the maximum electric motor temperature. A one-dimensional computational fluid dynamics (1D-CFD) model is utilized to generate a Design of Experiments (DOE) matrix, incorporating key parameters such as coolant flow rate and heat exchanger dimensions. A Radial Basis Function (RBF) neural network is trained on the simulation data to serve as a surrogate model, enabling rapid performance prediction. Optimization is performed using the Non-Dominated Sorting Genetic Algorithm II (NSGA2), yielding three distinct design solutions that meet the thermal
Paul, Kavin, Ganesan, Arul, Mansour, Youssef
Efficient Prediction of Electric Vehicle Battery Temperature2025-01-0419To be published on 10/07/2025
Maintaining the temperature of lithium-ion batteries within electric vehicles across a wide range of driving scenarios and ambient temperatures is critical for ensuring both safety and long battery life. However, accurately predicting the temperature of batteries that thermally interact with dynamic systems—such as drive cycles, cooling systems, and vehicle components—can be computationally expensive and too slow for the iterative nature of design processes. To address this, our research employs a combination of 1D thermal modeling, a modified lumped capacitance approach, and experimental testing to develop a fast and reliable framework for analyzing battery thermal performance. The model captures the interaction between the drive cycle, cooling plate, coolant flow, thermal interface material, and battery geometry and properties. This hybrid approach balances accuracy and computational efficiency, enabling rapid exploration of thermal design strategies during early-stage vehicle
Builes, Isabel, Bachman, John Christopher, Medina, Mario
The Role of EV Charging Infrastructure in Shaping Energy Pricing and Consumer Behavior – Case Study in Saudi Arabia2025-01-0421To be published on 10/07/2025
As the electric vehicle (EV) industry grows rapidly in Saudi Arabia, driven by the development of companies such as Ceer, Lucid, and Tesla, there is an increasing need to evaluate and adapt electricity tariff structures to address changing demand patterns. This study explores the interaction between EV charging infrastructure, electricity pricing strategies, and consumer behavior, aiming to provide insights that support the sustainable expansion of the electric mobility ecosystem in the Kingdom. The methodology incorporates demand-supply analysis, energy consumption forecasting, and comparative assessments of tariff models implemented in other countries, with Saudi Arabia serving as a case study aligned with Vision 2030 objectives. Although EV adoption is expected to increase electricity demand, the Kingdom’s generation capacity, which reached 453 TWh in 2023 and is projected to exceed future consumption, ensures a stable and sufficient supply. Currently, public EV charging services
AlJuhani, Haneen Radi A, Bedywi, Lama Mohammed A, AbdulNour, Bashar
Influence on Electric Vehicle Performance by Reproduced Real-world Driving Wind on Chassis Dynamometer2025-01-0410To be published on 10/07/2025
The latest electric vehicles (EVs) incorporate advanced thermal management systems to regulate heat distribution throughout the vehicle, thereby improving driving range. A key factor influencing thermal performance is the effect of driving wind during motion. However, evaluations of EV performance are often conducted using a chassis dynamometer (CHDY), where it remains unclear whether the driving wind specifications defined in the current Worldwide Harmonized Light Vehicles Test Procedure (WLTP) framework adequately replicate real-world conditions. This study investigates the vehicle performance of both internal combustion engine vehicles and EVs to verify the wind requirements of the WLTP. Specifically, we simulated the wind speed at the front and underside of the vehicle under real-world driving conditions, and modified the vehicle-cooling fan of the CHDY. We analyzed the impact of these modifications, and we discussed the future considerations for refining the driving wind
Okui, Nobunori
CFD and FE Toolset for Predicting Structural Temperatures in a Hydrogen Internal Combustion Engine.2025-01-0383To be published on 10/07/2025
Hydrogen has been identified as a promising decarbonization fuel in internal combustion engine (ICE) applications in many areas including heavy-duty on- and off-road, power-generation, marine, etc. Hydrogen ICEs can achieve high power density and very low tailpipe emissions. However, there are challenges; designing systems for a gaseous fuel with its own specific mixing, burn rate and combustion control needs, which can differ from legacy products. Being able to determine the thermal distribution and temperatures of the power cylinder components has always been critical to the design and development of ICE. SAE-2023-01-1675 presented an analytical FE-based tool, and validation using both FE and CFD methods for a Euro VI HD Diesel engine converted to operate on hydrogen gas using direct injection. In this study, updated methods and investigations are presented for Hydrogen ICE including applicability of the Woschni heat transfer correlation, use of CFD thermal wall functions and a
Bell, David J., Shapiro, Evgeniy, Turquand d Auzay, Charles, Hernandez, Ignacio, Hynous, Jan, Kohutka, Jiri, Osborne, Richard, Penning, Richard, Tomiska, Zbynek
Passive solution for Battery Disconnect Unit thermal management for electric vehicle fast charging: numerical study and experimental validation2025-01-0420To be published on 10/07/2025
Charging time is a major problem with electric vehicles development and use. The difficulty of finding a charging station and especially the duration needed for a full charge are becoming more and more important topics in electric vehicles selling points. Fast-charging is more and more used on new developed vehicles but also on existing vehicles. One of the limits of fast-charging electric vehicles is the overheating of the different components in the car, the station, and the charging system. One of the key components in this system is the battery disconnect unit. This element is responsible for monitoring, activating and deactivating the high voltage battery system. It is essential to maintain it at convenient temperatures and prevent it from overheating. These components are designed today for normal charging power, but with increasing charging powers and reducing charging time, thermal management of these components become essential. This paper presents a passive way to allow the
Salameh, Georges, Goumy, Guillaume, Chalet, David, Dubouil, Rémi, Frecinaux, Anthony, Palluel, Marlène, Ratajczack, Christelle, Noiseau, Pascal
Durable Aluminum Alloys for Brake Disc and Rotor Applications2025-01-035809/15/2025
Lightweight materials are essential in reducing the overall weight and improving the efficiency and performance of ICE and electric vehicles. The use of aluminum alloys is critical in transitioning to a more energy sustainable and environmentally friendly future. The accessible combinations of high modulus to density and strength to weight ratios, as well as their excellent thermal conductivity, make them an ideal solution for overall weight reduction in vehicles, thereby improving fuel efficiency and reducing emissions. Aluminum alloys with high strength and lifetime thermal stability have been industrialized for usage in brake rotor applications. Amongst the most used aluminum alloys with high thermal stability are 2618-T8 and 4032-T6 for use in aerospace and automotive industries, respectively. However, when it comes to prolonging the life of a product at temperatures that exceed 200°C, the properties of these alloys will quickly degrade within the first 300 hours of exposure
Duchaussoy, Amandine, Lorenzino, Pablo, Franklin, Jack, Tzedaki, Maria
Research on Validation and Research Platform for Automotive Air-Conditioning Control Strategy2025-01-505809/10/2025
In order to improve the efficiency of verification and optimization of control strategies for air-conditioning systems, a thermal management platform is established based on a rapid control prototyping (RCP) approach in the article. The platform is composed of a HVAC hardware bench, a real-time control system, and a control software model. This article describes the overall architecture of the platform, the control strategy, and an efficient method for development and optimization of air-conditioning control strategies. The cooling and heating modes of the air conditioner are tested. The results show that the control strategy can be directly modified via the platform to improve the performance of the whole system. The experimental results show that after modifying the control strategy, the cooling effect of the air conditioner is optimized and the cooling time is reduced by 10.6%. The CLTC cycle is also tested in this work to verify the dynamic control performance of the air
Liu, Shuqi, Yu, Yilong, Wang, Wei, Wang, Yuan, Zhang, Yilun, Xu, Xiang
Simulation Based Dynamic Thermal Emulation Unit for Thermal Preconditioning and Emulation of Hardware Components on the Thermal Testbed2025-24-013709/07/2025
Electrification of vehicles plays an important role in the transformation process towards sustainable mobility in the individual and transport sector. As a result, new challenges must be met during the development process regarding the vehicles overall energy management system. A key challenge is the development of thermal management systems to optimize overall vehicle efficiency and to minimize ageing effects of the powertrain components while maintaining passenger comfort. Efficiency and ageing effects are highly dependent on the conditioning state of the powertrain components due to their high thermal sensitivity with simultaneously narrow thermal operating limits. Comfort functions like cabin air conditioning must be fulfilled as well, which must be considered by the thermal management system. To develop innovative solutions for thermal management systems at an early stage of the development process, thermal emulation can be used to substitute hardware components. Therefore
Weimer, Niko, Hohenberg, Günter, Beidl, Christian, Fiore, Luis, Stenger, Erik, Seib, Rico
Comparison between Spark-Ignition and Passive Pre-Chamber Combustion in a Methanol Fuelled Heavy-Duty Engine at Different Speeds, Loads, and EGR Dilutions2025-24-003009/07/2025
Decarbonizing the transport sector requires solutions that reduce CO₂ emissions while improving the efficiency of existing engine platforms. This study explores a retrofit strategy in which a heavy-duty diesel engine is converted to Otto-cycle operation and equipped with a passive pre-chamber combustion (PPCC) system. Methanol was used as the fuel due to its high octane number, low carbon intensity, and favourable combustion properties. The performance of the PPCC system is experimentally compared to conventional spark ignition (SI) across varying engine speeds, loads, and exhaust gas recirculation (EGR) levels. A dual-dilution strategy, combining lean operation (λ = 1.6) with EGR, was applied to extend dilution tolerance and assess the feasibility of operating near stoichiometry. All tests were conducted under steady-state conditions with fixed spark timing. Results show that PPCC consistently delivers faster combustion than SI across all conditions, with greater stability and reduced
Fong Cisneros, Eric J., Hlaing, Ponnya, Cenker, Emre, AlRamadan, Abdullah, Turner, James WG
A Critical Assessment of Phase Change Materials for Boosting EV Efficiency2025-24-014709/07/2025
Effective thermal management in battery packs is a key technology for enhancing the efficiency and longevity of battery electric vehicles (BEVs). Traditional active cooling systems can consume significant amounts of energy, thereby impacting the vehicle's overall efficiency. This paper explores the use of phase change materials (PCMs) as a complementary cooling technology, enabling both an improved active and an extended passive conditioning of battery packs. By leveraging the unique properties of PCMs, it is possible to partially operate the battery system without active cooling, thus reducing the overall energy consumption and improving vehicle autonomy. The phase change phenomenon further offers the benefit of a homogeneous temperature distribution within the battery pack. This study addresses the potential of PCMs as a thermal management solution for battery packs by firstly identifying suitable materials meeting requirements specific to such application. In addition, the paper
Fandakov, Alexander, Nolte, Oliver, Herzog, Alexander, Sens, Marc
Experimental Study of the Lubricating Oil Impact on the Unsteady Performance of an Automotive Turbocharger2025-24-007809/07/2025
Turbocharging technique is a key technology for the development of hydrogen engines, allowing high lambda values to reach low NOx emissions. In ultra-lean mixture conditions, the thermal management of the lubricating oil and its cold condition becomes a crucial aspect that cannot be neglected. Accordingly, the impact of different lubricating oils and different lubricant thermal conditions is highlighted referring to the performance of a turbocharging system for automotive application. To this aim, an experimental campaign is conducted at the test bench for components of propulsion systems of the University of Genoa. Tests are performed on a turbocharger equipped with a variable geometry turbine under both steady and unsteady flow conditions, considering different positions of the turbine regulating device. A 4-cylinder engine head was coupled to the turbocharger in order to reproduce the pulsating flow related to the opening and closing of the engine valves. The influence of the
Marelli, Silvia, Usai, Vittorio, Cordalonga, Carla
Simulation Driven Thermal Optimization of an Innovative Battery System2025-24-013809/07/2025
BATSS project objective is to design a safe, effective and sustainable battery pack. To achieve this, the battery system (BS) will be mechanically, electrically and thermally optimized using cutting edge technology. Consequently, the battery system includes innovative 4695 cylindrical cells and advanced thermal management, carried out with the Miba FLEXCOOLER®. This work focuses on the BS thermal optimization using system simulation tools. First a simplified version of the BS is simulated with all physical phenomena involved in thermal behavior to identify first order parameters. It appears that various BS component and heat transfer can be neglected in comparison with the heat transfer due to cooling system. Then the simulation of the full battery system is conducted under nominal condition. Cooling system appears to be performant as it allows a controlled averaged temperature and very low cell-to-cell temperature variability. Finally, impact of both design and operating parameters is
Chevillard, Stephane, Popp, Hartmut, Galarza, Igor, Petit, Martin
Enabling Near-Zero Emissions and Superior Efficiency in Large-Bore, Medium-Speed Engines with a Hydrogen-Argon Power Cycle2025-24-000109/07/2025
Combustion engines operating on a hydrogen-argon power cycle (H-APC) offer potential for superior thermal efficiency with true zero exhaust emissions. The high specific heat ratio of argon allows extrapolation of the theoretical efficiency of the Otto cycle to almost 90%. However, this potential is significantly constrained by challenges in combustion control, excessive thermal loading, and system integration, particularly regarding argon recovery. This study investigates these trade-offs, within the context of real-world engine-based peaking power plants. An experimentally validated 1D-simulation model of a prototype Wärtsilä 20 DF engine serves as reference for analysis of a retrofit incorporating a closed-loop argon cycle, with dedicated H₂ and O2 injectors, a water condenser and water separator. Engine performance is evaluated at reference operating point of 75% load, considering pre-ignition, peak pressure and exhaust temperature constraints, condenser limitations, and impurity
Ahammed, Sajid, Ahmad, Zeeshan, Mahmoudzadeh Andwari, Amin, Kakoee, Alireza, Hyvonen, Jari, Mikulski, Maciej
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