A Simulation And Optimization Design Case for Heavy Truck Thermal Management
2022-01-0210
03/29/2022
- Event
- Content
- In order to meet CHINA VI Emission Standard and high-horsepower engine system integration for fourth-stage fuel consumption standards, which will put higher heat load to the entire cooling system, Faw Jiefang is conducting development on vehicle thermal management technology system. This requires redesign of front grill and the underhood cooling system components such as, cooling airflow duct, and fan shroud. Simply increasing the cooling air mass flow rate could improve the overall cooling airflow system performance; however, it will also increase the fan power consumption and aerodynamic drag of the vehicle, which will lead to an increased fuel consumption and escalate emission. Hence, a multi-objective optimization towards engine cooling system is necessary to achieve desired cooling performance while maintaining or lowering aerodynamic drag. An accurate simulation methodology is a key component for this iterative design and optimization process, as it will expedite the development and reduce physical testing cost. In this article, Faw Jiefang collaborated with DS SIMULIA and conducted the simulation driven design process. We use PowerFLOW to perform high fidelity CFD simulation and optimize cooling module. The project has two phases. Phase one focused on digital climatic wind tunnel construction and calibration. During this calibration stage, we achieved high accuracy in predicting both heat exchanger performance and thermal sensitive component temperatures by accurately simulate the wind tunnel size and boundary conditions and the proposed conjugate heat transfer methods. Finally, by adjusting cooling components layouts and operating parameters we proposed design variations to improve thermal management system design. The new design proposal significantly improved vehicle’s overall cooling performance and thermal management efficiency.
- Citation
- Guo, P., Chen, T., Liao, G., Yang, Y. et al., "A Simulation And Optimization Design Case for Heavy Truck Thermal Management," SAE Technical Paper 2022-01-0210, 2022, .