Browse Topic: Fans

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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
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.
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
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
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
Multiple Heat Exchangers for Automotive Systems – A Design Tool2022-01-020503/29/2022
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)11/09/2021
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 loss2021-28-015210/01/2021
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 Environment2021-26-031009/22/2021
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 Fan2021-26-029909/22/2021
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 Model2021-28-013309/15/2021
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
6.0.120 - Investigation of the Applicability of Numerical Noise Prediction of an Axial Vehicle Cooling FanSAE-PP-0027502/04/2021
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
Numerical Investigation of Narrow-Band Noise Generation by Automotive Cooling Fans2020-01-151306/03/2020
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 Fans2020-01-151606/03/2020
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
Experimental Analysis of a Multiple Radiator Cooling System with Computer Controlled Flow Rates2020-01-094404/14/2020
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
Lightyear One: 20 miles of solar driving range20AUTP04_1104/01/2020
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
Thermal Considerations for IncubatorsTBMG-3641904/01/2020
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.
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)09/25/2019
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
Intelligent Motion Controls for Smarter Air FlowTBMG-3481607/01/2019
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.
Simulation of Ice Particle Breakup and Ingestion into the Honeywell Uncertified Research Engine (HURE)2019-01-196506/10/2019
Numerical solutions have been generated which simulate flow inside an aircraft engine flying at altitude through an ice crystal cloud. The geometry used for this study is the Honeywell Uncertified Research Engine (HURE) which was recently tested in the NASA Propulsion Systems Laboratory (PSL) in January 2018. The simulations were carried out at predicted operating points with a potential risk of ice accretion. The extent of the simulation is from upstream of the engine inlet to downstream past the strut in the core and bypass. The flow solution is produced using GlennHT, a NASA in-house code. A mixing plane approximation is used upstream and downstream of the fan. The use of the mixing plane allows for steady state solutions in the relative frame. The flow solution is then passed on to LEWICE3D for particle trajectory, impact and breakup prediction. The LEWICE3D code also uses a mixing plane approximation at the boundaries upstream and downstream of the fan. A distribution of particle
Rigby, David L., Wright, William, Flegel, Ashlie, King, Michael
An Ice Shedding Model for Rotating Components2019-01-200306/10/2019
A CFD simulation methodology is presented to evaluate the ice that sheds from rotating components. The shedding detection is handled by coupling the ice accretion and stress analysis solvers to periodically check for the propagation of crack fronts and possible detachment. A novel approach for crack propagation is highlighted where no change in mesh topology is required. The entire computation from flow to impingement, ice accretion and crack analysis only requires a single mesh. The accretion and stress module are validated individually with published data. The analysis is extended to demonstrate potential shedding scenarios on three complex industrially-relevant 3D cases: a helicopter blade, an engine fan blade and a turboprop propeller. The largest shed fragment will be analyzed in the context of FOD damage to neighboring aircraft/component surfaces.
Nilamdeen, Shezad, Zhang, Yue, Ozcer, Isik, Baruzzi, Guido S.
An Experimental Study to Evaluate Hydro-/Ice-Phobic Coatings for Icing Mitigation over Rotating Aero-engine Fan Blades2019-01-198006/10/2019
Ice accretion on aero-engines, especially on the fan blades, is the very hazardous icing incident due to the potential performance degradation of jet-engines. In the present study, an experimental investigation was conducted to examine the performance of ice-phobic coatings for jet-engine fan icing mitigation. The experimental study was performed in the unique Icing Research Tunnel at Iowa State University (ISU-IRT) with a scaled engine fan model operated under wet glaze and dry rime ice conditions. To evaluate the effects of anti-icing coatings and to acquire the important details of ice accretion and shedding process on fan blade surfaces, a “phase-locked” imaging technique was applied with a high-resolution imaging system. The power input required to drive the engine fan model rotating at a constant prescribed speed was also measured during the ice accretion experiment. It was found that both super-hydrophobic surface (SHS) and ice-phobic coating have its advantage in engine anti
Tian, Linchuan, Liu, Yang, Li, Linkai, Hu, Hui
Design and Experiment on Aircraft Electromechanical Actuator Fan at Different Altitudes and Rotational Speeds01-12-01-000306/07/2019
For electromechanical actuators (EMAs) and electronic devices cooling on aircraft, there is a need to study cooling fan performance at various altitudes from sea level to 12,000 m where the ambient pressure varies from 1 to 0.2 atm. As fan static pressure head is proportional to air density, the fan’s rotational speed has to be increased significantly to compensate for the low ambient pressure of 0.2 atm at the altitude of 12,000 m. To evaluate fan performance for EMA cooling, a high-rotational-speed, commercially available fan made by Ametek with a diameter of ~82 mm and ~3 m3/min zero-load open cooling flow rate when operating at 20,000 rpm was chosen as the baseline. According to fan scaling laws, this fan was expected to meet the cooling needs for an EMA when operating at 0.2 atm. Using a closed flow loop, the performance of the fan operating in the above ambient pressure range and at a rotational speed between 15,000 and 30,000 rpm was evaluated. Unexpectedly, at 0.2 atm, the
Wu, Wei, Lin, Y.R., Gyasi, E., Kizito, J.P., Leland, Q.H., Chow, L.C.
Fuel Efficiency Technology Impact on Radiator Thermal Durability2019-01-049804/02/2019
With the increasing stringency of emission regulations, auto makers are now improving vehicle fuel efficiency via all kinds of technologies, such as hybrid systems, turbocharged or supercharged engines, engine auto start/stop, active grille shutters, etc. By implementing a variety of technologies, the engine cooling module’s working environment and work load has changed. This paper will mainly focus on the impact to the thermal durability of the engine cooling module’s main radiator from active grille shutter and electric thermostat implementation. A 2017MY hybrid vehicle using the above technology is evaluated by a wind tunnel test at a variety of ambient temperatures and driving conditions. First, such technologies’ control logic is studied by the wind tunnel test, so that the evaluation condition for evaluating the radiator’s thermal stress can be properly chosen to represent the actual field usage. Then, a single variable method is used to understand the difference in thermal
Tian, Yilin
Fan Guard for Off-Road MachinesJ1308_201901 (Current)01/10/2019
This practice applies to guarding of engine cooling fans used on Off-Road Self-Propelled Work Machines defined in SAE J1116. It does not include guarding for belts, pulleys, or other rotating equipment used on these machines.
OPTC1, Personnel Protection (General)
Radiator NomenclatureJ631_201810 (Current)10/09/2018
This SAE Recommended Practice documents nomenclature in common use for various types of radiator and radiator core construction, as well as for various radiator-related accessories.
Cooling Systems Standards Committee
SAE Eye on Engineering: Future of Chrysler and Dodge1235906/14/2018
Recently Fiat Chrysler chairman Sergio Marchionne presented his final 5-year plan for the company, before he retires next year. In this episode of SAE Eye on Engineering, Editor-in-Chief Lindsay Brooke looks at the future for FCA including worries for fans of Chrysler and Dodge. SAE Eye on Engineering also airs Monday mornings on WJR 760 AM Detroit's Paul W. Smith Show.
Novel Turboelectric Aircraft DesignTBMG-2886105/01/2018
NASA Langley Research Center has developed a novel aircraft design that can carry 150+ passengers over a range of 3,500 nautical miles. Key features include a turboelectric propulsion system, twin underwing turbofans, and a rear-fuselage, electrically driven, boundary layer ingesting fan. The design is developed for single-aisle-class aircraft (the largest commercial transport class in the world) to significantly reduce fuel burn compared to current aircraft.
Analytical Investigation of Fan Shroud on a Thermal Heat Exchanger for Automotive Applications2017-28-195107/10/2017
Thermal management is one of the most challenging and innovative aspects of the automotive industry. The efficiency of the vehicle cooling framework unequivocally relies upon the air stream through the radiator core. Significant advances in thermal management are being embraced in the field of radiator material and coolant. The radiator shouldn't be exclusively credited for the reliable cooling of the engine. There are other auto parts that play an essential role in keeping engine temperature at a manageable level. The fan-shroud assembly is an important component of the cooling system. While the fan is responsible for drawing in air, the fan shroud's job is to ensure uniform air distribution to the radiator core. By assisting airflow in the engine compartment the fan shroud helps in dismissing excess heat from the engine. This assembly also prevents the recirculation of heated air through the cooling fan. This paper endeavors to bring forth a new design and an improvement in the
Gopal, K Nantha, Ashok, B., Bahuguna, Rishabh, Prasad, Tanmay
Fan Noise Prediction for Off-Highway Vehicle2017-01-183406/05/2017
Fan noise can form a significant part of the vehicle noise signature and needs hence to be optimized in view of exterior noise and operator exposure. Putting together unsteady CFD simulation with acoustic FEM modeling, tonal and broadband fan noise can be accurately predicted, accounting for the sound propagation through engine compartment and vehicle frame structure. This paper focuses on method development and validation in view of the practical vehicle design process. In a step by-step approach, the model has been validated against a dedicated test-set-up, so that good accuracy of operational fan noise prediction could be achieved. Main focus was on the acoustic transfer through the engine compartment. The equivalent acoustic transfer through radiators/heat exchangers is modeled based on separate detailed acoustic models. The updating process revealed the sensitivity of various components in the engine compartment. Unsteady CFD included the build-up of a sliding mesh model which was
von Werne, Dirk, Chaduvula, Prasanna, Stahl, Patrick, Jordan, Michael, Huber, Jamison, Kucukcoskun, Korcan, Niculescu, Mircea
Rugged Smart DisplaysTBMG-2718006/01/2017
General Micro Systems, Inc. Rancho Cucamonga, CA 800-307-4863
Musclecar Godzilla: Dodge Reveals 840-hp Challenger SRT Demon17AUTP05_1205/01/2017
After months of teasing and a high-profile tie-in with the Fast & Furious film franchise, at the New York auto show FCA's Dodge division revealed its 2018 Challenger SRT Demon, a drag racer-in-street-clothes featuring an 840-hp variant of the now-famous 6.2-L supercharged OHV V-8 that the company boldly claimed makes the Challenger Demon the quickest production car in the world. Revealing the Demon at an event on the eve of the 2017 New York auto show, Tim Kuniskis, head of passenger cars- Dodge, SRT, Chrysler and FIAT, for FCA North America, catalogued the Demon's list of claimed firsts or record-setting accomplishments, most delivered by the car's heavily-revised Hemi V8. Kuniskis said the Demon is the world's fastest production vehicle to accelerate through the quarter mile, doing so in 9.65 s at a trap speed of 140 mph (225 km/h); the industry-standard metric of 0-60 mph (97 km/h) acceleration is dispatched in 2.3 s, which he claimed also is the world's best, although that figure
Visnic, Bill
Calibration and Demonstration of Vehicle Powertrain Thermal Management Using Model Predictive Control2017-01-013003/28/2017
Control of vehicle powertrain thermal management systems is becoming more challenging as the number of components is growing, and as a result, advanced control methods are being investigated. Model predictive control (MPC) is particularly interesting in this application because it provides a suitable framework to manage actuator and temperature constraints, and can potentially leverage preview information if available in the future. In previous SAE publications (2015-01-0336 and 2016-01-0215), a robust MPC control formulation was proposed, and both simulation and powertrain thermal lab test results were provided. In this work, we discuss the controller deployment in a vehicle; where controller validation is done through road driving and on a wind tunnel chassis dynamometer. This paper discusses challenges of linear MPC implementation related to nonlinearities in this over-actuated thermal system. Specifically, the fan and grill shutter actuators have a nonlinear influence on the
Bonkoski, Phillip, Karnik, Amey Y., Fuxman, Adrian
Numerical and Experimental Investigation on Heat Exchange Performance for Heat Dissipation Module for Construction Vehicles2017-01-062403/28/2017
In this work, a XD132 Road Roller from XCMG in China was employed as a research basis to study the heat exchange performance of the heat dissipation module under varied working conditions. The module in the XD132 consists of a cooling fan and three radiators. At first, the numerical investigation on the elementary units of radiators was performed to obtain Colburn j factor and Fanning friction f factor, which were used for the ε-NTU method to predict the radiator performance. The fan was numerically tested in a wind test tunnel to acquire the performance curve. The performance data from both investigations were transformed into the boundary conditions of the numerical vehicle model in a virtual tunnel. A field experiment was carried out to validate the simulation accuracy, and an entrance coefficient was proposed to discuss the performance regularity under four working conditions. The results show that the simulation results of radiators and fans could be applied to the vehicle
Liu, Jiaxin, Qin, Sicheng, Jiang, Yankun, He, Shumo
Reducing the Acoustic Surface Power of a Cooling Fan Using the Mesh Morpher Optimizer2017-01-161003/28/2017
Cooling fans have many applications in industrial and electronic fields that remove heat away from the system. The process of designing a new cooling fan with optimal performance and reduced acoustic sources can be fairly lengthy and expensive. The use of CFD with support of mesh morphing, along with the development of optimization techniques, can improve the acoustic’s performance of the fan model. This paper presents a new promising method which will support the design process of a new cooling fan with improved performance and less acoustic surface power generation. The CFD analysis is focused on reducing the acoustic surface power of a given cooling fan’s blade using the surface dipole acoustic power as the objective function, which leads to an optimized prototype design for a better performance. The Mesh Morpher Optimizer (MMO) in ANSYS Fluent is used in combination with a Simplex model of the broadband acoustic modeling. The broadband model assists to estimate the acoustic power
Kheirallah, Mike, Jawad, Badih, Liu, Liping
Experimental Investigation of the Impact of Nanofluids on Heat Transfer Performance of a Motorcycle Radiator2017-01-161103/28/2017
In the present work, the effect of various nanofluids on automotive engine cooling was experimentally studied. Al2O3, TiC, SiC, MWNT (multi-walled nanotube), and SiO2 nanoparticles with average diameter ranging between 1 and 100 nm were mixed with distilled water to form nanofluids. An ultrasonic generator was used to generate uniform particle dispersion in the fluid. A compatibility test was carried out on all nanofluids and it was found that TiC, MWNT, and Si3N4 nanoparticles settled and separated from the fluid within 3 hours after preparation. The engine cooling performance testing setup consisted of an Aprilia SXV 450 engine, the nanofluid cooling loop, a radiator, a fan, etc. Thermocouples and resistance temperature detectors (RTD’s) were attached to the inlet and outlet of the radiator hose to monitor the temperature changes taking place in the cooling system. A flowmeter was attached to the inlet hose of the radiator to monitor the coolant flow rate. Results of heat transfer
Mathivanan, Elankathiravan, Gasior, David, Liu, Liping, Yee, Kingman, Li, Yawen
Thermal Protection of Rear Mounted Engine and Its Components Using a Ventilation Fan with Unique Monitoring and Fault Diagnosis Technique2017-01-062003/28/2017
The engine compartment of passenger car application contains various source which radiates the produced heat and raises the temperature level of the compartment. The rise in compartment temperature increases the body temperature of individual component. The rise in body temperature of critical components can endanger the durability or functionality of the specific component or a system in which it operates. The aim of this paper is to strategize thermal protection of the rear mounted engine and its components of a vehicle having radiator and cooling fan mounted in front. An additional ventilation fan with speed sensor is fitted alongside rear mounted engine and a unique monitoring technique framed in the EMS ECU to protect critical components like HT cables, alternators, ECUs, wiring harness etc. from thermal damage. The EMS continuously monitors the engine speed, vehicle speed and the PWM signal of ventilation fan to ensure the intended operation of the ventilation fan. With the
Parmar, Chandrakant, Tyagarajan, Sethuramalingam, Tiwari, Sashikant, Thonge, Ravindra, Paul, S Arun
Fan Shroud Design for Low Speed Damageability2017-01-130003/28/2017
An engine cooling system in an automotive vehicle comprises of heat exchangers such as a radiator, charge air cooler and oil coolers along with engine cooling fan. Typical automotive engine-cooling fan assembly includes an electric motor mounted on a shroud that encloses the radiator core. One of main drivers of fan shroud design is Noise, Vibration, and Harshness (NVH) requirements without compromising the main function of airflow for cooling requirements. In addition, there is also a minimum stiffness requirement of fan shroud which is often overlooked in arriving at optimal design of it. Low Speed Damageability (LSD) assessment of an automotive vehicle is about minimizing the cost of repair of vehicle damages in low speed crashes. In low speed accidents, these fan motors are subjected to sudden decelerations which cause fan motors to swing forward thereby damaging the radiator core. So designing fan shroud for low speed damageability is of importance today. In this paper, the design
Jayachandran, Raj, Alavandi, Bhimaraddi, Niesluchowski, Matt, Low, Erika, Miao, Yafang, Zhang, Yi
Cooling Your Embedded System: What Can Your Open Standard Architecture Handle?TBMG-2643702/01/2017
Embedded computing systems for Mil/Aero applications are often conduction-cooled in an ATR or nonstandard chassis. However, there are many designs that require 19" rackmount systems with forced-air cooling. As more processing performance is packed into tight spaces, enclosures that provide advanced cooling options are increasingly common.
Cooling Your Embedded System17AERP02_0202/01/2017
What Can Your Open Standard Architecture Handle? Embedded computing systems for Mil/Aero applications are often conduction-cooled in an ATR or nonstandard chassis. However, there are many designs that require 19″ rackmount systems with forced-air cooling. As more processing performance is packed into tight spaces, enclosures that provide advanced cooling options are increasingly common. The open-standard embedded architectures have different recommended limitations for power. Sometimes these are electrical pinout limitations, and other times they are recommended thermal limitations. There are “tricks of the trade” to extend the power for certain architectures as well as the ability to maximize the thermal limits.
Design Optimization of Automotive Radiator Cooling Module Fan of Passenger Vehicle for Effective Noise Management Using CFD Technique2017-26-018301/10/2017
An automotive radiator cooling fan has been observed to be an important noise source in a vehicle and with increasing noise refinements, the need for a quieter but effective fan is of utmost importance. Although some empirical prediction techniques are present in literature, they are not sufficiently accurate and cannot give a detailed view of the entire noise spectrum and the various noise prone zones. Hence the need for highly accurate Computational Fluid Dynamics (CFD) study is essential to be able to resolve the minute acoustic stress. Large Eddy Simulation technique in CFD is used to resolve the minute scales of motion in the flow as the sound pressures simulated are very small compared to system level pressures and require immense accuracy. Detailed mesh dependency and Y+ studies are conducted to implement higher accuracy as well as keep mesh requirements within computationally feasible zone. The numerical results obtained by the CFD study is corroborated against the test results
Tare, Kedar, Mukherjee, Uttiya, Vaidya, Rohit J
Effect of Variable Cooling System for Fuel Economy Improvement on Scooter with Air Cooled Engine2016-32-009211/08/2016
A variable cooling system has been developed for scooters equipped with an air cooled, four-stroke, single cylinder gasoline engine. This system opens or closes louver located at the cooling air inlet using an oil-temperature sensitive actuator. When the engine is cold or the engine load is low, the louver shut off the cooling air for a quick warm-up and for maintaining the engine oil temperature high to reduce the friction losses that occur with low oil temperature while eliminating the loss from driving the cooling fan as well. The quick warm-up also decreases supplementary fuel injections necessary when the engine is cold. Consequently, fuel economy improvement by 3.3% was realized in running condition of the Urban Driving Cycle.
Kobayashi, Tomokazu, Kosei, Kazuyuki, Ito, Sadaaki, Iijima, Satoshi
Fan-shroud optimization for enhanced thermal performance16OFHP10_0610/01/2016
CFD helps researchers from Argonne, Cummins and CD-Adapco to maximize cooling air mass flow rates through heat exchangers. Tighter emissions requirements and underhood packing due to higher power demands from engines necessitate more optimized cooling packages. Fan and fan-shroud design is crucial for underhood airflow management. Fan shrouds funnel cooling air, which is sucked by the fan and passed through heat exchangers. Shroud design affects both the airflow and the noise generated by the fan. The vehicle underhood compartment consists of the engine and cooling package. In heavy-duty trucks, the cooling package includes the heat exchanger, fan shroud and fan. To optimize the fan-shroud shape to maximize cooling air mass flow rates through the heat exchangers, researchers from Argonne National Laboratory, Cummins and CD-Adapco used the Adjoint approach to optimization. Adjoint optimization is an efficient sensitivity analysis method for aerodynamic shape and pressure drop evaluation
The Research on the Temperature Control Stability of Hydraulic Retarder Oil Based on Organic Rankine Cycle2016-01-808509/27/2016
The hydraulic retarder is an auxiliary braking device generally equipped on commercial vehicles. Its oil temperature change influences the brake performance of hydraulic retarder. The Organic Rankine Cycle (ORC) is a good means to recover exhausted heat. Moreover, it can cool oil and stably control oil temperature with the help of heat absorption related with evaporation. Comprehensively considering the heat-producing characteristics of hydraulic retarder and the temperature control demand, the aimed boundary conditions are determined. Also the changing rules about the working medium flow rate are obtained. In this work, the heat-producing properties of hydraulic retarder under different conditions and the oil external circulating performance is firstly analyzed. By researching the system’s adaptation to the limiting conditions, the aimed temperature to control is prescribed. Then combined with the existing ORC structure, the variation of evaporation temperature and working medium flow
Ren, Yanjun, Tan, Gangfeng, Ji, Kangping, Zhou, Li, Zhan, Ruobing
Experimental Study of Hydraulic Retarder Waste Heat Recovery Based on the Organic Rankine Cycle2016-01-807909/27/2016
The hydraulic retarder is an important auxiliary braking device. With merits such as its high braking torque, smooth braking, low noise, long service life and small size, it is widely used on modern commercial vehicles. Transmission fluid of traditional hydraulic retarder is cooled by engine cooling system, which exhausts the heat directly and need additional energy consumption for the thermal management component. On account of the working characteristics of hydraulic retarder, this study designs a set of waste heat recovery system based on the Organic Rankine Cycle (ORC). Under the premise of ensuring stable performance of hydraulic retarder, waste heat energy in transmission fluid is recycled to supplement energy requirements for cooling system. First of all, a principle model, which is scaled down according to D300 retarder`s thermal power generation ration of 1:100, is established. Then through theoretical calculations, components' structural parameters of the ORC are determined
Zhang, Zhiwei, Tan, Gangfeng, Yang, Mengying, Yang, Zhongjie, Han, Mengzuo
Fan Shroud Optimization Using Adjoint Solver2016-01-807009/27/2016
Fan and fan-shroud design is critical for underhood air flow management. The objective of this work is to demonstrate a method to optimize fan-shroud shape in order to maximize cooling air mass flow rates through the heat exchangers using the Adjoint Solver in STAR-CCM+®. Such techniques using Computational Fluid Dynamics (CFD) analysis enable the automotive/transport industry to reduce the number of costly experiments that they perform. This work presents the use of CFD as a simulation tool to investigate and assess the various factors that can affect the vehicle thermal performance. In heavy-duty trucks, the cooling package includes heat exchangers, fan-shroud, and fan. In this work, the STAR-CCM+® solver was selected and a java macro built to run the primal flow and the Adjoint solutions sequentially in an automated fashion. In this analysis, the primal flow provides flow information (e.g. velocity, temperature and pressure) and the Adjoint solver provides surface morphing details
Vegendla, Prasad, Sofu, Tanju, Saha, Rohit, Madurai Kumar, Mahesh, Hwang, Long-Kung, Dowding, Steven
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