Browse Topic: Fans

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Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-05791/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges-such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations-no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
PATRA, SOMNATH, HIBARE, NIKHIL, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Impact of density in simulation model for extreme cold ambient conditions2026-26-03881/16/2026
Battery Electric Vehicles (BEVs) necessitate highly efficient thermal management strategies, as cabin heating directly consumes energy from the finite traction battery, potentially reducing driving range significantly. Early-stage design evaluations of warmup performance commonly rely on one-dimensional (1D) simulations due to their computational speed and efficiency. The accuracy and predictive capability of these models are critically dependent on how well they represent blower operation and account for temperature-induced variations in air density. This fidelity is essential because engineers depend on warmup simulations to set HVAC targets that will deliver real‑world comfort and defrost performance within stringent range constraints. Earlier, warmup simulations employed a Constant Mass Flow (CMF) approach, which simplifies computations by assuming a fixed air density at a standard reference temperature. However, this approach contrasts with real-world blower behavior, where
Subramanian, Karthik, Mishra, Abhishek
Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger2026-26-01771/16/2026
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 hydrodynamics2026-26-03841/16/2026
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
Advanced Thermal Management for High-Tonnage EVs: Increasing Coolant Flow and Reducing Energy Losses2026-26-01961/16/2026
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach to
DIXIT, SAMEER, Patil, Bhushan, Ghosh, Sandeep
Evaluating Thermal Control Strategies to Improve Electric Vehicle Range Using GT Suite2026-26-03621/16/2026
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating 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
A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides2026-26-03641/16/2026
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
Thermal System design of Inter-City Fuel Cell Electric Bus2026-26-04271/16/2026
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 Speedgoat2026-26-06851/16/2026
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 Tractor2026-26-01001/16/2026
In Last two decades, Farm customer expectation on Cabin comfort has been increased multifold. To provide the best-in-class customer experience in terms of comfort without adding cost and weight is bigger challenge for all NVH Engineers. It is evident from literature survey that cabin tractors with better comfort is well accepted by customers in US and European Market. Apart from engine excitation, customer has become more sensitive to customer-actuated-accessory noises due to overall reduction in cabin noise in last 2 decades. This paper presents the study conducted on HVAC blower noise in 30HP cabin tractor Tactile vibrations and Cabin Noise is not acceptable when AC is switched on due to low frequency modulating nature in frequency range of ~65Hz and 130Hz. The investigation is carried out systematically considering each component of Source-Path-Receiver model. HVAC blower unit as source is diagnosed in detail to understand root cause. Strong dominance of first order of blower been
K, Somasundaram, Chavan, Amit
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
Effect of Pressure Losses and Reynolds Number on Active Grille Shutter Characteristics and Its Prediction2025-01-50599/10/2025
In the present article it is investigated why active grille shutters (AGS) can have very different aerodynamic characteristics, ranging from progressive to strongly degressive, and which factors influence them. For this purpose, the authority concept known from the field of heating, ventilation, and air-conditioning (HVAC) is referred to. According to this theory, the control characteristics of dampers depend primarily on the ratio of the pressure losses at the fully open damper to the pressure losses of the rest of the system. The adaptation of the concept to the automotive field shows that, in addition to the pressure losses, the geometry of the cooling air ducting plays a decisive role in motor vehicles. The effect of driving speed and fan operation on the characteristic curves is also being investigated. In addition, authority theory can also be used to derive the conditions under which the opening characteristic curve of an AGS provides a good prediction of the real characteristic
Wolf, Thomas
Understanding the Aero-mechanical Behavior of a MGB Cooling FanF-0081-2025-02445/20/2025
The oil cooling fan of a Main Gearbox (MGB) is a mechanically-driven component whose purpose is to force an air flow through an air cooled oil cooler; its performance is crucial in ensuring that the MGB oil temperature does not exceed a predefined threshold, set to alert the crew in case of an abnormal situation. The design and the certification of a cooling fan is a process involving several steps and multiple disciplines; mechanical design, aerodynamic analysis, dedicated tests carried out both on rigs and at aircraft level need to be exploited as complementary tools to assess the correct aero-mechanical behavior of the system. The aerodynamic assessment is associated to performance, measured in terms of MGB oil temperature: considering a comparison between two cooling fans, one outperforms the other if the resultant MGB oil temperature is lower, keeping the same boundary conditions (engine torque, wind speed, ambient temperature, etc.). The correct mechanical behavior is instead
Sangiovanni, Andrea, Scaltritti, Diego, Podda, Daniele, Pisani, Paolo, Sartori, Sergio, Alari, Lorenzo
Modeling Activities of Propulsion System Engine Installation SurveyF-0080-2024-13525/7/2024
The multi-role utility helicopter T625 GÖKBEY is designed by Turkish Aerospace and it is equipped with a pair of two-spool CTS800-4AT turboshaft engine developed by Light Helicopter Turbine Engine Company (LHTEC). Components of the cowlings, intakes and exhausts were designed with supplementing CFD analyses and performance of various alternatives were evaluated. Final designs were achieved based on the helicopter performance and engine limits. In order to verify the estimated engine installed performance in design phase, performance of the instrumented engine with its integrated equipment on the platform is examined using flight test data. This paper focuses on the CFD simulations based performance predictions of the air induction system, exhaust system, and IPS blower exhaust. A comprehensive study is assessed to create more realistic models by using flight test data.
Sancar, Emre, Ezertaş, Ahmet Alper, Bayat, Akay, Çakıroğlu, Taylan, Daldal, Abdurrahman Burak
Effect of Gust on Coaxial Rotors using Free Vortex MethodsF-0080-2024-12625/7/2024
The current work focuses on understanding the aerodynamics of a single and coaxial rotor in hover subjected to 1-minus-cosine gust profiles. The work was performed using an in-house free-vortex method that includes the contribution of unsteady aerodynamic terms using the Duhamel integral. Studies were conducted on the Harrington single and coaxial rotor systems trimmed to CT /σ = 0.1, with the gust duration varying from 1-50 revolutions of the rotor, i.e., 0.3 - 15 seconds. Gust amplitudes were also varied from 0.1ωR-0.3ωR. Results were analyzed in terms of the deviation of thrust from the hover values, the frequency content of this signal, angle of attack variations across the span, and the structure of the wake as the system goes through the gust event. It was noted that for single and coaxial rotors, edgewise gusts result in higher frequency components being present in the thrust compared to the axial gust. Large changes in the angle of attack were observed, which could potentially
Narayanan, Shrivathsan, Govindarajan, Bharath, Chandel, Aaditya
HVAC NVH Refinement in Electric Vehicle2024-26-02061/16/2024
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
Development of Fuel efficiency Enhancement Module for tractors2024-26-00641/16/2024
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 Vehicles2024-26-01321/16/2024
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
Thermal Performance Prediction of Roots blower Using Coupled 3-D Multiphase CFD Thermal simulation with Experimental Validation2024-26-02971/16/2024
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
The Experimental Study of Reducing Cooling Fan Noise using Test Bench2025-01-01085/5/2023
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
Simulation of Pass-by Fan Noise Emissions and Advancing Test Regulations for Heavy-Duty Electric Vehicles2025-01-00865/5/2023
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 Engine88-16-02-00111/2/2023
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 Engine01-16-02-00111/2/2023
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.
UNDERHOOD THERMAL MANAGEMENT OF ELECTRIC TRACTOR 2022-01-01963/29/2022
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.2022-01-02383/29/2022
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
Minimizing Abnormal Noise by Altering Modal Frequency using Numerical Method and Validating through Experimentally2022-01-03663/29/2022
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
Research on the Bionic Design and Performance of Engine Cooling Fan with Blade Tip Serrated2022-01-01973/29/2022
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
Multiple Heat Exchangers for Automotive Systems – A Design Tool2022-01-02053/29/2022
A single radiator cooling system architecture has been widely applied in ground vehicles for safe equipment (e.g., engine block, electronics, and motors) temperature control. The introduction of multiple smaller heat exchangers provides additional energy management features and alternate pathways for continued operation in case of critical subsystem failure. Although cooling performance is often designed for maximum thermal loads, systems typically operate at a fraction of the peak values for most of their life cycle. In this project, a two-radiator configuration with variable flow rates and valve positions has been mathematically modelled and experimentally validated to study its performance feasibility. A multi-node resistance-capacitance thermal model was derived using the ε-NTU approach with accompanying convective and conductive heat transfer pathways within the system. This engineering model provides an analytical description of the system behavior that can be leveraged for
Syed, Zaker, Miller, Richard, Wagner, John
Self-Propelled Sweepers and Scrubbers Tank and Hopper Capacity RatingJ1793_202111 (Current)11/9/2021
This SAE Standard applies to self-propelled sweepers and scrubbers as defined in SAE J2130-1 and J2130-2.
MTC2, Sweeper, Cleaner, and Machinery
Experimental investigation of thermal safety of the IC engine in the event of coolant loss2021-28-015210/1/2021
Power density (power/engine cubic capacity) of the latest passenger car Diesel and Gasoline engine keeps increasing with a focus to deliver best in class performance along with meeting CAFE and emission norms. This increase in power density increases the thermal load onto the coolant system. Coolant temperature sensor monitoring the coolant temperature, proper radiator sizing, optimum water pump flow capacity and thermostat tuned to the required coolant temperature range are the typical measures taken to ensure safe operation of the engine and avoid any over-heating. Typical cooling system failures are mostly due to low coolant level, a defective thermostat, non-operative water pump & fan and blockage in the coolant circuit, etc. Most of these failures can be detected with the help of coolant temperature sensor and pre-emptive measures can be taken to avoid engine loss. However, in the event of complete loss of coolant in the engine, the coolant temperature sensor will become
Sithick basha, Abubakker, NAMANI, Prasad, Sebastian, Ranjit George, Malekar, Amit, Vellandi, Vikraman
Methodology development for Open Station Tractor OEL Noise Assessment in the Virtual Environment2021-26-03109/22/2021
There is a higher demand for quieter tractors in the agri-industry, as the continued exposure to noise levels have disastrous effects on operator’s health. To meet the world-wide regulatory norms and to be the global market leader, its mandatory to develop the comfortable tractor which meets homologation requirements and customer expectations. Typically, Operator Ear Level (OEL) noise has been evaluated in the test, after First Proto has been made. This approach increases cost associated with product development due to late changes of modifications and testing trails causing delay in time-to-market aspect. Hence, there is a need to develop the methodology for Predicting tractor OEL noise in virtual environment and propose changes at early stage of product development. At first, full vehicle comprising of skid, sheet metals and Intake-exhaust systems modelled has been built using Finite Element (FE) Preprocessor. In this methodology, reverse acoustic modelling approach has been used to
gunasekaran, pandiyanayagam, Chavan, Amit, K, Somasundaram
Reduction of Aeroacoustics Tonal Noise for a Tractor Cooling Fan2021-26-02999/22/2021
Currently, noise pollution has become one of the major environmental concerns. To address this, new noise standards and regulations are being introduced and mandate the tractor OEM's to meet the defined noise levels. Fan noise from the cooling fan is one of the key contributors to the overall vehicle noise. Hence, the reduction of fan noise at the source is a very important and critical task. Even though fan noise is broadband in nature its aerodynamic noise sources are most dominant at the higher harmonics of the blade pass frequency (BPF). Aerodynamic noise of a fan can be varied by changing the fan geometry viz. blade profile, fan width & diameter, no. of blades, and ring on its periphery. Cooling fan is an important component of the cooling system which ensures adequate airflow for radiator cooling and avoids engine overheating with uniform heat dissipation. The important parameters that need to be considered while designing a cooling fan are noise level, airflow, and power
Avinash, D., Shankar, M, Maller, Rathish, V, Ravindran
Methodology for optimized automotive grill opening area prediction based on 1D simulation approach and correlation with prototype test Model2021-28-01339/15/2021
This paper discusses the methodology setup for grill opening area prediction at the early development phase of product development lifecycle, using commercially available 1D simulation tool- AMESIM. Representative under hood has been modeled using Grill, Condenser, Radiator, intercooler, fan and engine components. Vehicle velocity is used as an input to derive the airflow passing through the grill and other under-hood components based on ram air coefficient, pressure drop through different components (Grill, Heat exchanger, Fan & Engine). This air flow is used to predict the top tank temperature of radiator. Derived airflow is correlated with air flow obtained from CFD simulation. A balance has been achieved between cooling drag & fan power consumption at different grill opening area for Target Top tank temperature. Top tank temperature has been predicted at two different extreme engine heat rejection operating points. Proposed methodology has shown good correlation with prototype
pauriyal, Rohit Chandra, Thiyagarajan, Rajesh
Innovative Control and Monitoring Algorithms and Strategies Based on Judicious Functional Partitioning and Frugal Engineering Concepts2021-01-01244/6/2021
As embedded electronic control systems are increasingly penetrating vehicle subsystems, the designers are faced with a dilemma of providing state of art vehicle features on one hand and ensuring frugal implementation of the same to meet competitive pressures on the other. For embedded software and hardware systems this means adoption of judicious and innovative design choices with reusable building blocks. This paper dwells upon various design aspects of control and monitoring which are frequently used for automotive applications such as feed-forward and proportional integral control, diagnostics for sensor boundary conditions, handling of intermittent faults without causing nuisance to the vehicle users etc.
Vaidya, Vishwas Manohar
6.0.120 - Investigation of the Applicability of Numerical Noise Prediction of an Axial Vehicle Cooling FanSAE-PP-002752/4/2021
This paper focuses on the applicability of numerical prediction of sound radiation caused by an axial vehicle cooling fan. To investigate the applicability of numerical methods, a hybrid approach is chosen where first a CFD simulation is performed and the sound radiation is calculated in a second step. For the acoustic simulation an integral method described by Ffowcs-Williams-Hawkings is used to predict the sound propagation in the far-field. The simulation results are validated with experiments. The corresponding setup in experiments and simulation represents an overall system which includes the cooler, the cooling fan and a combustion engine dummy. To optimize the economical applicability in terms of simulation setup and run time, different approaches are investigated. This includes the simulation of only one blade using a periodic boundary condition as compared to the whole fan geometry. In the CFD simulation an SAS-turbulence-model is applied. The results show that this is a very
Mutagaana, Festo
3D-Printed Sweating Robot MuscleTBMG-3800711/1/2020
One of the hurdles for making enduring, adaptable, and agile robots is managing the robots’ internal temperature. If the high-torque-density motors and exothermic engines that power a robot overheat, the robot will cease to operate. This is a particular issue for soft robots made of synthetic materials. While more flexible, they hold their heat unlike metals, which dissipate heat quickly. An internal cooling technology, such as a fan, may not be much help because it would take up space inside the robot and add weight.
Numerical Study of Distributed Variable Geometry Ducted Fans for eVTOLsF-0076-2020-1648210/5/2020
The effects of key design parameters of tilting distributed ducted fans are investigated through steady-state CFD simulations to assess the benefits of using variable geometry ducts in urban air mobility applications. The analysis is made on three adjacent ducted fans mounted at the trailing edge of a semi-span wing. The fans are represented by body forces calculated using the blade element theory. The duct expansion ratio, the duct thickness and the fan design expansion ratio are varied along with the fan speed, the crosswind speed in hover and the airspeed in forward flight. For each combination of the parameters, the hover Figure of Merit and crosswind stall speed as well as the forward flight lift coefficient, thrust coefficient and propulsive efficiency are evaluated. From these results, variable geometry ducted fans are benchmarked against fixed geometry ducted fans using a simplified 1 hour mission with 10% of hover time. It is found that a ducted fan equipped with a Krueger
Marois, Francis, Picard, Mathieu, Rancourt, David
Enhancement and Validation of VPM-Derived State-Space Inflow Models for Multi-Rotor SimulationF-0076-2020-1628710/5/2020
State-space inflow models have long been the standard for rotor wake modeling for flight dynamics and control simulation. As rotorcraft design continues to trend toward Future Vertical Lift (FVL) multi-rotor configurations in order to overcome the limitations of traditional design, the use of state space inflow models must similarly evolve to capture the complex aerodynamic interactions inherent to these new rotorcraft configurations. There is a demand for a state-space inflow model that accurately captures the significant aerodynamic interactions that occur between multiple rotors, ducted fans, wings, and complex airframes that preexisting inflow formulation fails to address. This paper discusses the ongoing effort to establish a robust methodology for deriving a state-space inflow model suitable for FVL applications from first-principle based viscous Vortex Particle Method (VPM) using the CIFERR system identification tool. The paper focuses on areas of enhancement that expand the
Gladfelter, Matthew, Tischler, Mark, Juhasz, Ondrej, He, Chengjian, Chang, Chongseok, J., Mark
Numerical Investigation of Narrow-Band Noise Generation by Automotive Cooling Fans2020-01-15136/3/2020
Axial cooling fans are commonly used in electric vehicles to cool batteries with high heating load. One drawback of the cooling fans is the high aeroacoustic noise level resulting from the fan blades and the obstacles facing the airflow. To create a comfortable cabin environment in the vehicle, and to reduce exterior noise emission, a low-noise installation design of the axial fan is required. The purpose of the project is to develop an efficient computational aeroacoustics (CAA) simulation process to assist the cooling-fan installation design. This paper reports the current progress of the development, where the narrow-band components of the fan noise is focused on. Two methods are used to compute the noise source. In the first method the source is computed from the flow field obtained using the unsteady Reynolds-averaged Navier-Stokes equations (unsteady RANS, or URANS) model. In the second method, the azimuthal modes of the flow field obtained using the steady RANS with the moving
Fares, Omar, Weng, Chenyang, Zackrisson, Linus, Yao, Huadong, Knutsson, Magnus
Installation Effects on the Flow Generated Noise From Automotive Electrical Cooling Fans2020-01-15166/3/2020
With the electrification of road vehicles comes new demands on the cooling system. Not the least when it comes to noise. Less masking from the driveline and new features, as for example, cooling when charging the batteries drives the need for silent cooling fans. In this work a novel e-fan is studied in different generalized installations and operating conditions. The fans (a cluster configuration) are installed in a test rig where the operation could be controlled varying the speed, flow rate and pressure difference over the fan. On the vehicle side of the fan a generalized packaging space (similar to an engine bay for conventional vehicles) is placed. In this packaging space different obstruction can be placed to simulate the components and radiators used in the vehicle. Here generalized simple blocks in different configuration are used to provide well defined and distinct test cases. Of special interest are cases with poor inlet flow profile and the influence of this on the sound
Karlsson, Mikael, Etemad, Sassan
Wearable Air ConditioningTBMG-368445/1/2020
One day, soldiers could cool down on the military battlefield — preventing heat stroke or exhaustion — by using wearable air conditioning, an on-skin device that offers numerous human healthcare applications such as the ability to monitor blood pressure, electrical activity of the heart, and the level of skin hydration.
How Ford mobilized its engineers in the COVID-19 fight20AUTP05_075/1/2020
The fight against COVID-19 forced disparate industries to collaborate on a technical level not seen since World War II, in order to boost supply of vital medical equipment. In just one of many industry-wide examples, creativity and speed were key to Ford Motor Co.'s partnership with 3M and GE Healthcare: they teamed to rapidly boost production of the urgently-needed face shields and bring solutions for simpler, easier-to-make designs of respirators and ventilators. The unusual triad's progress within the first 10 days together demonstrated their ability to deliver technical solutions quickly, while united against a common foe. “Engineers are all about problem solving, and in this crisis the three organizations are speaking the same language,” said Marcy Fisher, Ford's director of global body exterior and interior engineering, in late March; Fisher is leading multiple Ford teams in the partnership. “We're working around the clock with 3M and GE Healthcare and have learned from them and
Brooke, Lindsay
RDE Plus - A Road to Rig Development Methodology for Whole Vehicle RDE Compliance: Overview2020-01-03764/14/2020
To aid Original Equipment Manufacturers (OEM) in meeting Real Driving Emissions (RDE) regulation criteria [1] across the moderate and extended boundary conditions of temperature, altitude and driving style, an integrated Road to Rig (R2R) whole vehicle development, calibration and verification approach known as RDE Plus (RDE+) has been developed by HORIBA. Connecting testing on the road, chassis dynamometer, Engine-in-the-Loop (EiL) and virtual testing methodologies, real world driving scenarios can be deployed by OEMs further upstream during vehicle and engine development programmes; hence reducing development timescales and costs that will otherwise inevitably increase due to RDE regulations. Reported in the current paper is a brief introduction to the baseline RDE road tests followed by replication of several real RDE cycles that cover the RDE moderate and extended boundary conditions with the vehicle driven by a robot driver on the chassis dynamometer. A HORIBA Multi-function
Roberts, Philip, Mason, Alex, Whelan, Steve, Tabata, Kunio, Kondo, Yosuke, Kumagai, Tatsuki, Mumby, Richard, Bates, Luke
Experimental Analysis of a Multiple Radiator Cooling System with Computer Controlled Flow Rates2020-01-09444/14/2020
The automotive cooling system configuration has remained fixed for many decades with a large radiator plus fan, coolant pump, and bypass valve. To reduce cooling system power consumption, the introduction of multiple computer-controlled heat exchangers may offer some benefits. A paradigm shift from a single large radiator, sized for maximum load, to n-small radiators with individual flow control valves should allow fine tuning of the heat rejection needs to minimize power. In this project, a series of experimental scenarios featuring two identical parallel radiators have been studied for low thermal load engine cooling (e.g., idling) in ground transportation applications. For high thermal load scenarios using two radiators, the fans required between 1120 - 3600 W to maintain the system about the coolant reference temperature of 85oC. In contrast at reduced thermal loads, a single radiator configuration with half the heat transfer surface area required between 550 - 1000 W for the same
Syed, Zaker, Wagner, John
Thermal Considerations for IncubatorsTBMG-364194/1/2020
Incubators, used for cell and tissue cultivation in hospital and laboratory settings, grow and maintain cell and tissue samples under controlled conditions for hours, weeks, or even months. They create the ideal environment for cell and tissue sample growth by maintaining optimum levels for temperature, humidity, carbon dioxide, and oxygen. Precision control of these factors enables research and experimental work in industries where cell culture is vital.
Lightyear One: 20 miles of solar driving range20AUTP04_114/1/2020
It's been more than a decade since Toyota first developed a photovoltaic system for the roof of a Prius hybridelectric vehicle (HEV). Those solar cells, available on Japan-based models around 2010, had a peak capacity of 50 watts - generating only enough power to run auxiliary devices such as a ventilation fan. Further development for the past 10 years by Toyota, as well as Hyundai, Nissan and Tesla, opened the possibility of a vehicle's rooftop solar charging an electric vehicle's (EV's) batteries, adding maybe a few miles of range when the vehicle is left in the blazing sun for a several hours. Those efforts were baby steps compared to Lightyear One, the the ground-up, “solar EV” created by Lightyear, the startup based in Helmond, Netherlands.
Berman, Bradley
Replacing Twin Electric Fan Radiator with Single Fan Radiator2019-28-238111/21/2019
Downsizing is one of the crucial activities being performed by every automotive engineering organization. The main aim is to reduce - Weight, CO2 emissions and achieve cost benefit. All this is done without any compromise on performance requirement or rather with optimization of system performance. This paper evaluate one such optimization, where-in radiator assembly with two electric fan is targeted for downsizing for small commercial vehicle application. The present two fan radiator is redesigned with thinner core and use of single fan motor assembly. The performance of the heat exchanger is tested for similar conditions back to back on vehicle and optimized to get the balanced benefit in terms of weight, cooling performance and importantly cost. This all is done without any modification in vehicle interface components except electrical connector for fan. The side members and brackets design is also simplified to achieve maximum weight reduction. Further Cooling system performance of
Bhargava, Aashish, Soni, Gaurav, Warkhade, Tushar
Maintenance of Design Voltage - Snowmobile Electrical SystemsJ277_201909 (Current)9/25/2019
This SAE Recommended Practice provides test methods and requirements for maintenance of design voltage in snowmobile electrical systems. It pertains to both battery-equipped and battery-less systems.
Snowmobile Technical Committee
Terahertz Data Links Without Direct Line of SightTBMG-351439/1/2019
Today’s cellular networks and Wi-Fi systems rely on microwave radiation to carry data but the demand for more bandwidth is quickly becoming more than microwaves can handle. That has researchers thinking about transmitting data on higher-frequency terahertz waves, which have as much as 100 times the data-carrying capacity of microwaves. But terahertz communication technology is in its infancy — there is much basic research to be done and plenty of challenges to overcome.
Intelligent Motion Controls for Smarter Air FlowTBMG-348167/1/2019
No longer a trend, automation has become the foundation in technology for manufacturing. This article addresses three areas that require new thinking and innovative approaches for next-generation cooling technology manufacturing: where intelligent motion controls are used, whether they increase product life and performance, and what they protect.
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