Browse Topic: Thermal management

Items (694)

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

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

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

XU, shenao

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

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

Sahoo, Pranati

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

Sen, Somnath

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

Hug, Thimo

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

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

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

Zheng, Teng

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

Use of Thermally Conductive Electrically Insulative (TCEI) Materials in E-motor Slot Liner Applications

2022-01-022403/29/2022

Slot liners are commonly used in electric motors to electrically insulate the motor windings from the laminated core. However, thermal conductivity of materials commonly used as slot liners is very low compared to other components in the motor thus creating a barrier for heat transfer. This thermal barrier affects overall motor performance and efficiency. Also, slot liners typically lack intimate contact with the laminated core resulting in air gaps which further increase thermal resistance in the system. Slot liners are traditionally made from high temperature films/papers that are cut and slid into slots of motors. The proposed work looks at developing an injection moldable slot liner to minimize air gaps. Additionally, use of TECI materials further lowers thermal resistance. A thermal finite element model has been developed to evaluate effects of slot liner thermal properties and air gaps on temperature distribution within the motor. The model incorporates varying material

Sundararaman, Saikrishna, Szparagowski, Ray

Digitalization of a climate and altitude simulation test bench for handheld power tools to automate its thermal management system

2022-01-072703/29/2022

Mechanical systems accomplish their tasks better when enhanced with cyber technologies. With the rapidly escalating desire for high efficiency, optimization and flexibility, these physical systems ought to be integrated with cyber technologies that enhance exhaustive manipulation of resources and unsurpassed productivity. The gateway for such a synergetic integration can be referred to as digitization. Details regarding the digitization of a High-altitude Simulation chamber are discussed thoroughly in this paper. The simulation chamber was originally designed and developed as a test bench to study the characteristics of alternative fuels used in the engines of handheld tools in different altitudes and thermal conditions. It encompasses all the possible realistic temperature variations with altitude raising to 3500m above sea level. Since the testbed’s effectiveness is highly dependent on achieving a combination of desired temperature and altitude values to maintain them for a defined

Nenninger, Philipp, Hadamek, Christof, Renner, Marius, Derbie, Arsema, Kettner, Maurice, Aslan, Ferhat

A Simulation And Optimization Design Case for Heavy Truck Thermal Management

2022-01-021003/29/2022

In order to meet CHINA VI Emission Standard and high-horsepower engine system integration for fourth-stage fuel consumption standards, which will put higher heat load to the entire cooling system, Faw Jiefang is conducting development on vehicle thermal management technology system. This requires redesign of front grill and the underhood cooling system components such as, cooling airflow duct, and fan shroud. Simply increasing the cooling air mass flow rate could improve the overall cooling airflow system performance; however, it will also increase the fan power consumption and aerodynamic drag of the vehicle, which will lead to an increased fuel consumption and escalate emission. Hence, a multi-objective optimization towards engine cooling system is necessary to achieve desired cooling performance while maintaining or lowering aerodynamic drag. An accurate simulation methodology is a key component for this iterative design and optimization process, as it will expedite the development

Guo, Ping, Chen, Tao, Liao, Genghua, Yang, Yang, Li, Han, Friz, Heinz, Mukutmoni, Devadatta, Kandasamy, Satheesh

Multiple Heat Exchangers for Automotive Systems – A Design Tool

2022-01-020503/29/2022

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

Design and Optimization of an SUV Engine Compartment Undershield based on Latin Hypercube Design Method and Multi-island Genetic Algorithm

2022-01-020103/29/2022

Vehicle engine compartment thermal management performance ensures engine performance and reduces pollutant emissions, and a suitable temperature range in the engine compartment during vehicle operation is critical to reducing carbon emissions. The design of the engine compartment components affects the thermal fluid flow performance in the engine compartment, which in turn affects the engine compartment thermal management performance, so it is necessary to explore the optimization of engine compartment components. In this paper, based on the phenomenon that the engine compartment undershield of an SUV caused abnormally high temperature on the surface of the engine compartment parts due to design defects, the engine compartment was modeled and simulated by STAR-CCM+, and it was found that the undershield caused hot air flow back, which was not conducive to engine compartment heat dissipation, so the undershield needed to be redesigned. The shape of the undershield was redesigned and

Liu, Yong

Numerical and Experimental Investigation of heat transfer enhancement in an off-road radiator using Al2O3 nano fluids

2021-28-017710/01/2021

Water and ethylene glycol are considered as conventional coolants from years in automotive industry for engine cooling. With the advancements in nanotechnology, Nano fluids have become prominent in increasing the rate of heat transfer compared to that of conventional fluids. Present study enlightens the CFD simulation of Nano-fluids in a radiator with base fluid as Ethylene glycol- water and Al2O3 as nanoparticles at different volume concentrations. The Nano fluid rheology is simulated in Ansys-Fluent CFD tool using standard k-ε two equation turbulence model with enhanced wall treatment and a standard y plus values. Various available fluent single phase and multiphase models are evaluated and compared with the experimental results in a simple circular pipe to setup the standard simulation methodology for radiator analysis. The effective temperature dependent thermos-physical properties of Nano fluids were estimated from the literatures. The result shows that alumina oxide nano fluids

Dewangan, Nitin, Kattula, Nitin, Kumar PhD, Kiran, naidu, Ramesh

Comparison of different thermal management strategies in tropical conditions for Li ion batteries and the effect of using Phase change materials (PCM)

2021-26-014009/22/2021

The automobile sector is moving towards electrification as a replacement for the conventional IC Engine as the power source of vehicles. In electric vehicles, Li-ion battery is the widely used energy source for traction and is a major differentiator among various sub components that affect vehicle performance, safety and efficiency. The life of the battery pack is affected by different stress factors like SoC (state of charge), DoD (depth of discharge), C-rates (charge and discharge currents) and battery temperature. Out of the mentioned stress factors, the life of batteries is most influenced by the temperature excursion seen by the li-ion cells in the battery pack. There are various thermal management strategies available to keep the temperature under control like air cooling , chilled liquid cooling and hybrid cooling systems. The benefit of using Phase Change Materials (PCM) in case of hybrid cooling systems in mitigating thermal runaway propagation within the battery pack and the

Kumar, Tirukoti Mohan, C, Vijay Ram

Case Study on Optimized Cooling System Concept for Electric Compact-SUV with Indian Environmental Conditions

2021-26-041009/22/2021

With the rising emission level in Indian cities, the focus on pure battery electric vehicle is increasing also in India. The Government of India his also focusing on preparing right policies like FAME-2 to promote the acceptability of EV's by providing subsidies as well as creating the required infrastructure. The environmental conditions in India is much different than other developed countries of Euro, China etc. The max. temperatures in India can go up to 55℃ in the hottest summer time, while during winters temperature can go up to <-25℃ in the northern Himalia region. In these conditions the cooling system of the electric-powertrain components like E-Machine Battery pack etc have to be protected for worst case scenarios specific to Indian conditions. Major cost driver of EV's lie in the HV battery packs and it is very important for acceptability of EV's that the Battery is maximized. With fast discharging and charging phenomena of battery pack required in automotive application can

Emran, M.Sc. Ashraf, Garg, Shivam, Manns, M.Sc. Patrick, Sharma, Vijay

Simulation based approach to improve the engine oil warmup behavior using exhaust gas during NEDC cycle

2021-26-042209/22/2021

During the cold start conditions engine must overcome higher friction loss, at the cost of fuel penalty till the optimum temperatures are reached in coolant and lubrication circuits. The lower thermal capacity of the lubrication oil (with respect to the coolant) inverses the relation of viscosity with temperature, improves engine thermal efficiency benefit. Engine oil takes full NEDC test cycle duration to reach 90°C. This leads to higher friction loss throughout the test cycle, contributing a significant increase in fuel consumption. Increasing oil temperature reduces viscosity, thereby reducing the engine friction. This helps to identify the focus for thermal management in the direction of speeding up the temperature rise during a cold engine starting. This work aims at the study and experiment of an exhaust recovery mechanism to improve the NEDC fuel economy. The objective of the work is to use the exhaust gas energy, post after treatment system to heat up the engine oil temperature

Krishnan, Karthikeyan N., Ramadandi, Padmavathi, M, Vikramraj, Elumalai, Sakthivel

1D modelling of fuel cell losses including the water and thermal management

2021-26-022509/22/2021

To study the functioning of a fuel cell and optimize its operating parameters to achieve the best efficiency in operation it is important to have a robust fuel cell model that can simulate the behavior of the fuel cell stack under various operating conditions. The operating voltage of the fuel cell at different current densities depends upon thermodynamic parameters like temperature and pressure of the reactants as well factors like the state of humidification of the electrolyte membrane. A 1D model is developed to capture the variation in voltage at different current densities due to internal losses and changes to operating conditions like temperature and pressure. Additionally since the stack temperature and moisture content within the stack influence the stack operation directly models for the thermal management of the stack and humidification of the membrane are also developed. The results of the internal losses and humidification models are validated against experimental and

S A, Yogesha, Jacob, Joe, Arikapudi, Suresh

Development of an Intelligent Thermal Management System for BYD DM-i Hybrid Engine

2021-01-115309/21/2021

BYD recently introduced its new DM-i (Dual Mode-Intelligent) plug-in hybrid architecture with a new dedicated 1.5NA (Naturally Aspirated) high-efficiency engine, which can reach a peak of 43% brake thermal efficiency. With this architecture, the vehicle is mainly driven by motors and engine only starts when required. This requires that once started, the engine can reach its best working temperature as quick as possible. To achieve this target, a new intelligent thermal management system was designed. This system adopted an advanced split cooling strategy to control the flow ratio between cylinder block and head, which was realized by the combination of one electronic thermostat and one wax thermostat. An electronic water pump was used to actively control the coolant flow rate. Together with the intelligent control of thermal needs under all working conditions, the new thermal management system realized the following benefits: faster engine warm-up, better fuel economy and lower

lu, Guoxiang, Yang, Dongsheng, Rong, Yulong, Gong, Zewen, Wang, Bo

Advanced developments in solid desiccant coated heat exchangers and their potential applications

2021-28-014209/15/2021

To meet the increasing thermal comfort requirements in recent times, applying a solid desiccant coated heat exchanger (SDCHE) air-conditioning system is one of the thrust areas of focus due to its energy efficiency benefits. Fixed stationary bed and rotary wheel desiccant systems are being used widely for dehumidification. In these systems, the increase in the relative humidity of intake process air increases the adsorption heat release from the desiccant, and the desiccant’s temperature increases due to the lower heat transfer efficiency. This effect reduces the COP of these systems since the desiccant adsorption capacity is inversely proportional to the desiccant’s temperature. To overcome the limitations of the fixed stationary beds and rotary wheel desiccant dehumidifiers, SDCHE is a suitable technology for standard vapor-compression air conditioners. These heat exchangers can deliver combined heat and mass transfer between the process air and the working fluid. The process air can

Muthu, Selvaraji, N, Sekarapandian, KANNAIYAN, Ashok, ARIVUKKARASU, Hariprasath

Alternate Methodology for Air Conditioning Compressor Capacity Measurement

2021-28-014109/15/2021

The actual compressor capacity is generally different from the theoretical capacity due to internal leakages and manufacturing imperfections. Conventionally, compressor volumetric efficiency is measured using system level testing consisting of evaporator, condensor & TXV in a closed loop system with known refrigerants. In this paper a methodology is demonstrated for evaluating any auto mobile air conditioning compressors' volumetric efficiency & capacity by using atmospheric air in an open loop system. Wide range of compressors (~70cc to ~220 cc) were tested and data generated. The process parameters of the test rig was continuously monitored until stabilization and readings were taken. It is observed that the results are comparable with closed loop performance results. Comparative study is presented for tested volumetric capacity and theoretically calculated value along with variations. Henceforth, the outlined approach gives deeper insight into design effectiveness, any imperfections

Yadav, Aditya Pratap, Goel, Arun Kumar, Sharma, Kamal

EXPERIMENTAL INVESTIGATION ON THE EFFECT OF NATURAL BASED ADDITIVES ON SINGLE-CYLINDER DI DIESEL ENGINE

2021-28-013009/15/2021

In this experimental study, an attempt is made to enhance the performance characteristics of diesel fuel with two different natural additives (NA). Borassus Flabelifer (NB1) and Oryza Sativa straws (NB2) were chosen as natural additives. The selected natural additives were milled for 150 hours using a planetary ball mill and obtained particle size was 120-140nm. The milled natural additives were stirred using a magnetic stirrer followed by ultrasonication their stability was ascertained. The presence of high carbon and oxygen content was noted on EDS results of milled powder The properties of fuel were analyzed as per ASTM standards and it was observed that there was a marginal decrease in calorific value, flash point, and fire point of the fuel. Performance analysis of fuel was carried out in a diesel engine at different load conditions and it was observed that brake thermal efficiency was reduced by 1.73 % and 1.24 % for NB1 and NB2 doped diesel respectively. Reduced CO and HC

Velusamy, Raja, Annamalai, Suresh Babu, Swaminathan, Mangudi Rangawamy, Periyana Pillai, Hariharan, Ganapathy, Sakthinathan, Radhakrishnan PhD, Vignesh, Kumar, Premkumar

Methodology for optimized automotive grill opening area prediction based on 1D simulation approach and correlation with prototype test Model

2021-28-013309/15/2021

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

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