Browse Topic: Thermodynamics

Items (2,490)

EDITORIAL: Farewell and thanks, Mr. Birch

21AUTP06_0401/27/2025

“We pay close attention to the SAE magazines because your guy in Europe writes interesting articles,” a BMW engineering executive told me one year at the Frankfurt Motor Show. He was referring to Stuart Birch, our veteran European Editor, who has recently decided - after nearly 37 years of outstanding reporting for SAE International - to hang up his keyboard and spend more time with his wife, Kim, their family and friends in the British countryside, and his classic Porsche 911. Our staff had been dreading the day that Stuart would announce his retirement, foremost because he's been a great friend as well as a colleague. And because journalists with his qualities - professionalism, perspective, a powerful work ethic and great wit - are increasingly rare in the mobility-technology space. As SAE's global audience knew, Stuart Birch delivered compelling technical and business information. He covered product, processes and people with equal poise. And he thrived on the R&D beat: Virtual

Brooke, Lindsay

Performance Analysis of Graphene-Coated Heat Pipe Heat Exchangers for Automobile Exhaust Cooling and Purification

2025-01-500601/23/2025

This research investigates the development of a heat pipe heat exchanger coated with graphene for cooling and purification of automobile exhausts. The heat exchanger directly affects the performance of the engine because proper heat dissipation and transfer can improve engine performance, reduce fuel consumption, and decrease the emission. Moreover, this effect is much more noticeable on coated heat pipes because of the enhanced thermal conductivity and mechanical properties of the graphene films. A heat null emitted by internal combustion engines was used in the experimental setup to test the thermal performance, cooling efficiency, and purification efficiency of the newly designed in-house exhaust simulation system where the new heat pipes were inserted. The results of the experiment show that the heat pipes have very high thermal performance as the efficiency of the heat pipes was calculated to be around 85%. Furthermore, the temperature decrease over the surfaces of the heat

Karthigairajan, M., Seeniappan, Kaliappan, Balaji, N., Natrayan, L., Sheik, Salman Basha, Ravi, D.

Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials

2025-01-500301/23/2025

Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96

Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.

Cost Effective Pathways Toward Highly Efficient and Ultra-Clean Diesel Engines, Part II: Air-handling and Exhaust Aftertreatment

2024-26-004401/16/2024

Following global trends of increasingly stringent greenhouse gas (GHG) and criteria pollutant regulations, India will likely introduce within the next decade equivalent Bharat Stage (BS) regulations for Diesel engines requiring simultaneous reduction in CO2 emissions and up to 90% reduction in NOx emission from current BS-VI levels. Consequently, automakers are likely to face tremendous challenges in meeting such emission reduction requirements while maintaining performance and vehicle total cost of ownership (TCO), especially in the Indian market which has experienced significant tightening of emission regulation during the past decade. Therefore, it is conceivable that cost effective approaches for improving existing diesel engines platforms for future regulations would be of high strategic importance for automakers. In this second of a two-part article, several component levels advancements are discussed including both engine and the aftertreatment system (ATS). For engine, role of

Kumar, Praveen, Shah, Ashish, Lago, Rafael, Echeverri Marquez, Manuel, Cleary, David, Gothekar, Sanjeev, Thipse, Sukrut S

A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack

2024-26-010901/16/2024

EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of

Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar

Effect of Busbar Design on the Thermal Performance of Battery Packs

2024-26-013501/16/2024

Li-ion batteries face challenges which is not usually present with other chemistries is cell balancing. If a high imbalance occurs within a parallel circuit, possibly because of the poor cell -grading or due to temperature localization, the other cells will charge the unbalanced cell and it may be possible that the imbalance never completely fades away and the other cells also end up unbalanced, One of the key solutions to maintaining cell balance is to ensure that all cells within a battery pack are kept at a uniform temperature. This requires careful thermal management, which can be achieved through a combination of conduction and convection circuits. In this paper, a 1D-3D simulation study has been performed on a 12 V 4s4p pack by varying the thickness of HV busbars and temperature localization effects and temperature uniformity has been observed. The holder has 16 cells with a 4*4 grid pattern, each cell has a diameter of 18 mm and a length of 65mm. The cells are connected in

Jagtap, Aditya, Khan, Faiz, Shah, Harsh, Malani, Shekhar

A Novel Approach to Make an Efficient Thermal Management of a Solar Electric Four-Wheeler Through Model-Based System Simulation

2024-26-013001/16/2024

The objective of this paper is to determine and design an optimized thermal management system for a solar electric four-wheeler while considering system influence. The major systems that will be analyzed and optimized include the HVAC, solar system, and battery. The HVAC system imposes a challenge to the designers to fulfill the passenger's comfort and to operate it efficiently under a wide range of external loads from solar radiation, ambient temperature & humidity, human metabolic activity, and also other loads like the propulsion system temperature on the cabin. From the literature, it is found that the air conditioning system reduces on average 14% of the total battery capacity whereas the heating system reduces it by 18%, which makes the HVAC system design a crucial aspect to consider for the system influence. The battery car voltage changes significantly to meet the power demand and because of this, the battery system produces a large amount of heat while discharging which will

Karthikeyan, Vikram Raj, Gumma, Muralidhar

Predictive Underhood Thermal Management Model

2024-26-027201/16/2024

In the automotive industry, thermal management is a very important way to solve the problems of energy saving and emission. The underhood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts the

P V, NAVANEETH, Prasad, Suryanarayana A N, ML, SANKAR

Thermal Management of An Automotive Headlamp

2024-26-028601/16/2024

These days, the use of virtual simulations through Computation Fluid Dynamics (CFD) methodology is increasing exponentially during the development phase of an automotive headlamp. Thereupon, the automotive industries are becoming competent enough to build an ingenious and creative design with optimal performance within the coherent time. Considerable amount of heat is generated inside the headlamp when it is switched on for a longer time. Hence it becomes vital to reduce the risks if any during the development phase by providing an adequate thermal management strategy within the headlamp. The present study conducted an experimental analysis on an automotive headlamp to determine its thermal characteristics and behavior. Numerical analysis was also performed to determine the airflow and temperature distributions within a headlamp. This study also focuses on finding the main hotspot regions over the headlamp through virtual simulations. The methodology shows a consensus with the

Kolhe, Shailesh Madhukar

Research on Cold Start Strategy of Vehicle Multi-Stack Fuel Cell System

2023-01-703610/30/2023

To study the cold start of muti-stack fuel cell system (MFCS), a novel thermal management subsystem structure and corresponding cold start strategies are proposed. Firstly, leveraging the distinctive configuration of the MFCS that can be sequentially initiated, we augmented the existing thermal management subsystem with the incorporation of two additional collection valves and two bypass diverter valves, which affords an increased degree of flexibility in the formulation of cold-start strategies. Secondly, we innovatively propose a hierarchical auxiliary heating cold start strategy and an average auxiliary heating cold start tailored for MFCS consisting of power levels of 20 kW, 70 kW, and 120 kW. Furthermore, we have developed a controller to address temperature control challenges during the start-up process. The results demonstrate that the multi-stack hierarchical auxiliary heating cold start strategy yields a significant reduction in energy consumption and startup time during the

Jin, Yapeng, Yuan, Tanghu, Fan, Lei, Zhou, Su

Backend-based State-of-Charge Control as an Operating Strategy for a Serial PHEV

2023-01-120106/26/2023

In previous work, a serial hybrid powertrain concept with a phlegmatised ICE has been described. Drivability is to be ensured through an innovative predictive operating strategy. Battery State-of-Charge (SoC) is controlled using a backend-based prediction of energy consumption on a given route based on road map and traffic data. In this paper, a spotlight is thrown on the proposed control architecture. On the top level of the controller, a Dynamic Programming algorithm finds an optimal reference trajectory for the SoC over a known route with the goal of avoiding certain Worst-Case scenarios commonly associated with the serial hybrid powertrain topology. Close adherence to the reference trajectory is ensured on a lower level through Model Predictive Control, taking into account additional factors such as battery stress. These control layers closely represent the map data distributed on the on-board bus network of state-of-the-art road vehicles under the current ADASIS standard. The

Böhme, Maximilian, Gerdts, Matthias, Trapp, Christian

Modeling of Air Spring Dynamical Characteristics using Fractional Derivative Model and Thermal Hysteresis

2025-01-004505/05/2023

Air springs are one of the most common used groups of vibration isolators and their dynamical characteristics are extensively studied. One of the main challenges of modeling of air spring dynamical characteristics is to model for hysteresis characteristics of air spring. Hysteresis characteristics of air spring are contributed by friction and viscosity of rubber bellow and by thermal hysteresis of compressed air inside air spring. In this paper, dynamic behaviors of air spring are modeled and analyzed. Firstly, force versus displacement data are obtained by the tests under static, harmonic and random excitations. Secondly, a nonlinear model is presented to capture the measured air spring’s behaviors. The model is consisted of Berg’s friction and fractional derivative model to describe rubber bellow behaviors and heat exchange model to describe thermal hysteresis of air. Furthermore, the proposed model parameters are identified using finite element model and test data. Finally, the air

Noise analysis and optimization of thermal management integrated module

2025-01-008105/05/2023

Abstract：The thermal management integration module is a multifunctional integrated component. The thermal management integration module includes water pumps, flow channel plates, brackets, sensors, etc. However, due to the large range of speed changes, the water pump will generate a wide range of frequency excitation. This excitation will cause the integrated module to vibrate and generate noise. This article studies and analyzes an integrated module that generates noise. An integrated module of a certain new energy vehicle is used as an example. Firstly, a vehicle experiment was conducted. It was found that the noise came from the integrated module. And then use finite element method to analyze the causes of noise generation. Based on the characteristics of multiple integrated module components, high integration degree, and complex structure. This article simplifies components such as brackets, heat exchangers, sensors, etc. And they are replaced by centralized quality points

Electric compressor integration noise influence in Battery Electric Vehicles

2025-01-007505/05/2023

Within the automotive industry’s shift to Battery Electric Vehicles, in order to meet the global zero emission target, thermal management systems are key aspects to address. For instance, vehicle cooling requirements are reinforced to take into account the cabin comfort as well as battery management performances. Consequently to the increased cooling requirements, the critical component that is the Electric Drive Compressor, must operate at higher speeds and refrigerant pressures to achieve these targets. This trend results in increased noise levels which might occur inside the car cabin and outside. In this paper, noise investigations were performed on different Battery Electric Vehicles to assess the behavior of the electric compressor within a temperature controlled environment. Then, the electric compressors alone were investigated on specific test benches with compressor load units. The vehicle level assessment highlighted significant noise differences between vehicles. Further

Bennouna, Saad, Yamayoshi, Itsukyo, Del Valle, Edward

A Methodology to Design the Flow Field of PEM Fuel Cells

04/11/2023

Proton Exchange Fuel Cells (PEMFCs) are considered one of the most prominent technologies to decarbonize the transportation sector, with emphasis on long-haul/long-range trucks, off-highway, maritime and railway. The flow field of reactants is dictated by the layout of machined channels in the bipolar plates, and several established designs (e.g., parallel channels, single/multi-pass serpentine) coexist both in research and industry. In this context, the flow behavior at cathode embodies multiple complexities, namely an accurate control of the inlet/outlet humidity for optimal membrane hydration, pressure losses, water removal at high current density, and the limitation of laminar regime. However, a robust methodology is missing to compare and quantify such aspects among the candidate designs, resulting in a variety of configurations in use with no justification of the specific choice. This contrasts with the large operational differences, especially regarding the pressure loss

Corda, Giuseppe, Cucurachi, Antonio, Diana, Martino, Fontanesi, Stefano, D'Adamo, Alessandro

An Experimental Study for Reduction of Refrigerant Flow Induced Noise in a Passenger Vehicle

2022-28-043911/09/2022

Air conditioning these days has become an indispensable part of human comfort due to rising global temperatures. Air conditioners are installed to achieve thermal comfort in enclosed spaces such as rooms, vehicle passenger cabins, laboratories etc. As the air conditioning units employ dynamic processes to maintain thermal comfort it creates many unwanted noises which lower the acoustic comfort. One of these unwanted noises is the refrigerant flow induced noise inside passenger cabin of an automobile when the air conditioning is switched on in a thermally soaked vehicle. This paper elaborates about the study done on a calorimetric bench inside a semi-anechoic environment for identification of the noise signature and its acoustic interpretation. It also compares the noise readings obtained on the bench and at vehicle level in a semi-anechoic setting. The paper discusses about the possible mechanism for the occurrence of the refrigerant flow induced noise. It also discusses about various

Sharma, Rachit, Kumar, Mukesh, Kumar, Shubham, Patra, Subhashree

Cost Effective Method of Improving the Cabin Air Quality using HVAC Case Coating

2022-28-045211/09/2022

Cost effective method of Improving the Cabin Air Quality using HVAC case Coating Among many environments, the motor vehicle cabin micro-environment has been of public concern. Infact Air pollution more harmful to children in cars than outside. Although commuters typically spend only 1-2hrs per day of their time in vehicles, the emissions from various interior components of motor vehicles as well as emissions from exhaust fumes carried by ventilation supply air are significant sources of harmful air pollutants that could lead to unhealthy human exposure due to their high concentrations inside vehicles' cabins. This N9 silver ion technology helps significant reduction of microbial & viruses in inside vehicle cabins air. On contact silver will neutralize harmful bacteria on plastic surfaces giving them long lasting freshness and long-term protection. Silver is a natural antimicrobial. That means that microbes-germs can't survive in the presence of silver ions. Silver ions released from

Anandan, Ram, Anugu, Anil, EEDALA, V V N CHOWDARY, Sampath, Karthikeyan

Application of Packing in Sealing Doors and Reducing Fluid Leakage in Automotive HVAC of Climate Control System.

2022-28-045711/09/2022

The heating, ventilation and air conditioning system is one of the complex system install inside the cabin of automobile vehicle. Each HVAC discipline has specific design requirement in terms of packaging space, performance target etc. Technical specification such as airflow, noise, air distribution, allowable leakage rate varies as per vehicle segment and interior design accordingly. While maintaining the design parameter of HVAC, design engineers often faces challenges related to water leakage, air leakage, water infiltration etc. Controlling these parameters becomes crucial for customer satisfaction and for safety features. Several researches on seal proof technology is done and still going on, either for air based application or water based application or any other fluid material. Application of sealing technology spread over almost everywhere from domestic purpose to industrial application. Similarly in HVAC, application of packing for sealing doors or reducing leakage plays a

raj, Abhishek, Bajpai, Himanshu, Agarwal, Roopak

AC System COP Optimization Through Major or Minor Adjustment of Component Design

2022-28-042311/09/2022

In the process of designing of complete cycle of vapour compression refrigerant system, most important part is optimization of performance of all components including compressor, condenser, expansion valve, evaporator and piping and COP of the system . For balancing and COP optimization of air conditioning cycle, it is extremely important that all component selected must be balanced and synchronized with other components relatively. Many researches have been done related to system COP and performance optimization through various method as well as component performance optimization. While optimizing the cycle, changing one component parameter effects the other components behavior and becomes challenge to control all other characteristic. Sometimes even a minor adjustment in the cycle leads change in output result of components which are not preferable. The present paper is about optimization of system COP of refrigerant cycle through various combination of iteration that includes

raj, Abhishek, Bajpai, Himanshu, Agarwal, Roopak, Anal, Rajeev

Carbon-Neutral Powertrains for Future Mobility and its Impact on Thermal Management

2022-28-041511/09/2022

In this article we summarize the main classification of hybrid powertrains for automotive sector and quantify the scope and benefit these powertrains using gasoline and diesel as mono fuel or dual fuel with CNG, Flex fuel (Ethanol blended). Such power trains have high potential to achieve lower carbon emissions for the near future usage and implementation, until the carbon-neutral powertrain reaches its majority in the market. The major focus is on the H2 combustion engine powertrain as it is one of the potential solutions to achieve carbon-neutral powertrain solution using the optimized IC engine. We highlight the benefits and challenges involved to commercialize H2 combustion engine powertrain against the e-fuel based carbon-neutral powertrain for the new-energy vehicles such as Battery powered electric vehicles (BEVs) and Fuel Cell powered electric vehicle (FCVs). Finally we discuss about the link between the capacity and size of the thermal cooling system of the automotive vehicle

Muthu, Selvaraji, N, Sekarapandian, KANNAIYAN, Ashok

Immersion Cooling for Power Electronics

2022-28-044611/09/2022

The ability to precisely control electrical voltages on a large scale has made possible many efficient, powerful innovations, from high-speed electric trains to wind turbines to electric drive motors for everything from heavy earthmoving equipment to personal electric vehicles (EVs). But the equipment that manages this process — including power inverters, thyristors and variable-speed drives — requires high-performance power electronics cooling. As temperatures rise, the efficiency, reliability, and life spans of these devices drop, and the power electronics inside HEVs and EVs are no exception. Advancements in power electronic thermal management technologies will enable next generation automotive to fulfill increasingly demanding mission objectives. DC-DC converter and inverter systems slated for higher performances, reliable and sustainable applications. Even with very high efficiencies, the components of these systems produce kilowatts of power loss in the form of heat. The current

Design of Hybrid Air Conditioning System Using Phase Change Material for Commercial Sleeper Vehicles

2022-28-044811/09/2022

Many road accident happens due to fatigue & deprive sleep of drivers. Many times driver use AC system for their quick thermal comfort during night with engine ON. This scenario is very critical from human's safety & vehicle functionality point of view. This also consumes additional 10-15% of fuel requirements in AC running condition. So, to address social problems of driver's sleep & pollution free environment by reducing the use of fossil there is a need of alternative techniques for air cooling which works during engine OFF condition. Various alternatives options for air cooling have been reviewed & extensive evaluations are mapped on the various performance parameters. Based on this the phase change material technology can be easily adopted due to its packaging flexibility. Phase change material (PCM) technology available in the market since decades for the use of storing the thermal energy. Perhaps the use of PCM material in controlled manner in not fully known for longer period of

Shalgar, Sandeep, Nagarhalli, Prasanna V, BEDRE, PALLAVI, SRIVASTAVA, SARVESH, Tupe, Akshay

Performance Analysis of Integrated Battery and Traction Motor Cooling Systems for Two-Wheeler Electric Vehicles Applications

2022-28-041311/09/2022

The automotive industry is a huge industry as millions of vehicles are running on the road & it's growing at a rapid rate. The emission from these vehicles are harmful in nature & are bigger concerns for the human being as its increasing day by day at an alarming rate. The emissions are causing various global problems such as global warming, green house effects, air pollutions etc. due to the use of fossil fuels in abundance. This drives to think for alternative solutions, which are eco-friendly & having less or no emissions. The electric vehicles (EVs) are the most reliable solution as it is having high performance & efficiency without emissions. EVs are most suitable option to reduce global warming & greenhouse effects etc. The evolution of EVs has fueled the two-wheeler EVs industry to flourish at a fast pace. Li-ion battery & traction motor is the most important components in two-wheeler EVs. Li-ion batteries are compact, light-weight, fast-chargeable, having low self-discharge

Suman, Saurabh, Kushwah, Yogendra Singh

Feasibility Analysis of Submerged Battery Cooling System for Electric Vehicles

2022-28-041111/09/2022

Due to the depletion of fossil fuels and excessive air pollution, the world is moving towards electric vehicles. Usage of electric vehicles avoids the global warming and safeguard the earth. Batteries are the primary source of electricity for electric vehicles which generates lot of heat during its operation. Now a days, firing accidents of electric vehicles on roads are frequent. One of the most significant systems to avoid this fire accident is thermal management system. Effective thermal management of high-power density battery is essential for battery’s performance, life, and safety. Components that are used for the thermal management are to be as efficient as possible to achieve effective cooling of batteries. Direct Liquid Cooling has received lot of interest in recent years. A non-conductive dielectric fluid is used to submerge the battery cells. As the fluid is dielectric, the direct contact with the cell surfaces will not be tend to short circuit the battery. This direct

Deepan Kumar, Sadhasivam, M, Boopathi, Praveenkumar, Nagarajan, Sabariraj, R

Performance Improvement on Electric BUS A/C Through CAE & CFD Simulation

2022-28-043411/09/2022

Light weight, structural integrity, dynamic behavior, selection of material, performance, electrical energy consumption evaluation are very challenging areas while designing electrical vehicle AC components. Structural integrity and dynamic behavior of the component predicted by conducting dynamic analysis of the assembly under standard load conditions. Selection of material is another challenging part which been decided out based on the analysis result. Achieving the required cooling capacity with less compressor power is also another challenging area which been achieved by proper design changes on condenser and evaporator side. For this CFD analysis been performed on the unit. In this paper, durability analysis of the unit been carried out to check the strength of the unit as per the std and CFD analysis carried out to check the air flow on the condenser side and design modification to improve the air flow to meet the cooling capacity. On dynamic analysis, modal frequency and

Parayil, Paulson, Goel, Arunkumar, Singh, Shobit Kumar, Sen, Somnath

Design and Thermal Analysis of Intake Manifold and Investigation of Charge Motion in CI Engine

2022-28-044311/09/2022

It is close important so much a suitably designed consumption flatulence manifold is vital because the top-of-the-line performance concerning an IC Engine. This venture offers with the three-D simulation regarding a device yet the outcomes wish stand mentioned using computational softened dynamics (CFD) analysis. For foremost IC engine performance, airflow intimate the consumption miscellaneous is some regarding the necessary factors. The atmosphere rate is brought on at some point of the intake blow then another altered all through the suppression process, and the kinetic power on the fluid consequential between swirl and turbulence reasons quick mixing about gasoline yet wind inward the cylinder. Therefore, it is entirely a lot integral in conformity with recognize the in-cylinder fluid rate thoroughly. So up to expectation the version among special parameters certain namely drift coefficient, swirl coefficient, swirl velocity, swirl ratio, then version about stubborn electricity at

Deepan Kumar, Sadhasivam, A, Tamilselvan, M, Vignesh, P, Somasundaram, Singaravel, M

Faster Cool-Down of a Reefer Unit by Optimizing the System Losses through Experimental Investigation

2022-28-044211/09/2022

Refrigerated shipping containers are one of the four segments of the cold chain; cooling and storage; refrigerated transport; distribution centre and refrigerated display in super markets. The term reefer has become an established term to refer refrigerated shipping containers. It is one of the emerging areas in transport segments. With the onset of ongoing pandemic this area has further drawn global attention recently and due focus is being given to the development and improvement of reefer unit Hence with the growing demand in this field the energy consumption is also leapfrogging day by day. Primary energy sources (fossil fuel) are depleting and their environmental impact is raising anxiety around the world. In order to minimize unnecessary energy waste in refrigerated shipping container system, it needs to be designed to be energy efficient and provide high cooling capacity to ensure rapid pull down to carriage temperature and to maintain product quality at idle. Improper operation

Numerical Investigation of cylindrical Li-Ion Battery Pack Thermal Management

2022-28-041811/09/2022

Rapid movement of vehicle industry towards electrification has generated need for efficient and time saving methods to predict temperature across battery pack in different operating conditions which will assist in designing effective cooling methods for battery. The main requirements for efficient working of Li-Ion battery are (a) optimum operating temperature range and (b) small variation of temperature across the battery pack cells. Temperature across pack increases during charging and discharging cycles of battery in different operating cycles of machine. Especially due to high current rates in discharging, there is large temperature rise in battery. Elevated temperature profiles inside battery adversely affects many performance parameters like power, charge acceptance, life cycle and influences electrochemical reaction inside cells. Temperatures above the specified limits will cause degradation of performance and deterioration of material. If dissipation of heat is not efficient

Dewangan, Nitin

Real-World Emissions of Motorcycles in Delhi-NCR Region, India

2022-28-043511/09/2022

This research quantifies the real-world emissions of motorcycles plying in Delhi-National Capital Region (NCR), India covering the urban, rural and highway driving patterns. The emissions estimation by standard driving cycles in the laboratory does not represent the emissions factors estimated in real-world driving conditions experience on road. In the real-world driving conditions, the emissions of motorcycles were influenced by vehicle driving parameters, and traffic conditions. The time-speed data was collected using a BS VI motorcycle in Delhi-NCR during peak and non-peak hours on weekdays and weekends. The emissions factors were estimated by simulating the time-speed data on chassis dynamometer interfaced with 5-gas analyzer, and emissions factors were analyzed for traffic conditions. The average and maximum speed of 29 km/h and 60 km/h in urban, 33 km/h and 72 km/h in rural, and 47 km/h and 79 km/h in highway respectively were observed. The CO and HC emissions were higher during

Sithananthan, M., Kumar, Ravindra, Maheshwari, Mukul, Saxena, Deepak

Design Optimization and Thermal Simulation of a Plate Type Heat Exchanger (“Chiller”) for EVs Applications

2022-28-044111/09/2022

The rapid evolution of electric vehicles (EVs) has considerably forced the automotive industry to design compact & highly efficient heat exchangers due to lower temperature applications. The plate type heat exchangers (Also known as "Chillers" in automotive industry) are one of the most important components in EVs thermal management systems. It is a type of heat exchanger, which uses metallic plates arranged like a staggered sandwiched structure to exchange heat between two working fluids. The heat transfer between the plates occurs due to highly compact structural design as compare to any conventional heat exchangers. The chiller is having very large surface area, which is exposed to the working fluids as the distribution happens all across the plates. The chillers are more suitable design for transferring heat between ranges of working fluids pressure varying from low to high pressures. Various types of welded, semi-welded plate heat exchangers are available. The working fluids flow

Suman, Saurabh, Kushwah, Yogendra Singh, SHUKLA, ANKIT, Singh, Shobhit Kumar

Technical and Economical Evaluation of Different EXV Concepts

2022-28-045911/09/2022

Due to the increased requirements to the thermal management in PHEV and BEV, the request for an electronic control has led to a large variety of electronically controlled Expansion valves. The spectrum concludes variation on the actuator such as Stepper motors, DC- and BLDC motors, but also variation on the valve type, such as needle-, ball- and Slider Valves, and -finally- the basic structure of the valve, which orientates on the refrigerant and the respective pressure levels such as R1234yf on the lower side and R744 on the higher side. In this paper, the different concepts are shown and ranked regarding technical and economical aspects. Therefore, a recommendation for the respective applications is included.

Wild, Stephan, Willers, Eike

"Operation Strategies of Heat Pump Systems in High-Performance Electric Vehicles"

1329909/15/2022

"The energy consumption of a thermal management system cannot be neglected and is a significant contributor compared to the total energy consumption of a battery electric vehicle. Using a heat pump as part of the thermal management system, can heat and reduce energy consumption at low ambient temperatures. A state-of-the-art heat pump system consists of numerous actuators such as fans, pumps, electrical heater, compressor, and valves. An existing challenge remains to develop efficient operational strategies for these components with the corresponding interactions in dynamic boundary conditions. A physical model of the system can be used to optimize the control method and consequently, helps to save energy. The objective of this investigation is to obtain an operating strategy, which efficiently distributes the electric power between the heat pump compressor and the electric heater. In this context, the influence of an optimized, model-based control of the compressor speed on the

Non-parametric Optimization of Heat Sinks for Power Dense Motor Controllers

2022-26-117505/26/2022

With the future of mobility moving towards electrification there is an ever-increasing demand in both aerospace and automotive industry for achieving higher power density in inverters, controllers, etc. In the aviation industry, the trend of more electric aircraft has resulted in transition from central to zonal architecture. In zonal architecture, controller units are kept close to the actuator systems and localized harsh bay conditions, space constraints coupled with the necessity for high power density has made thermal management a challenging task. This warrants a need for exploring innovative cooling techniques to manage the dissipated heat. This paper focuses on a liquid cooled thermal management system for power dense applications. The heatsink design presented here is a pin fin arrangement staggered to induce swirling flow, which has been proven to enhance heat transfer. The traditional heatsink optimization involves creating a design of experiments (DoE) with parameters like

Bhardwaj, Divyanshu, Datta, Sauradeep, Borkar, Kishor

To Develop the model for heat transfer coefficient with Machine Learning Techniques.

2022-26-123505/26/2022

Being the Need of Increasing the heat transfer for domain which under heat stress index,key parameter is heat transfer coefficient, Which majorly depends upon the float rate of the context, the input of the heating element which ultimately decide the the time of contact of fluid which raise the concern about heat transfer. The Main goal of the presented study is to Investigate and develope model for the heat transfer coefficient in forced convection.The study comprising two section as conduction the experiment by considering the parameters like air flow, heater input, varying one at a time, which will creat the dataset, with dependent label as heat transfer coefficient using empirical relation. Three Machine learning algorithm i.e is Support Vector Machines, Decision Tree and XG boost are tested over the dataset. The metrics like Root mean squre error and Mean absolute error is plooed with the doamin, All algorithm implemented with the Python.

Dorwat, Ajit L., Dhotre, Sanchit, Biradar, Ashish, Lokhande, Pravin

Design of a thermal energy storage panel for reducing the temperature fluctuations in a CubeSat or a NanoSat using a passive thermal cooling system.

2022-26-117205/26/2022

The application of CubeSat or a NanoSat for low-orbit data collection has expanded because of their economical cost for development and lightweight structures. Thermal analysis is one of the vital components during the design and configuration procedure of CubeSat or a NanoSat as the thermal loads in orbit can undoubtedly harm the functions of components in the system and therefore the whole framework can be affected. When the satellite travels from the dark side of the planet to the one facing the sun there is a major change in fluctuations of temperature. Due to heat absorption, transfer and emission on one side, the satellite surface presents an asymmetric temperature distribution and causes a change in momentum which can manifest in spinning and non-spinning satellites in different manners which can cause orbital decays in satellites. The purpose of a thermal management system is to maintain the temperatures within each system to their operating range and to minimize the

Mishra, Prem Sangam, Mankar, Suyash, Subudhi, Sudhakar

Machine learning assisted analysis of heat transfer characteristics of a heavy duty natural gas engine

2022-01-057203/29/2022

Heat transfer affects engine performance, efficiency, and emissions. Hence, it was essential to investigate the heat transfer characteristics after converting a compression ignition engine to a spark ignition and natural gas. The heat transfer for each engine speed and load was calculated based on Woschni’s correlation. As the number of experiments that provided engine response was limited, an artificial neural network approach was proposed to predict the engine heat transfer characteristics and aid in the analysis. The good agreement between the experimental results and data predicted by the machine learning algorithm validated the predictive capability of the artificial neural network model. The results of the data-driven analyses suggested that the heat transfer increased as the spark timing advanced. Moreover, increasing the engine speed reduced the heat flux form the combustion chamber to the engine coolant. Further, leaning the mixture lowered the heat transfer rate to the

Liu, Jinlong, Dumitrescu, Cosmin, Ulishney, Christopher

Engine Thermodynamic Design, Optimization, Test & Analysis of Daimler SuperTruck2 Program Towards 55% BTE Target

2022-01-050403/29/2022

Daimler's effort toward demonstration of 55% brake thermal efficiency for the US Department of Energy SuperTruck2 program relied on a holistic approach to optimization of the Daimler heavy-duty 12.8L diesel engine. Core technical approaches used in this effort include efficient two-stage turbocharging with intercooling, valve timing optimization, improved combustion system design, friction and parasitics reduction through optimized lubrication system, and in-cylinder heat transfer reduction. These measures in combination provided an anticipated engine efficiency of over 50% BTE before application of an additional waste heat recovery system. Utilization of high-fidelity simulations from 1D physical model simulation studies and CFD/FEA framework allowed for optimization of the engine pumping loop and heat transfer reduction efforts. Test bench data provides high-level overview of combustion improvement, friction & parasitics reduction, improvement in in-cylinder heat transfer reduction

Development of Vehicle Thermal Management Model for Improving the Energy Efficiency of Electric Vehicle

2022-01-022603/29/2022

Recently, automobile manufacturers are interested in the development of battery electric vehicle (BEV) having a longer mileage to satisfy customer needs. The BEV with high efficiency depends on the temperature of the electric components. Hence it is important to study the effect of the cooling system in electric vehicle in order to optimize efficiency and performance. In this study, we present a 1-D vehicle thermal management (VTM) simulation model. The individual vehicle subsystems were modeled including cooling, power electric (PE), mechanical, and control components. Each component was integrated into a single VTM model and it would be used to calculate energy transfer among electrical, thermal, and mechanical energy. As a result, this simulation model predicts a plenty of information including the state of each component such as temperature, energy consumption, and operating point about electric vehicle depending on driving cycles and environmental conditions. The characteristic of

Hong, Seokbin, Kyoung, Song, Sung, Wonjune, Lee, Dongkyu, Choi, Kyungwook, Park, Minjung, Seo, Heung Seok, Park, Sunghoon, Jung, Young Ho

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

Dynamic modeling method of electric vehicle thermal management system based on improved moving boundary method

2022-01-020803/29/2022

The thermal management system, which is used to improve driving safety and thermal comfort, is one of the most important systems in electric vehicles. In recent years, researchers have coupled the heat pump system and the battery cooling system to effectively improve the heating COP (Coefficient of Performance), and therefore an accurate dynamic model of thermal management system plays a key role in studying system performance and optimal control strategies. In this paper, an electric vehicle thermal management system based on the four-way valve heat pump system is designed, and the moving boundary method is improved by considering the unsteady flow of the external fluid. And then a 14-order dynamic model of the thermal management system is established. Firstly, the control equations of the evaporator, condenser and chiller are derived according to the principle of conservation, and then a dynamic model of the thermal management system is established and implemented in Simulink

Gao, Mingyang, Li, Ruilong, Zhen, Ran, Shangguan, Wen-Bin

Research on Engine Compartment Thermal Management Based on STAR-CCM+ software

2022-01-020903/29/2022

Nowadays, energy conservation and emission reduction have raised the awareness of more and more people. The heat dissipation of the engine compartment is an important evaluation index for automobile thermal management, which directly affects the vehicle's power, economy, durability and riding comfort. In this paper, aiming at the problem of unsatisfactory thermal management effect of a certain passenger car engine compartment, the systematic model of engine compartment thermal management is used to carry out research and program optimization. Based on the STAR-CCM+ software, we discuss the distribution law of the speed field and pressure of the engine compartment, and the influence of the front frame baffle on the flow field. The longitudinal position of the oil cooler was investigated for the cooling module, and it was found that the block position of the oil cooler has a certain degree of influence on the heat dissipation of the radiator. In the actual vehicle design, the up-down

Heat Transfer Analysis of an Electric Motor Cooled by a Large Number of Oil Sprays Using Computational Fluid Dynamics

2022-01-023703/29/2022

This paper reports on an analytical study of the heat transfer and fluid flow in an electric vehicle e-Motor cooled by twenty five sprays/jets of oil. A three-dimensional, steady state, multi-phase, computational fluid dynamics (CFD) and conjugate heat transfer (CHT) model was created using a commercial CFD software. The transport equations of mass, momentum, energy and volume fraction were solved together with models for turbulence and wall treatment. An explicit formulation of the volume of fluid (VOF) technique was used to simulate the sprays, a time-implicit formulation was used for the flow-field and three dimensional conduction heat transfer with non-isotropic thermal conductivities was used to simulate the heat transfer in the windings. An important challenge was to formulate an efficient solution algorithm that can rigorously comprehend twenty five sprays in order to accurately predict the temperature distributions in the windings, without thrifting physics, and within

Srinivasan, Chiranth, Wan, Jingyi, Saha, Rohit, DHAR, Sujan, Paciura, Krzysztof, Nichani, Varun, Ranganathan, Raj

Proposed Standards And Methods For Leak Testing Lithium-Ion Battery Packs Using Glycol-based Coolant With Empirically Derived Rejection Limits

2022-01-084803/29/2022

Lithium-ion batteries are a highly suitable energy source for many applications, particularly in the automotive sector due to their high energy density and low self-discharge rate. During the production of battery cells, rapid detection of leaks is essential to achieve necessary lifetime service-life and safety requirements. Once assembled into packs, whether made of prismatic, cylindrical or pouch cells, packs must be cooled by common automotive thermal management systems, for example those employing engine coolant and radiator, and in which manufacturers must prevent various leak-producing defects that affect durability, longevity and safety Two types of cooling systems are used in automobiles, an active variant in which refrigerant, compressor, evaporator and heat exchanger are used to operate the air conditioning system, or a passive variant with a cooling medium, typically a water/glycol mixture, and a heat exchanger cooled by ambient air. While good industry standards are

Wetzig, Daniel, Blaufuß, Marc

Flexible Reduced Order Modelling Applied to the Performance Optimization of a Catalytic Range Extender for Electric Vehicles

2022-01-071803/29/2022

A major inhibitor to large scale adoption of battery electric transportation systems is their single-charge range. For passenger vehicles, limited charging infrastructure gives rise to range anxiety, whereas for commercial fleets, the higher cost of such vehicles still outweighs the gains from better overall efficiency and tax concessions. One way to mitigate such barriers is through the inclusion of a range extender in the drive train. These devices take on different forms, but generally offer improvements in the critical customer requirements of power-to-weight ratio and overall running cost. Delta-Cosworth have developed a catalytic range extender based on a recuperated Brayton cycle. This system comprises a rotating shaft on which are mounted a centrifugal compressor (φ 89.5 mm), a radial turbine (φ 106 mm), and an electric machine with an inverter to capture the net shaft power. Between the compressor and turbine, a heat exchanger raises the air temperature to 650°C followed by a

Mason, Alexander

The Rotating Liner Engine under Medium Loads and Speeds. Fuel economy benefit exceeds 10%

2022-01-050703/29/2022

The Rotating Liner Engine (RLE) is a design concept where the cylinder liner of a Heavy Duty Diesel engine rotates by about 2-4 m/s surface speed in order to eliminate the piston ring and skirt boundary friction near top and bottom dead center. Based on testing results from our single cylinder RLE prototype (a converted four cylinder Cummins ISB 3.9 diesel) compared to a similar baseline, under idle conditions, the friction reduction is approximately 50 kPa in FMEP (friction mean effective pressure), which translates to about 40% for a complete engine. In this new set of experiments, we are comparing the RLE performance under load of up to about 7 bar IMEP (indicated mean effective pressure). It has been proven that the elimination of metallic contact between the compression rings and cylinder persists under up to 75 bar peak cylinder pressure and 1.5-2 m/s liner surface speed (283-383 rpm) for the 850-1150 rpm crankshaft speed. Additionally, the RLE FMEP is substantially reduced under

Dardalis, Dimitrios, ALHAJ ASAD, Osama, Basu, Amiyo, Hall, Matthew, Matthews, Ron

Simulation of 2-Stroke D-Cycle Engine Concept for Agricultural Tractor

2022-01-046403/29/2022

This paper explains to modify conventional 4-Stroke 2.7L 4-Cylinder CRS (Common Rail System) Naturally aspirated (NA) Diesel engine into 2-Stroke D-Cycle (i.e. Differential Stroke) engine for Agricultural Tractor applications. 1D Performance simulation was performed using GT-POWER to focus on how to maximize the combustion efficiency and power/torque demand using a 2-stroke D-Cycle by taking advantages of deficits in a 4-stroke engine, optimizing for improving emissions and realizing higher torque demands for Tractor field applications. Furthermore, appropriate cam geometries ensuing specific application of puddling, tillage etc. are generated which can be accommodated without major design changes. Exhaust, heat transfer, pumping, frictional losses, and volumetric efficiency are analyzed. Performance Simulation results shows that Fuel economy improvement of ~ 10%, average increase in Power output of ~ 30%, average NOx emission reduction of ~ 15% and better drivability at low engine

S, SHANKAR, Paulraj, Lemuel

Analysis of energy and exergy distribution for improving fuel economy of marine low-speed two-stroke diesel engine

2022-01-046303/29/2022

Increasingly strict emission regulations and unfavorable economic climate bring severe challenges to energy conservation of marine low-speed engine. Besides traditional methods, the energy and exergy analysis could acknowledge the losses of fuel energy from a global perspective to further improve the engine economy. Therefore, in this study, a thermodynamic model is built based on experimental data to conduct the energy and exergy analysis for marine low-speed engine. Results of energy analysis shows that the exhaust gas accounts for the highest proportion of energy losses, and it rises with the increment of engine load. The proportion from heat transfer is just after the exhaust gas. But, it is negatively correlated to engine load. The energy analysis results indicate that reducing the proportions of exhaust gas and heat transfer is the best way to improve the fuel economy of engine. However, the exergy analysis demonstrates that there is still another more effective approach to

Zhang, Heng, Deng PhD, Kangyao, Wang, Dawei, LONG, Wuqiang, Qian, Yuehua

An experimental study of heat loss and spatially temperature distributions of the impinging plate

2022-01-060703/29/2022

Spray impingement tends to occur in compact-size engines and it affects the fuel-air mixing, local heat transfer between fluid and solid, and possibly leads to fuel deposition on the hard surface. The deposits which are typically called “film” become one of the main sources of soot particles generated in the subsequent combustion. Wall temperature is one of the factors that affect fuel deposition. A higher wall temperature would enhance the film evaporation and reduces the risks of fuel deposition to partially avoid the soot particles formed from the film. Also, the wall temperature would affect the ignition characteristics such as ignition delay and ignition location. However, in realistic operating engines, the wall temperature is not consistent but changed by the heat conduction from charge gas and heat convection when the spray hits the wall and propagates near the surface. Due to the arrangement of injectors in the engines, an oblique injection is typically observed. This scenario

Zhao, Zhihao, Lee, Seong-Young

Research on Heat Dissipation Performance of Automobile Motor Based on Heat Pipe Optimization Design

2022-01-088403/29/2022

In new energy vehicles, the electric motor, as the main power source, is developing toward high power density. However, its heat generation problem always affects the overall performance of the motor, so an efficient motor cooling system is especially important. In desert or water-scarce areas, liquid cooling cannot meet the needs of new energy vehicle motor cooling. When glycol or other liquid coolants are low or depleted, motor heat dissipation becomes less effective. Heat pipe is a heat dissipation technology with advantages such as fast thermal response and light weight. In this paper, by improving the heat pipe arrangement and reducing the overall mass of the heat dissipation system, a heat pipe optimization design based on a drive motor heat dissipation scheme is proposed, and the overall stability of the motor working under high temperature conditions is improved. In this paper, the heat pipe arrangement scheme is set up with the heat pipe heat transfer characteristics, and the

Impact of the vehicle environment on the thermal behavior of the electrical wiring

2022-01-015403/29/2022

The thermal behavior of wires within the electrical distribution system (EDS) has a strong impact on the conductor cross section, the type of insulation, the derating and the fusing system, and therefore on weight, cost, and reliability. Consequently, significant efforts have been made to develop sound static and dynamic thermal models for single wires and wire bundles. However, these models are based on the simplifying assumption that the object is completely surrounded by air, where, with the exception of internal convection, airflow can be neglected, and where no interaction with other objects is considered. The approach presented in this paper takes into account the real environment and routing within a vehicle, where some objects such as metal sheets can be considered as heat sinks and other objects, e.g. a motor block, as heat sources. For this reason, measurements were performed using an experimental set-up that allows any desired positioning and alignment of the DuT (device

Brabetz, Ludwig, Ayeb, Mohamed, Koppe, Christian, Hesse PhD, Benjamin

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