Browse Topic: Engine cooling systems

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Innovative Multi-Axial Testing approach for Enhanced Reliability of Cooling Modules in Commercial Vehicles2026-26-0530To be published on 01/16/2026
This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test
V Dhage, Yogesh, Satale, Sunil
A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides2026-26-0364To be published on 01/16/2026
An air guide in a car directs fresh air onto the Heat Exchangers (HXs) to facilitate efficient thermal management. It is of paramount importance that the air guide creates a proper sealing and prevents any leakage of the incoming fresh air. It is achieved in two ways – 1) In the design condition, the air guide is manufactured in a way so that it overlaps/intersects with the surrounding components 2) the air-guide is made flexible with a highly elastic rubber seal at the edge. When the air-guide is assembled, the rubber portion of the air-guide deforms to produce a proper fit leading to a sealed air-intake pathway. At high-speed condition as well as high airflow conditions by the radiator fan during idling/stationary, like DC charging – incase of BEV, etc., the air guide encounters high pressure. Being elastic and flexible, these conditions make the air guide susceptible to deformation with potential leakage of incoming air. Digital evaluation of the air guide deformation at different
GADASU, RAVISHASTRI, CHOUDHURY, SATYAJIT, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
Cabin modelling approach in 1D simulation for studying the impact of partial recirculation in warmup for BEV at extreme cold ambient conditions2026-26-0450To be published on 01/16/2026
The inclusion of the cabin in HVAC simulations gained more importance with the introduction of BEV’s. Thermal management and efficiency being in the forefront, exploration for the possible opportunities to reduce the energy consumption for meeting the comfort of passengers gained importance. The energy consumed by the Electric coolant or air heaters for heating the cabin at extreme cold ambient temperatures to deliver similar comfort to that of an ICE version is 2 to 3 times that of the energy required for cooling the cabin in a high ambient condition. Even during the sizing of HVAC system, if traditional method of ambient or fresh air conditions is considered for calculating the requirements, the result is we would require a product which will have unrealistic performance demand. Hence to explore different possibilities for studying the system, usage of recirculation air was considered as one of the options. This paper talks about the approach followed in creating the cabin model in
Veerla, Eswar, Subramanian, Karthik
Thermal System design of Inter-City Fuel Cell Electric Bus2026-26-0427To be published on 01/16/2026
In the current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries commitment towards carbon neutrality by 2050. Hydrogen is considered as one of the cleaner fuels and 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 selected based on the 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 using simulation models using software KULI
M S, Vignesh, KIRAN, NALAVADATH
Accelerating EV Thermal Controls Development: A Rapid controls prototyping framework using Speedgoat2026-26-0685To be published on 01/16/2026
In the era of software-defined vehicles, the complexity and requirements of automotive systems have increased significantly. Thermal management systems have become more complicated, incorporating multiple functions and strategies within software frameworks. This shift poses substantial challenges, increased development efforts and extending timelines in creating an efficient thermal management system for EVs. Fulfilling them in the early stages of design makes it more challenging due to the unavailability of key components such as fully developed ECU hardware, the battery pack, and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation, enabling the testing and validation of thermal control strategies without fully matured system and ECU hardware. The framework uses the Speedgoat platform as the central controller which hosts the control and thermal models developed in Simulink and Simscape. Speedgoat is physically
Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh
Low idle boom noise reduction on Light Weight Agricultural Cabin Tractor2026-26-0100To be published on 01/16/2026
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
Advanced Sensor less Machine Learning Technique for Early Detection of Engine Oil Degradation2026-26-0656To be published on 01/16/2026
Maximizing vehicle uptime and reducing maintenance costs are critical objectives in modern automotive systems, making efficient resource utilization a top priority. One key factor is engine oil degradation, which directly affects engine performance, longevity, and overall vehicle efficiency. Current Conventional oil monitoring approaches are real time based on dedicated sensors—can be inefficient, costly, or poorly adapted to varying usage conditions. While earlier studies have explored sensor-based or chemical analysis methods for oil health monitoring, these solutions often lack scalability and cost-effectiveness for widespread adoption. This paper introduces a Machine Learning-based Engine Oil Degradation Detection System that operates non-intrusively using existing vehicle CAN signals, requiring no additional sensors. Key engine parameters such as RPM, Torque, Gear Position, Engine Power, Coolant Temperature, and Odometer readings are trained with tri-bological properties
Dusane, Mangesh, Tade, Vilas, Iqbal, Shoaib
Development of Flex fuel Vehicle for Indian Market2026-26-0117To be published on 01/16/2026
This paper presents the methodology and outcomes of modifying a 1.2L naturally aspirated (NA) engine to enable flex-fuel compatibility, targeting optimal performance with ethanol blends ranging from E20 to E93. The road map for Ethanol Blending released by Govt of India call for progressively increase in ethanol blending in gasoline, with a target of 20% by April 2025. Ethanol is promoted as a renewable fuel due to its potential to reduce greenhouse gas emissions and provides an additional source of income for farmers. This work is in alignment with the broader push for development of flex-fuel vehicles, which necessitates engine adaptations capable of operating on varying ethanol blends. The primary objective was to retain the performance with E20 while mitigating the fuel consumption penalties when the vehicle is operating on higher ethanol concentrations upto E93. The engine upgrade incorporated key modifications, including optimizing the compression ratio, implementing Variable
Tyagarajan, Sethuramalingam, Pise, Chetan, Kavekar, Pratap, Agarwal, Nishant Kumar
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-0579To be published on 01/16/2026
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
Impact of density in simulation model for extreme cold ambient conditions2026-26-0388To be published on 01/16/2026
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, Mishra, Abhishek
Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger2026-26-0177To be published on 01/16/2026
Efficient thermal management in electric vehicle (EV) charging stations is critical for ensuring the reliability, safety, and longevity of power electronics. This study presents a comprehensive bench test analysis of three key parameters influencing charger cooling efficiency: filter resistance, louver airflow, and fan heat dissipation. A test bench was developed to measure pressure drop, temperature gradients, and air velocity variations across multiple filter types, louver orientations, and fan configurations. The results show that higher-efficiency filters (e.g., HEPA, MERV13) significantly reduce airflow, increasing thermal stress on electronic components, while optimized louver angles improve directional airflow, reduce turbulence, and enhance cooling performance. High-performance axial and centrifugal fans with adaptive control mechanisms further contribute to effective heat dissipation, maintaining stable operating temperatures under varying load conditions. This study provides
S, Sri Saran, chinnanna, Manjunath, Ajith, Arjun, B, Viswanathan, Kulkarni, Mukund, R, Vigneshwaran, Dhachinamoorthi, Sivanantham
Wetting prediction of power train components under the influence moving components using smooth particle hydrodynamics2026-26-0384To be published on 01/16/2026
Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water pool the components are not just wet by the direct inflow of water but also by water being splashed by moving
Shukrey, Sarthak, Pattankar, Rohan, Yenugu, Srinivasa
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-0376To be published on 01/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
Advanced Thermal Management for High-Tonnage EVs: Increasing Coolant Flow and Reducing Energy Losses2026-26-0196To be published on 01/16/2026
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 to
DIXIT, SAMEER, Patil, Bhushan, Ghosh, Sandeep
Evaluating Thermal Control Strategies to Improve Electric Vehicle Range Using GT Suite2026-26-0362To be published on 01/16/2026
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 sub-systems such as the high-voltage battery (HVB), e-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 e-powertrain 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
Measurement of Exterior Noise Produced by Aircraft Auxiliary Power Units (APUs) and Associated Aircraft Systems During Ground OperationARP1307C (Current)11/26/2025
Test procedures are described for measuring noise at specific receiver locations (passenger and cargo doors, and servicing positions) and for conducting general noise surveys around aircraft. Procedures are also described for measuring noise level and directivity at noise source locations to facilitate the understanding and interpretation of the data. Requirements are identified with respect to instrumentation; acoustic and atmospheric environment; data acquisition, reduction and presentation, and such other information as is needed for reporting the results. This document makes no provision for predicting APU or component noise from basic engine characteristics or design parameters, nor for measuring noise of more than one aircraft operating at the same time. No attempt is made to suggest acceptable levels of noise or suitable subjective criteria for judging acceptability. ICAO Annex 16 Volume I Attachment C provides guidance on recommended maximum noise levels.
A-21 Aircraft Noise Measurement Aviation Emission Modeling
Model based design and numerical analysis of a downsized centrifugal pump for engine cooling applications2025-32-007811/03/2025
The water pump is the crucial component of the engine cooling system. It is usually designed using a roughly methodology based on the maximum power of the engine, and this results in an overdesign of the pump itself, if the real operating points during a driving mission is considered. An improper design can cause the engine to overheat or operate below optimal temperatures, or it can stress too much the control devices, negatively impact engine efficiency. Hence, designing an effective water pump is essential. In this work, a model based procedure to design the pump in a proper engine working point is considered. The procedure starts with an estimation of the engine thermal needs in different working conditions and on a driving cycle. Hence, a flow rate can be targeted, and a pressure drop of the cooling circuit estimated, in order to have the specifics of the design of the pump. The model is able to evaluate all the hydraulic losses of the pump in its impeller and volute. The geometry
Di Battista, Davide, Di Bartolomeo, Marco, Cipollone, Roberto, Di Prospero, Federico, Di Giovine, Giammarco, Fatigati, Fabio, DERISZADEH, Ali
Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit2025-01-501703/21/2025
Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed
Birgül, Çağrı Emre, Meydan, Ömer
TitleAIRS12242024 (Current)12/24/2024
SS
A-20A Crew Station Lighting
TightAIR12122024A (Current)12/12/2024
New Scoop
A-6 Aerospace Actuation, Control and Fluid Power Systems
testARPTEST3008A (Current)12/12/2024
Sc
A-6 Aerospace Actuation, Control and Fluid Power Systems
TTAIR12092024 (Current)12/09/2024
SS
A-6 Aerospace Actuation, Control and Fluid Power Systems
HVAC NVH Refinement in Electric Vehicle2024-26-020601/16/2024
Customers expect much more advanced features and comfort in electric vehicles. It is challenging for NVH engineers to reduce the vibration levels to a great extent in the vehicle without adding cost and mass. This paper focuses on reducing the tactile vibration in electric vehicle when AC is switched on. Vibration levels were high and modulating in nature in test vehicle. Electric compressor is used for cabin cooling and battery cooling in the vehicle. Compressor is connected to body with the help of isolators. Depending upon cooling load, the compressor operates between 1000 rpm and 8000 rpm. The 1st order vibration of compressor was dominant on tactile locations at all the compressor speeds. Vibration levels were improved by reducing the dynamic stiffness of isolators . To reduce the transfer of compressor vibration further, isolators are provided on HVAC line connection on body and mufflers are provided in suction and discharge line to reduce the effect of pulsation. With the above
S, Nataraja moorthy, Rao, Manchi, Raghavendran, Prasath, Manivannan, Giridharan
An optimum solution to meet the Thermal load challenge in a high mobility military vehicle2024-26-024601/16/2024
Military vehicles are intended to operate at rugged terrains in adverse environmental conditions. Unlike a regular truck, these vehicles are powered by a much bigger engine and transmission to meet the vehicle performance parameters. Thermal systems in these vehicles are challenging. With the adverse climatic condition and driving terrains, the criticality of Engine cooling system are intensified. In this paper, a Cooling system is finalised for a high mobility military vehicle with high power engine, Automatic transmission and a hydraulic retarder. Thermal load cases are different for each. Modelling is done in thermal simulation software KULI. A steady state simulation is done for engine and automatic transmission. Transient simulation is performed for retarder. The aim is to finalise a cooling system circuit consisting of radiator, oil to air cooler and oil to water cooler which are interconnected to meet the heat load demand of engine, transmission and retarder together.
AT, SHAJAHAN, KIRAN, NALAVADATH, RAO, BONTHALA
Predictive Underhood Thermal Management Model2024-26-027201/16/2024
In the automotive industry, thermal management is a very important way to solve the problems of energy saving and emission. The underhood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts the
P V, NAVANEETH, Prasad, Suryanarayana A N, ML, SANKAR
Development of Fuel efficiency Enhancement Module for tractors2024-26-006401/16/2024
In farm tractors, the available drawbar power and Power Take-Off (PTO) power are generally lower than the engine power due to parasitic losses. These losses are caused by engine-driven auxiliary loads such as cooling fans, hydraulic pumps for power steering, alternators, etc. Minimizing these parasitic losses can increase the available drawbar power and PTO power, resulting in direct fuel savings by reducing fuel consumption. The continuous increase in fuel costs and the environmental impact of emitted gases from burned fuel into the atmosphere have necessitated the replacement of hydraulic power steering and mechanical fans with electric power steering (EPS) and electric fans, respectively, to improve efficiency. The existing battery has been replaced with a higher capacity battery to provide power to the electric fan, electric power steering, and other electrical components. Additionally, the existing alternator has been replaced with a higher capacity alternator to meet the
Arjun, P., Natarajan, Saravanan, Chinnathambi, Manikandan, a, Radhakrishnan, nabar, Omkar
Study on Range Improvement Controls and Method for Electric Vehicles2024-26-013201/16/2024
Electric Vehicles are rapidly growing in the market yet various failure incidents were noted all along the globe. On the other hand, range anxiety has greatly inspired manufacturers to explore new practices to improve. One of the most important components of an EV is the battery, which converts chemical energy to electrical energy thereby liberating heat energy as the loss. This heat loss when high, capability of system to deliver required energy to wheels is reduced significantly. With a higher heat loss in the battery, system is prone to failure or reduced mileage. Therefore, controlling/maintaining system temperature under safe usable zone even during harsh conditions is ideal. Simple reduction in energy consumption of electrical cooling/heating devices used with regenerative energy techniques can greatly help in range improvement. The intention of this paper is to explore easy methods to improve electric vehicle range in different ambient conditions. Few of the key benefactors here
MR, Vikram, Pattalwar, Ashutosh, Verma, Mrinal, Bawa, Vikas
INVESTIGATION OF GASKET SEALING BEHAVIOUR OF AN ALL-ALUMINIUM HIGH PERFORMANCE, NEW GENERATION PASSENGER CAR ENGINE UNDER EXTREME ENGINE OPERATING CONDITIONS2024-26-003301/16/2024
The increasing demand for higher specific power, fuel economy, Operating Costs as well as meeting global emission norms have become the driving factors of today’s product development in the automotive market today. Substitution of high-density materials and more precise adjustment of material parameters help in significant weight decrease, but it is accompanied by undesirable cost increase and manufacturing complexity. This becomes a challenge for every automotive engineer to balance the above parameters to make a highly competitive design. This work is a part of the Design and Development of 2.2 L, 4 Cylinder TCIC Diesel Engine for a complete new monocoque vehicle platform, focused on automotive passenger car application. This paper explains the selection of a suitable cylinder head gasket technology for a lightweight engine that acts as a sealing interface between the cylinder block and cylinder head. The decision to select an aluminum alloy for both cylinder block and head still
DHADSE, ASHISH, Dharan R, Bharani, Vellandi, Vikraman, Sasikumar, M
Thermal Performance Prediction of Roots blower Using Coupled 3-D Multiphase CFD Thermal simulation with Experimental Validation2024-26-029701/16/2024
Abstract Roots blower is a rotary positive displacement pump which operates by pumping a fluid with a pair of meshing lobes. Recent trends in automotive industry demands high power density solutions for various applications. In comparison with legacy applications, compressors for high power dense applications demands more continuous operation with harsher duty cycle, demanding higher pressure ratios. Because of longer duty cycles, it will be subjected to high heat loads which will cause a rise in temperatures of timing gears, bearings, and other components within assembly. Accurate prediction of thermal performance is critical to design a durable and efficient roots blower for high power density applications. Thermal analysis of an assembly of roots blower involves modelling of multi-physics. This paper details a coupled CFD analysis approach to predict temperatures of roots blower components and timing gear case oil. Timing gears are lubricated using wet sump lubrication. The oil
C, Anandha krishnan, Jambare, Giridhar, Raut, Nikhil, Niranjan, Bhanupratap
Engine Warm-up Prediction using Machine Learning Methodology.2024-26-029501/16/2024
In the recent times, when emission & CO2 legislations are becoming more stringent, we need to adjust our simulation methods to the engine warm-up for better prediction. A typical fuel economy simulation for a WLTP drive cycle with and without considering warm-up effect differentiates up to 6-8%. Thus, there is a need to consider engine warm-up parameters for drive cycle simulations. The engine warm-up can be predicted in multiple ways but the most common way is detailed Physics based 1D modelling. These thermodynamic based models have a very good accuracy in temperature characteristics compared to actual test but take a lot of simulation time. The current requirement is to have models, which can do the same with 0.3 times real time so that these can be coupled with SiL simulation. The current paper will portrait a machine learning based methodology to predict Engine Oil & Coolant temperature based on driving profile and fuel consumption. ML model is trained by using data from one drive
Kelkar, Kshitij, Bensch, Simon, Gopalkrishnan, Suresh Kumar, Meissner, Ronny
3-D Multiphase Flow Simulation of Coolant Filling and Deaeration Processes in an Engine Coolant System2024-26-031001/16/2024
The thermal performance of an engine coolant system is efficient when the engine head temperature is maintained within its optimum working range. For this, it is desired that air should not be entrapped in the coolant system which can lead to localized hot spots at critical locations. However, it is difficult to eliminate the trapped air pockets completely. So, the target is to minimize the entrapped air as much as possible during the coolant filling and deaeration processes, especially in major components such as the radiator, engine head, pump, etc. The filling processes and duration are typically optimized in an engine test stand along with design changes for augmenting the coolant filling efficiency. However, it is expensive and time-consuming to identify air-entrapped locations in tests, decide on the filling strategy and make the design changes in the piping accordingly. In the current effort, a simulation-based testing method for coolant filling and deaeration processes is
Khandagale, Vitthal, Pasunurthi, Shyam Sundar, Maiti, Dipak, Bollu, Theja, Saha, Rohit
Optimization of Cooling Air Flow for improved Heat Dissipation through Radiator.2024-26-004201/16/2024
Optimization of Cooling Airflow for improved Heat Dissipation through Radiator Authors: Paurnima Thakur, Amit Aher, Vishal Chavan, Chandrakant Palve Mercedes-Benz Research and Development India Private Limited Key Words: Radiator, Temperature, Heat Dissipation, Airflow, Cooling, Thermal Efficiency Abstract: Heat regulation is indispensable factor during operation of internal combustion engine. Automotive engine cooling system takes care of excess heat produced during engine operation. It regulates Engine surface temperature for engine optimum efficiency and plays important role in meeting CO2 emission target set by Environmental Protection Agency (EPA). Insufficient heat dissipation results into Engine overheating. This will affects thermal efficiency & ultimately brake specific fuel consumption of the Internal Combustion Engine. Radiator is the central component of a vehicle cooling system to monitor and regulate engine temperature and prevent it from overheating. Heat dissipation
Palve, Chandrakant, Thakur, Paurnima, Chavan, Vishal, Aher, Amit
Enhanced impeller blade design for water coolant pump in IC engines2024-26-003401/16/2024
Enhanced impeller blade design for water coolant pump in IC engines Sudeshna Roy Pratihar, Amol Barve, Onkar Mokashi, Naveen Patil Mercedes-Benz Research & Development India Private Ltd, India. Keywords: Turbulence; hydraulic efficiency; friction loss; computational fluid dynamics; tubercles Abstract: This paper illustrates scope for improvement in water pump hydraulic efficiency by proposing novel design of impeller blade for internal combustion engine. For water pump, hydraulic efficiency is directly proportional to fluid drag imposed on impeller blades. Friction loss & turbulence during typical operating conditions needs to considered, by keeping in mind optimum performance of water pump. Increase in drag losses results in higher power consumption of water pump. Considerable literature study indicates that, tubercles design in area of IC Engines more precisely in topics relevant to water pump design has never tested for Automotive application. Extensive analytical calculation
Barve, Amol, Roy Pratihar, Sudeshna, mokashi, Onkar, Patil, Naveen
Experimental Study of Piston temperature profile with respect to varying engine parameters – Using Telemetry Method2024-26-034101/16/2024
As emissions standards become more stringent, OEMs are pushing engines to run on leaner fuel mixtures, which puts increased thermal stress on components, particularly pistons, causing them to operate at higher temperatures. This requires more robust design and rigorous testing of components. Telemetry methods offer accurate and real-time feedback, allowing designers to test components at various operating conditions, providing more flexibility than other traditional methods. Piston temperature measurement is a critical aspect of engine development because it directly affects engine performance and durability. Among the various techniques available for this purpose, telemetry methods have gained considerable attention in recent years. This method involves integrating temperature sensors and transmitter on the piston, which transmit temperature data wirelessly to a receiver outside the engine. In this paper, we evaluate the impact of coolant temperatures, valve timing, ignition timing
Pandey, Ram Krishan, KUMAR, ATUL, Jangra, Sumit
Determination of the Heat-Controlled Accumulator Volume for the Two-Phase Thermal Control Systems of Spacecraft01-17-01-000809/29/2023
For spacecraft with high power consumption, it is reasonable to build the thermal control system based on a two-phase mechanically pumped loop. The heat-controlled accumulator is a key element of the two-phase mechanically pumped loop, which allows for the control of pressure in the loop and maintains the required level of coolant boiling temperature or cavitation margin at the pump inlet. There can be two critical modes of loop operation where the ability to control pressure will be lost. The first critical mode occurs when the accumulator fills with liquid at high heat loads. The second critical mode occurs when the accumulator is at low heat loads and partial loss of coolant, for example, due to the leak caused by micrometeorite breakdown. Both modes are caused by insufficient accumulator volume or working fluid charge. To analyze the loop characteristics in critical modes, experiments were conducted on a test bench with ammonia coolant, and a mathematical simulation of a two-phase
Hodunov, Artem, Gorbenko, Gennadiy, Turna, Rustem, Koval, Polina
The Experimental Study of Reducing Cooling Fan Noise using Test Bench2025-01-010805/05/2023
The blade pass frequency (BPF) noise for axial flow cooling fans in Electrical Vehicles (EV) is much obvious in some of rotational speeds. The root cause of this BPF noise is due to the cooling fan loading which is caused by the pressure difference between inlet and outlet of the fan. The pressure difference is defined as the resistance value of the fan. The resistance value of fan in EVs is much higher than the value of internal-combustion engine (ICE) vehicles. It is very difficult to obtain the resistance valve in full vehicle condition. A new method to estimate the vehicle resistance value is developed using bench tests. By assuming, on the same operating parameters of the same fan both in vehicle and in test bench, such as inlet voltage, current and rotational speed, the resistance value of the fan in vehicle is the same as in test bench, thus, the operating parameters are used in the bench testing to simulate the resistance value of the fan in vehicle. Once the resistance value
Duan, Andy, Yu Sr, Jing, shao Sr, 1Lt Siyuan, zhou, changshui, Gu, Perry
Noise analysis and optimization of thermal management integrated module2025-01-008105/05/2023
Abstract：The thermal management integration module is a multifunctional integrated component. The thermal management integration module includes water pumps, flow channel plates, brackets, sensors, etc. However, due to the large range of speed changes, the water pump will generate a wide range of frequency excitation. This excitation will cause the integrated module to vibrate and generate noise. This article studies and analyzes an integrated module that generates noise. An integrated module of a certain new energy vehicle is used as an example. Firstly, a vehicle experiment was conducted. It was found that the noise came from the integrated module. And then use finite element method to analyze the causes of noise generation. Based on the characteristics of multiple integrated module components, high integration degree, and complex structure. This article simplifies components such as brackets, heat exchangers, sensors, etc. And they are replaced by centralized quality points
XU, shenao
Simulation of Pass-by Fan Noise Emissions and Advancing Test Regulations for Heavy-Duty Electric Vehicles2025-01-008605/05/2023
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
Infrared Signature of Fixed and Variable Area C-D Nozzle of Aircraft Engine88-16-02-001101/02/2023
The use of converging-diverging (C-D) variable area nozzle (VAN) in military aeroengines is now common, as it can give optimal expansion and control over engine back pressure, for a wide range of engine operations. At higher main combustion temperatures (desired for supercruise), an increase in the nozzle expansion ratio is needed for optimum performance. But changes in the nozzle throat and exit areas affect the visibility of engine hot parts as the diverging section of the nozzle is visible for a full range of view angle from the rear aspect. The solid angle subtended by engine hot parts varies with change in visibility, which affects the aircraft infrared (IR) signature from the rear aspect. This study compares the performances of fixed and variable area nozzles (FAN and VAN) in terms of engine thrust and IR signature of the engine exhaust system in the boresight for the same increase in combustion temperature. This study is performed for two cases: (i) variable throat area and
Baranwal, Nidhi, Mahulikar, Shripad P.
Infrared Signature of Fixed and Variable Area C-D Nozzle of Aircraft Engine01-16-02-001101/02/2023
The use of converging-diverging (C-D) variable area nozzle (VAN) in military aeroengines is now common, as it can give optimal expansion and control over engine back pressure, for a wide range of engine operations. At higher main combustion temperatures (desired for supercruise), an increase in the nozzle expansion ratio is needed for optimum performance. But changes in the nozzle throat and exit areas affect the visibility of engine hot parts as the diverging section of the nozzle is visible for a full range of view angle from the rear aspect. The solid angle subtended by engine hot parts varies with change in visibility, which affects the aircraft infrared (IR) signature from the rear aspect. This study compares the performances of fixed and variable area nozzles (FAN and VAN) in terms of engine thrust and IR signature of the engine exhaust system in the boresight for the same increase in combustion temperature. This study is performed for two cases: (i) variable throat area and
Baranwal, Nidhi, Mahulikar, Shripad P.
Design and Development of a Novel Air Cycle Refrigeration System for Passenger Vehicles2022-28-044711/09/2022
Current AC system use hydrofluorocarbons (HFC) as refrigerant to transfer heat from cabin and cool the passengers. However, most refrigerants used today have severe environmental effects due to high global warming potential leading to global warming effects. Montreal Protocol and Kigali amendment calls for all nations to reduce refrigerant usage and transport sector being one of the main consumer of refrigerant, regulations regarding refrigerant usage and emission are becoming more stringent day by day. In this paper, a novel air cycle refrigeration system has been designed and also tested for passenger vehicle applications. Currently used refrigerant R134a with high GWP of 1400+ in mobile air conditioning system is completely eliminated in the air refrigeration system. The aim is to achieve a passenger comfort using air as heat transfer medium and power input either from the engine exhaust air of an ICE vehicle or a secondary air compressor. The effect of performance of various
Gupta, Rajat, Arora, Maneesh, Mohite, Yashwant, Ghate, Pravin, CHIGULLAPALLI, ANIL KUMAR, Maurya, Anurag
Computing Complexity Reduction for Predictive Control of Engine Thermal Management System2022-01-023903/29/2022
This paper presents the design and performance evaluation of a reduced complexity algorithm for a model predictive control (MPC) which is based on our previously published SAE paper (2021-01-0225). That paper presented a MPC design concept and demonstrated improved energy efficiency by enabling engine pre-cooling based on GPS/Navigation data to recognize future vehicle speed limit and road grade in anticipation of high load demand. When compared to conventional control, the predictive control demonstrated considerable energy and fuel savings. However, the predictive control strategy is much more complicated due to its highly coupled nonlinear behavior. Also, the MPC strategies are limited to the computational resources in engine control units. Therefore, to address these challenges, a reduced-complexity MPC controller is developed to achieve control objectives and to be executed on a modern ECU within a computation budget. One of the key control logics in the previously published SAE
Chen, Yue-Ming, Holmer, Justin, Lee, Jason, Ha, Jinho
Numerical Modelling of Coolant Filling and De-aeration in a Battery Electric Vehicle Cooling System2022-01-093703/29/2022
Trapped air bubbles inside coolant systems have adverse effect on the cooling performance. Hence, it is imperative to ensure an effective filling and de-aeration of the coolant system in order to have less air left before the operation of the coolant system. In the present work, a coolant/air multiphase VOF method was utilized using the commercial CFD software SimericsMP+® to study the coolant filling and subsequent de-aeration process in a battery electric vehicle (BEV) cooling system. First, validations of the numerical simulations against experiment were performed for a simplified coolant recirculation system. This system uses a tequila bottle for de-aeration and the validations were performed for different coolant flow rates to examine the de-aeration efficiency. A similar trend of de-aeration was captured between simulation and experimental measurement. Next, the same numerical techniques were further applied to a BEV cooling system to evaluate the efficiency of de-aeration
Tao, Mingyuan, Slike, Jody, Bhagat, Meghraj, Srinivasan, Chiranth, Zhang, Yi, Motin, Abdul
UNDERHOOD THERMAL MANAGEMENT OF ELECTRIC TRACTOR 2022-01-019603/29/2022
The global issues of energy crisis and air pollution have offered a great opportunity to develop electric vehicles. This study investigates the underhood thermal management of the newly introduced electric tractor, with the target of managing the heat generated out from the major heat contributing sources. The alignment of the fan with some design modification has been made on the basis of CFD simulation. For this work, a Reynolds-Averaged Navier-Stokes (RANS) method utilizing the k-Ɛ turbulence model have been implemented in the commercial CFD software STAR-CCM+. The results show that the existing design configuration was not effective enough to handle the cooling requirement of the tractor. The angular orientation of the fan along with a baffle design capable enough to redirect the air in to the desired locations made it possible to achieve the desired cooling even in hot summer days. The closure of the side grills along with the aforementioned baffle modification made us to achieve
Babu, Richu John, Kumar, Vibhay, Salve, Nishant, Kumar, Nayaka
Design optimization of engine cooling system for light duty diesel engine for weight and cost reduction purpose.2022-01-023803/29/2022
In current market situation, automotive makers are targeting light weighting and cost reduction as key areas to improve energy efficiency and total cost of ownership respectively. One such area which is becoming increasing popular is use of alternate cost-effective design solutions in various light duty engine application. In presented approach, engine cooling system for light duty diesel engine has been optimized by use of single fan radiator with resistor unit assy. in place of dual fan radiator assy. Selection of fan motor and new design of shroud was done to achieve weight and cost reduction benefits. Existing dual fan radiator assy. uses a high speed and low speed fan to regulate air flow towards radiator. In novel design, a single fan along with resistor is used to direct the air flow towards radiator and thereby pursue required engine cooling in order to achieve BS-VI emission targets. Finally developed components were verified and validated at vehicle as well as test bed level
DIXIT, Rohan, Khaire, Mahesh, Deshpande, Shirish, Bhargava, Aashish
Proposed Standards And Methods For Leak Testing Lithium-Ion Battery Packs Using Glycol-based Coolant With Empirically Derived Rejection Limits2022-01-084803/29/2022
Lithium-ion batteries are a highly suitable energy source for many applications, particularly in the automotive sector due to their high energy density and low self-discharge rate. During the production of battery cells, rapid detection of leaks is essential to achieve necessary lifetime service-life and safety requirements. Once assembled into packs, whether made of prismatic, cylindrical or pouch cells, packs must be cooled by common automotive thermal management systems, for example those employing engine coolant and radiator, and in which manufacturers must prevent various leak-producing defects that affect durability, longevity and safety Two types of cooling systems are used in automobiles, an active variant in which refrigerant, compressor, evaporator and heat exchanger are used to operate the air conditioning system, or a passive variant with a cooling medium, typically a water/glycol mixture, and a heat exchanger cooled by ambient air. While good industry standards are
Wetzig, Daniel, Blaufuß, Marc
Benefits of a Dual HP and LP EGR Circuit on a Turbocharged Direct Injection Gasoline Engine2022-01-051803/29/2022
Internal combustion engines (ICE) will be a part of personal transportation for the foreseeable future. One recent trend for engines has been downsizing which enables the engine to be run more efficiently over regulatory drive cycles. Due to downsizing, engine power density has increased which leads to problems with engine knock. Therefore, there is an increasing need to find a means to reduce the knock propensity of downsized engines. One of the ways of reducing knock propensity is by introducing Exhaust Gas Recirculation (EGR) into the combustion chamber, however, volumetric efficiency also reduces with EGR which places challenges on the boosting system. The individual benefits of high-pressure (HP-EGR) and low-pressure (LP-EGR) loop EGR system to assist the boosting system of a 2.0 L Gasoline Direct Injection (GDI) production engine are explored in this paper. Further, the benefits of the individual systems are coupled in a ‘Blended-EGR’ concept to generate BSFC maps for each EGR
Handa, Gaurav, Denton, Bradley, Rengarajan, Sankar, Chadwell, Christopher, Conway, Graham
Minimizing Abnormal Noise by Altering Modal Frequency using Numerical Method and Validating through Experimentally2022-01-036603/29/2022
The main Objective of this paper is to remove the abnormal noise by altering the modal frequency. From the numerical method, very high deflection is reported at HVAC assembly level, cause unwanted vibrations. Due to high deflection at low frequency (1st modal frequency), abnormal noise coming near blower assembly under experimentally dynamic conditions. Then, improved the design by adding the stiffeners on the flange to minimize unwanted vibrations and hence abnormal nose. Thereafter, modal frequency has been increased and reduced the high deflection. The same has been validated experimentally with proto sample and found no abnormal noise from the blower side. A good correlation between the numerical and experimental result is observed and matching numerical & experimental modal frequencies within the accuracy of ±10%.
Meena, Avadhesh Kumar
Cross-flow Radiator Design using CFD for FSAE Car Cooling System and its Experimental Validation using the GEMS Data Acquisition System 2022-01-044903/29/2022
The cross flow design of the radiator and the heat transfer, in conjunction with the temperature drop, was simulated and validated by the data acquisition system during the static and dynamic conditions of a car. The optimum design of the radiator decides the engine's operating temperature and the desired temperature drop gain by proper design of the inner core, number of fins and tubes, and the material used for the manufacturing of the radiator. The purpose of the radiator's proper design is to prevent the combustion engine from heating up more than then its operating temperature [1]. The design of the radiator is per CBR 600RR engine operating temperature. The highest temperature recorded around is 105°C, and during the worst condition, it reaches up to 110°C. So, approximately 10°C temperature drop must be there for proper working at operating temperature. The resulting heat dissipated through the water jackets and aluminum tube routing. The cooling temperature sensor(CTS) along
Jain, Jeevesh, Rajagopal, Thundil, Selvaraj, Arunsaco, Devaraj, Elangovan
Research on the Bionic Design and Performance of Engine Cooling Fan with Blade Tip Serrated2022-01-019703/29/2022
Turbulence caused by the blade tip of engine cooling fan is one of important noise generating factors. Existing theoretical researches show that the bionic serrated designs applied at the front and rear edges of fan blades can effectively improve the airflow characteristics and reduce the aerodynamic noise. However, the effect of its application at the blade tip needs to be explored and verified. In this research, vehicle engine fans whose tips are designed and remodeled with different size of triangular serrated edge have been tested on air duct, to explore the fan static pressure and noise that caused by changing of period and amplitude size.The large eddy simulation (LES) and FW-H acoustic analogy method are used to calculate the transient noise of each designed fan.Both experimentation and calculation results show that the application of serrated edge can improve the static pressure efficiency to a certain extent, and have a direct influence on the formation and development of tip
Ma, Zhanlin
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