With ever tightening emission standards, the automotive industry is continuously seeking novel ways to improve the aftertreatment system (ATS). Exhaust treatment systems using diesel emission fluid (DEF), in conjunction with selective catalytic reduction (SCR) and diesel oxidation converters (DOC), have been gaining popularity in the heavy equipment industry. Spraying DEF (mixture of urea and water) into the exhaust flow can convert harmful NOx gases into N2 and H2O. Design of ATSs focuses on high evaporation rate and uniform mixing of ammonia at the entrance to the SCR catalyst. This study applied support vector regressor (SVR), a machine learning (ML) method to a database of computational fluid dynamics (CFD) simulations to develop a highly efficient mixer with high heat exchange characteristics. Over 500 mixer designs were evaluated using CFD and were then used to train the SVR model. The trained ML model was then used as a surrogate to the CFD and coupled with the genetic algorithm

Singh, Samrendra K., Braginsky, Daniel, Tamamidis, Panos, Gennaro, Monacelli

The Numerical Study on the Effect of CuO Nanoparticle Additive into SI Engine Coolant on the Engine Power

2020-01-203209/15/2020

The goal of the study was to investigate the effect of different amounts of the CuO nanoparticles used as additive in the coolant on the power and efficiency of the analyzed SI engine. The temperature gradients in the engine body and its components were obtained using the elaborated model of the heat exchange in engine cooled with different fluids. The simplified model of combustion was used to estimate the temperature and power values generated during the combustion process in the engine under given load and speed values. The efficiency of the engine was estimated using the model taking into account various resistances generated during the operation of a given type of engine. The obtained changes in the engine power and efficiency resulted from the changed composition of the engine coolant were presented.

Siczek, Krzysztof, Wozniak, Marek, Diaconu, Mihai, Dima, Georgiana, Ion, Luiza, Bica, Ionela

The Use of CuO Nanoparticles as Additive to the Engine Coolant

2020-01-223609/15/2020

Cooling is one of the most important processes conditioning proper operation of combustion engines. The development of the higher-power engines entails greater thermal loads, in which in turn require an increased cooling. The use of nanofluids (NFs) with admixture of metallic or nonmetallic nanoparticles (NPs) promises a potential platform for miniaturization of heat exchangers and/or lower energy consumption. This is attributed to an extended surface area related to NPs in the fluid, which allows for increase of thermal conductivity and a considerable increase of the heat transfer coefficient of the fluid with NPs. Their thermo-physical properties, such as particle size, stability, viscosity, dispersion, heat dissipation efficiency, zeta potential and thermal conductivity and also their behavior under different amount in the base fluid are systematically investigated from the point of view of the choice of the best candidate for coolant applied in modern engines. The CuO NPs turn out

Siczek, Krzysztof, Wozniak, Marek, Rylski, Adam

Numerical Investigations on Heat Transfer and Flow Characteristics of Climate Control Systems in Electric Vehicles

2020-28-001004/30/2020

Earth's surface temperatures would increase from 2.90 C to 3.40 C by the year 2100 due to global warming, leads to conceivable calamitous effects on human livelihoods, livestock, ecosystems and biodiversity. Overall globally several policies were made to reduce the carbon dioxide emission and other greenhouse gases. The transportation sector is one of the prominent sources of carbon dioxide emissions. On account of the significant emissions caused by conventional buses, migrating to electric buses which have zero tailpipe emissions for public transport fleets is essential. Taken into consideration of the energy density of traction batteries, and cost, energy utilized for HVAC applications should be optimized. Heat transfer and flow characteristics in the condenser and the evaporator zone of climate control system for electric buses were numerically studied and compared with experimental results. Grid independence and turbulence studies were carried out to develop the CFD methodology

Radha, Mahendravarman, S, Vijayaraghavan, D, Govindaraj, Radha, Mahendravarman, S, Vijayaraghavan, D, Govindaraj

Parametric Analysis of Impact of Geometrical Parameters on Thermal Performance in Compact Heat Exchangers

2020-28-002504/30/2020

Compact heat exchangers are extensively used in the automotive sector, especially in engine cooling and passenger cabin cooling. Considering the evolution of compact heat exchangers from the past several years, development on the compactness has grown up rapidly with the market demand. In line with the futuristic view, it has become mandatory to optimize their thermal performance along with compactness, manufacturing feasibility and durability requirement. The present work investigates the impact of various geometrical parameters of tube & fin design on the heat transfer coefficient and pressure drop. The parametric study determines the most optimized core matrix by considering the manufacturing constraints using mathematical & analytical modeling. The system is mathematically modeled and then simulated to estimate the heat transfer rate, weight, free flow area, wetted area, etc. The output parameters are normalized with respect to the existing product performance benchmark and the

Nawani, Rachit, Suman, Saurabh, Kushwah, Yogendra Singh

Effect of Variable Geometry Fin in Automotive Condenser using Analytical and CFD Approach

2020-28-002804/30/2020

Due to stiff competition among the Original Equipment Manufacturer (OEM's), the Comfort, Fuel efficiency & Safety are the key factors that drive the vehicle business, from that context Air Conditioning for a car plays a pivotal role in the area of comfort of the passengers and fuel efficiency point of view. In addition, condenser plays a pivotal role in Power train cooling system & air conditioning system. Therefore, it is a big challenge for the automotive engineer to propose an innovative design that can improve the thermal performance of Condenser without not compromise the package size. Also, it's a challenge for the OEM's to select the optimal heat exchanger from the supplier basket during the design phase of product development cycle. The objective of this paper to focus on analytical calculation or frame work was developed using excel tool considering the variable geometry of fin which includes louver pitch, louver angle and louver length in a multi-pass condenser. Further this

Anandan, Ram

UDM Tip Temperature Control using Thermosyphon Principle

2020-28-004004/30/2020

In today’s automobile industry where BS6 is posing a high challenge and with limited timeline. The main target is to provide the cooling system to have less impact on the in terms of cost, weight and meeting challenging engineering requirement. Thus, the frugal engineering comes into the picture. An important technology that has come into highlight in recent years is the application of thermosyphon principle for UDM injector cooling thereby reducing the rotation parts and power consumption such as an electric pump. Thermosyphon is a method of passive heat exchange and is based on natural convection, which circulates a fluid without the necessity of a mechanical or electric pump. The natural convection of the liquid commences when heat transfer to the liquid gives rise to a temperature difference from one side of the loop to the other. The Flow through the UDM is maintained by changing Temperature (hence density) of the fluid at one end using the force airflow. The main objective of the

Solomon, Samson, Thiyagarajan, Rajesh, Khan, Parvej

Adaptation of Subcool Condenser for An Air Conditioning System Employing An Internal Heat Exchanger.

2020-28-002604/30/2020

Recently, the use of air conditioning systems is growing rapidly due to increasing global temperatures. Considering enormous growth in the application of the air conditioning system, there is an urgent need to improve design, performance, and efficiency thereof. For example, the air conditioning systems that are being used these days are required to provide improved efficiency per unit of power consumed, and they are also required to have a smaller form factor as compared to conventional air conditioning systems. Therefore, a lot of modern air conditioning systems employ components such as internal heat exchangers, thermal expansion valves and forth to improve their performance while having a small form factor. In this study a condenser is adapted to be used for an air conditioning system employing an internal heat exchanger. Wherein the condenser subcool area is in a optimized range of a frontal condenser area; and a free flow area within the plurality of tubes of the subcool region

Suman, Saurabh, Kushwah, Yogendra Singh, maske, Suraj

Laboratory Testing of Vehicle and Industrial Heat Exchangers for Heat Transfer and Pressure Drop Performance

J1994_202004 (Current)

04/28/2020

This SAE Recommended Practice is applicable to all heat exchangers used in vehicle and industrial cooling systems. This document outlines the tests to determine the heat transfer and pressure drop performance under specified conditions. This document has been reviewed and revised by adding several clarifying statements to Section 4.

Cooling Systems Standards Committee

Transient Simulation of Heat Exchangers with Phase Change Material

2020-01-015604/14/2020

Heat exchangers with Phase Change Material (PCM) are finding more energy storage applications for both Internal Combustion Engine Vehicles (ICEVs) and Electric Vehicles (EVs). These applications include cold storage evaporators for stop-start cars, thermal storage system for EV cabin heating and cooling, and other Heating, Ventilation, and Air Conditioning (HVAC) and Power Train Cooling (PTC) peak load shaving applications. The energy stored in a PCM heat exchanger is typically charged/discharged using refrigerant, coolant, or air, depending on the system design of different applications. Due to the low thermal conductivity of state-of-art PCM, the PCM heat exchangers generally rely on aluminum fins to enhance the speed of charging and discharging of the stored energy. Different fin shape, height and density will result in different PCM freezing/melting rate. In this paper, two different fin designs (folded-sine-wave fin and off-set-strip fin) are simulated with Computational Fluid

Xia, Yanping, Wolfe, Edward, Craig, Timothy

3-Dimensional Numerical Simulation on CuO Nanofluids as Heat Transfer Medium for Diesel Engine Cooling System

2020-01-110904/14/2020

CuO-water nanofluids was utilized as heat transfer medium in the cooling system of the diesel engine. By using CFD-Fluent software, for 0.5%, 1%, 3% and 5% mass concentration of nanofluids, 3-dimensional numerical simulation about flow and heat transfer process in the cooling system of engine was actualized. According to stochastic particle tracking in turbulent flow, for solid-liquid two phase flow discrete phase, the moving track of nanoparticles was traced. By this way, for CuO nanoparticles of different mass concentration nanofliuds in the cooling jacket of diesel engine, the results of the concentration distribution, velocity distribution, internal energy variation, resident time, total heat transfer and variation of total pressure reduction between inlet and outlet were ascertained. It is proved by simulation results that nanofluids as heat transfer medium can evidently enhance diesel engine heat transfer capability, when the concentration of nanoparticles increases, the

Yang, Shuai, Yang, Xiaolin, Liu, Haifeng, Li, Xiuyuan

Enhancement of Heat Exchanger Performance Using Oscillating Flow

2020-01-094304/14/2020

In this research work, the heat transfer enhancement by using oscillatory flow of the thermal fluid between cold and hot reservoir has been analyzed both theoretically and using simulation methods. The main objective of this study is to examine the feasibility of a system working under oscillatory flow conditions compared to its steady flow counterpart. The principle of incrementing thermal diffusion over molecular diffusion by establishing oscillatory flow has been utilized in this case. The system has been designed and the effect of the flow condition has been analyzed using ANSYS Fluent k-epsilon model. The effect of change in the magnitude and frequency of oscillation on local Nusselt number has been computed. The observed increment in the Nusselt number by increasing the amplitude and frequency of the fluid has been bolstered by analytical calculation. A comparison in the heat transfer of a system working under oscillating and a steady flow conditions has been generated to

Rajagopalan, Haripriya, Premchandra Tavorath, Adhithiya, Pol, Sakshi, Dhamangaonkar, Pradyumna, Rajagopalan, Haripriya, Premchandra Tavorath, Adhithiya, Pol, Sakshi, Dhamangaonkar, Pradyumna

Adaptive sampling in the design space exploration of the automotive front end cooling flow

2020-01-014904/14/2020

Adaptive sampling in the design space exploration of the automotive front end cooling flow (Author)Venkata Krishna Mohan Chagarlamudi, FCA NA - mohan.chagarlamudi@fcagroup.com, (Co-Author) Arturo Guzman FCA NA - arturo.guzman@fcagroup.com, (Co-Author) Mark Doroudian FCA NA - mark.doroudian@fcagroup.com, (Co-Author) Dr. Malik KAYUPOV Dassault Systemes Simulia Corp - malik.kayupov@3ds.com One of the key inputs 1-D transient simulation takes is a detailed front end cooling flow map. These maps that are generated using a full vehicle 3D CFD model require expensive computational resources and time. This paper describes how an adaptive sampling of the design space allowed the reduction of computational efforts while keeping desired accuracy of the analysis. The idea of the method was to find a pattern of DOE sampling points for 3D CFD simulations that would allow a creation of an approximation model accurate enough to predict output parameter values in the entire design space of interest

Chagarlamudi, Venkata KrishnaMohan, Doroudian, Mark, Kayupov, Malik, Guzman, Arturo

A Lumped-Parameter Thermal Model for System Level Simulation of Hybrid Vehicles

2020-01-015004/14/2020

Commercial vehicle electrification is a path to meeting stringent fuel consumption and emission targets. Considering extended operations in different applications, the powertrain components need to be selected and sized together with the cooling system to ensure consistent performance and longer product life. In order to maintain the interactions between subsystems in the optimization routines, multi-physics models should be utilized. A simplified thermal network model is developed in this work for hybrid powertrain cooling systems based on the analogy between heat transfer and current flow equations. The assumption of a lumped system is valid for these components as the conductive heat transfer is much higher than convective heat transfer (Biot number <0.1). The energy equations are solved to calculate component temperatures in state space form, whereas, in literatures, detailed object-oriented 1-D models are mainly used for this purpose. This approach reduces simulation setup time

Caicedo Parra, Dina, Ramakrishnan, Kesavan, Farrell, Lisa, Narula, Manik, Sill, Patrick, Benjamin, Jithin

Thermal Performance Augmentation of Automobile Radiator Using Water-Based Al ₂ O ₃ and CuO Nanofluid as a Coolant

2020-01-134004/14/2020

An engine cooling system in a vehicle engine is a must, which carries away unutilized heat produced in the engine cylinder. However, usage of low thermal conductivity engine coolant limits the ability of the cooling system to extract the heat, which ultimately results in difficulties in maintaining the compact size of the cooling system. Also, increasing the cooling rate by conventional technologies i.e. providing fins and microchannel has already reached their limits. Researchers are thus focusing on immersing and analyzing new types of cooling fluids in recent days. In the present study, the thermal performance of two different nanofluids, Al2O3 and CuO in a flat tube automobile radiator has been studied. Experimental results have been obtained for 0.02% volume concentration of both Al2O3 and CuO nanofluid, and water as coolants. A numerical model considering the ε-NTU method is also developed using MATLAB code. The analytical results are validated with experimental results. Further

Maisuria, Mahendrakumar, Rathod, Manishkumar K., Parmar, Akashkumar Pravinbhai

Rear Axle Heat Exchanger Utilization of Engine Coolant for Reduced CO2 Emissions and Fuel Consumption

2020-01-141104/14/2020

This paper describes the design, development, and operation of a rear axle dual-shell heat exchanger on a RAM 1500 Light Duty truck. This system has been proven to increase fuel economy and reduce exhaust emissions, particularly CO2 on the EPA Cold City schedule. Through heat transfer math models, the energy conversion strategy will be explored. A PUGH analysis associated with concept selection is included. To refine the hardware and develop a control strategy prior to testing, a portable flow cart was developed to assess system performance and to correlate the multi-node heat transfer model. Bench testing focused on the durability and functional aspects of integrating the dual-shell axle cover with the axle and coolant delivery system through a comprehensive design and validation plan. Vehicle testing included various fuel economy and emissions related driving schedules to quantify the benefits.

Schumaier, Timothy, Bartlett, Matthew, Laugen, Alex, Scott, Timothy, Singh, Jasbir, Sopko, Jay, Troy, Paul

Utilization of bench testing in vehicle thermal system development for extreme cold ambient condition

2020-01-139004/14/2020

Automotive thermal systems are becoming complicated each year. The powertrain efficiency improvement initiatives are driving transmission and engine oil heaters into coolant network design alternatives. The initiatives of electrified and autonomous vehicles are making coolant networks even more complex. The coolant networks these days have many heat exchangers, electric water pumps and valves, apart from typical radiators, thermostat and heater core. Some of these heat exchangers including cabin heaters deal with very small amount of coolant flow rates at different ambient conditions. This paper describes how viscosity can be a major reason for simulation inaccuracy, and how to deal with it for each component in the coolant network. Both experimental and computational aspects have been considered in this paper with wide range of ambient temperatures. Methods have been proposed to handle these issues in the simulation phase at the early phase of automotive thermal system development

Khandaker, Masuma, Uddin, Ahmed, Sanikal, Vijay, Fuad, Kaji, Lindquist, Craig, Baker, Gary, Rahman, Sadek

Accounting Thermal Exchanges in Coanda Effect

2020-01-0026

03/10/2020

An exhaustive model of Coandã effect has not been defined, and fundamental questions are still open. One of them is the influence of convective heat exchange on Coandã adhesion. This paper presents an even preliminary numerical study of this problem. It analyses the behaviour of a fluid stream on a convex surface in the presence of a temperature gradient between the fluid and the convex surface. It approaches the problem by a set of CFD simulations, analyses previous hypotheses, which are based on Prandtl number, and evidences the need for a model that account Reynolds number. The performed simulations are still not sufficient for an exhaustive comprehension of Coandã effect in the presence of heat exchange phenomena. It allows producing some consideration that may help future scientific work in toward a better comprehension of these phenomena. In particular, it verifies the importance of Reynolds number, because it is intrinsic in the adopted model, with good accordance with CFD data

Trancossi, Michele, Pascoa, Jose