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2017-11-05
Technical Paper
2017-32-0027
Chien-Hsiung Tsai, Hui-Hui Huang, Wei-Chun Chang
In this paper, the temperature of coupling system including cylinder, head, inlet/exhaust valve, and the cooling jacket of a 400cc engine is investigated by computational fluid dynamic (CFD) method. Firstly, the total pressure loss of water jacket, radiator, and thermostat is calculated first, and then the mass flow rate inside the cooling system can be determined by fitting the water pump’s performance curve (P-Q curve). The thermal boundary conditions for analysis of conjugate heat transfer of cooling system, such as combusting gas temperature and heat transfer coefficient are utilizing the results of 1-D engine simulation software (Ricardo WAVE). The current approach is that the heat transfer coefficients of valve while opening are calculated by considering the intake and exhaust stroke using FLUENT to overcome the difficulty of these values that are not modeled in such 1-D software. Finally, the finite element method (FEM) is used for the valve stress calculation.
2017-11-05
Technical Paper
2017-32-0079
Tsukasa Shimizu, Jin Itou, Hideki Shirazawa, Yasuyuki Muramatsu
It is important to make small and light weight motor for small EV. It is necessary to select appropriate cooling system (liquid cool or air cool) according to motor output. We thought that there is a threshold output that makes the volume smaller and the weight lighter including the liquid cooling system. As a result of the rough calculation, it was found that the weight can be reduced by adopting the liquid cooling for at about 10kW or more. In this study we focused on motor and cooling system volume and weight and tried to clarify appropriate cooling system according to motor output.
2017-10-13
Technical Paper
2017-01-5014
Maurilio Pereira Gomes, Igor Santos, Camila Couto, Cristiano Mucsi, Jesualdo Luiz Rossi, Marco Colosio
Abstract This work consists of evaluating the influence of heat treatment on sintered valve seat insert (VSI) obtained with two different high-speed steels powders and one tool steel: AISI M3:2, AISI M2 and AISI D2, respectively. The high-speed / tool steel powders were mixed with iron powders and additives such as manganese sulphide, zinc stearate, graphite and niobium carbide. All the high-speed / tool steel powders had its particle size distribution and morphology analyzed. The heat treatment of the VSI consisted of air quenching followed by double tempering it in seven different and equidistant temperatures, ranging from 100 °C until 700 °C. A data acquisition system with a thermocouple type k attached to the samples was used to determine the air-quenching cooling rate. The mechanical and physical properties measurements were carried out, i.e., apparent density, apparent hardness and crush radial strength.
2017-10-08
Technical Paper
2017-01-2456
Yun Li, Jing Shang, Shiwu Zhu, Alina Ma, Robin Lyle, Zijian Li, Nannan Wang, Hua Rong
Abstract This paper presents an Integrated Power Module (IPM) and an Integrated Power Unit (IPU) based on IGBT double-sided cooling technology. The IPU can be used as the motor controller in electric vehicle applications, and the IPM integrated in the IPU is packaged with the latest trench field-stop IGBT devices and is utilized with planar bonding as well as double-sided cooling technology. By adopting the planar bonding and double-sided cooling technology, module design has achieved elimination of the traditional wire bonds, even temperature distribution for the surface of dies, and improvement of thermal performance, which results in lower junction temperature rise. Through these factors, power cycling capability and long-time reliability of the module can be significantly improved. Test results show that compared with traditional single-sided direct liquid cooling module with a pin-fin structure, thermal resistance has been reduced by 23%.
2017-10-08
Technical Paper
2017-01-2219
Xihui Wang
Abstract The conventional cooling fluids in vehicle engine cooling water jacket have relatively poor heat transfer performance. The key to enhance heat transfer in cooling-jacket is to research a kind of new coolants. Nanofluids have heat transfer enhancement merits. In present study, the numerical simulation on Fe3O4 nanofluid flow in cooling water jacket of Gasoline direct injection engine was performed using computational fluid dynamics ( CFD) software FLUENT. The heat transfer coefficient of nanofluids was calculated and verified by experiment. Fe3O4 nano-particles were used in mixture of water/ethylene glycol as a base fluid. The thermal performance of the nanofluid was studied, also the thermal performance of a cooling-jacket was studied with CFD technology. The simulation was performed for different volumetric concentrations of(1%,2%,5%) nanofluids at different engine speeds. The results showed that heat transfer enhanced compared to the base fluid.
2017-10-08
Technical Paper
2017-01-2223
Vikram Singh, Per Tunestal, Martin Tuner
Abstract In recent years, stricter regulations on emissions and higher demands for more fuel efficient vehicles have led to a greater focus on increasing the efficiency of the internal combustion engine. Nowadays, there is increasing interest in the recovery of waste heat from different engine sources such as the coolant and exhaust gases using, for example, a Rankine cycle. In diesel engines 15% to 30% of the energy from the fuel can be lost to the coolant and hence, does not contribute to producing work on the piston. This paper looks at reducing the heat losses to the coolant by increasing coolant temperatures within a single cylinder Scania D13 engine and studying the effects of this on the energy balance within the engine as well as the combustion characteristics. To do this, a GT Power model was first validated against experimental data from the engine.
2017-10-08
Technical Paper
2017-01-2204
Hoon Lee, Kwangwoo Jeong, Sanghoon Yoo, Byungho Lee, Sejun Kim
Abstract Hyundai-Kia Motor Company recently developed a multi-way, electrical coolant valve for engine thermal management module (TMM). The main purposes of the TMM are to boost fuel economy by accelerating engine warm-up and also to enhance engine thermal efficiency by actively controlling the operating temperature. In addition to those, the system can improve vehicle heating and cooling performance as well. The electrical coolant valve is a key component in the TMM as it modulates the amount of coolant flow to individual components in cooling system such as engine oil heat exchanger, heater core, and radiator. The coolant flow modulation is done by controlling the electric valve’s position with using an electric motor attached to the valve. The objective of the valve control is to manage coolant temperature at a desired level that varies depending on vehicle’s operating condition. This paper discusses the control algorithm developed for controlling electrical coolant valve.
2017-10-08
Journal Article
2017-01-2427
Suresh Kumar Kandreegula, Rahul Jain, Shivdayal Prasad, Rahul Machiya, Avinash Mandyam
Abstract Automotive vehicle includes various systems like engine, transmission, exhaust, air intake, cooling and many more systems. No doubt the performance of individual system depends upon their core design. But for performance, the system needs to be fastened properly. In automotive, most of the joints used fasteners which helps in serviceability of the components. There are more than thousands of fasteners used in the vehicle. At various locations, we found issue of bolt loosening and because of this design intent performance has not met by the system. During product development of ECS (Engine cooling system), various issues reported to loosening the bolt. The pre-mature failure of bolt loosening, increases the interest in young engineers for understanding the behavior of fastener in vehicle running conditions. This paper focuses on the design of wedge shape of washer to avoid bolt loosening.
2017-09-19
Technical Paper
2017-01-2045
Shivam Mishra, Sanjay Y
Abstract Air-film cooled gas turbine is widely used in aero-derivative gas turbines. The present paper reviews previously developed air-film blade cooling models. The article further proposes a new blade cooling model for estimating blade coolant mass fraction which takes into account the effect of radiative heat transfer from hot flue gases to aero-derivative gas turbine blade surface. Various possibilities to achieve enhanced performance from aero-derivative gas turbine have been enumerated namely effect of advanced design philosophies, thermal barrier coatings, advancement in blade material. Also adoption of advanced design philosophies such as 3-D CFD would lead to improved component design. Further use of advanced blade material specifically for gas turbine blade application including single-crystal blade, directionally solidified blade material being nickel-chrome-molybdenum alloys may be explored.
2017-09-04
Technical Paper
2017-24-0158
Teresa Castiglione, Giuseppe Franzè, Angelo Algieri, Pietropaolo Morrone, Sergio Bova
Abstract In this paper, we propose a novel control architecture for dealing with the requirements arising in a cooling system of an ICE. The idea is to take advantage of the joint action of an electric pump and of an ad-hoc regulation module, which is used to determine adequate flow rates despite engine speeds. Specifically, a robust Model Predictive Control approach is exploited to take care formally of input/output constraints and disturbance effects of the resulting lumped parameter model of the engine cooling system, which incorporates the nucleate boiling heat transfer regime. Numerical simulations and test rig experimental data are presented. The results achieved show that the proposed control scheme is capable of providing effective and safe cooling while mitigating disturbance effects and minimizing coolant flow rates when compared with the action pertaining to standard crankshaft driven pumps.
2017-09-04
Journal Article
2017-24-0160
Mario Marchetti, Riccardo Russo, Salvatore Strano, Mario Terzo
Abstract The activity described in this paper has been carried out in the framework of a funded project aimed at evaluating the feasibility of a controllable water pump based on an integrated magnetorheological fluid clutch. The advantages consist of an improvement of the overall vehicle performance and efficiency, in the possibility of disengaging the water pump when its action is not required, and in the control of the cooling fluid temperature. So, the design constraints have been defined with reference to the available space, required torque, and electrical power. After an iterative procedure, in which both mechanical design and magnetic field analyses have been considered, the most promising solution has been defined and a first physical prototype has been realized and tested. A preliminary experimental characterization of the developed prototype has been presented.
2017-07-10
Technical Paper
2017-28-1951
K Nantha Gopal, B. Ashok, Rishabh Bahuguna, Tanmay Prasad
Abstract Thermal management is one of the most challenging and innovative aspects of the automotive industry. The efficiency of the vehicle cooling framework unequivocally relies upon the air stream through the radiator core. Significant advances in thermal management are being embraced in the field of radiator material and coolant. The radiator shouldn't be exclusively credited for the reliable cooling of the engine. There are other auto parts that play an essential role in keeping engine temperature at a manageable level. The fan-shroud assembly is an important component of the cooling system. While the fan is responsible for drawing in air, the fan shroud's job is to ensure uniform air distribution to the radiator core. By assisting airflow in the engine compartment the fan shroud helps in dismissing excess heat from the engine. This assembly also prevents the recirculation of heated air through the cooling fan.
2017-06-05
Technical Paper
2017-01-1787
Jan Biermann, Adrien Mann, Barbara Neuhierl, Min-Suk Kim
Abstract Over the past decades, interior noise from wind noise or engine noise have been significantly reduced by leveraging improvements of both the overall vehicle design and of sound package. Consequently, noise sources originating from HVAC systems (Heat Ventilation and Air Conditioning), fans or exhaust systems are becoming more relevant for perceived quality and passenger comfort. This study focuses on HVAC systems and discusses a Flow-Induced Noise Detection Contributions (FIND Contributions) numerical method enabling the identification of the flow-induced noise sources inside and around HVAC systems. This methodology is based on the post-processing of unsteady flow results obtained using Lattice Boltzmann based Method (LBM) Computational Fluid Dynamics (CFD) simulations combined with LBM-simulated Acoustic Transfer Functions (ATF) between the position of the sources inside the system and the passenger’s ears.
2017-06-05
Technical Paper
2017-01-1834
Dirk von Werne, Prasanna Chaduvula, Patrick Stahl, Michael Jordan, Jamison Huber, Korcan Kucukcoskun, Mircea Niculescu
Abstract Fan noise can form a significant part of the vehicle noise signature and needs hence to be optimized in view of exterior noise and operator exposure. Putting together unsteady CFD simulation with acoustic FEM modeling, tonal and broadband fan noise can be accurately predicted, accounting for the sound propagation through engine compartment and vehicle frame structure. This paper focuses on method development and validation in view of the practical vehicle design process. In a step by-step approach, the model has been validated against a dedicated test-set-up, so that good accuracy of operational fan noise prediction could be achieved. Main focus was on the acoustic transfer through the engine compartment. The equivalent acoustic transfer through radiators/heat exchangers is modeled based on separate detailed acoustic models. The updating process revealed the sensitivity of various components in the engine compartment.
2017-03-28
Technical Paper
2017-01-1077
Nicolas Arnault, Nicolas Batailley, Arnaud Maria, Laurent Bechu
Abstract PSA Group, SOLVAY and SOGEFI have teamed-up to produce the first Plastic Diesel Fuel Filter fully made of recycled polyamide 66, ready for mass-production. This has been achieved by using the brand new plastic compound developed by SOLVAY Engineering Plastics. This material is 100% recycled from airbag wastes, providing a premium material able to stand demanding applications requirements supplied through circular economy, which is quite unusual in automotive industry yet. SOGEFI has used this material through its existing plastic injection process, and tested the parts on extensive bench validation tests. It confirmed that this material is fully compatible with standard injection process, and that all the tests have been passed successfully. Finally, PSA Group has driven the choice of the tested parts: DV engine 1.6l Euro6b application, homologated the material grade and evaluated the whole validation process.
2017-03-28
Technical Paper
2017-01-1076
Mohammad Moetakef, Abdelkrim Zouani, Esra Demren
Abstract In this presentation, two cases of CAE simulations of oil pump-induced tonal noises are presented. The first case involves oil pump-induced whine in an I4engine during coast down. The second case addresses oil pan moan during hot idle and the effect of oil pump pick-up tube positioning inside the oil pan of an I5 engine. The investigations include several design modifications to the pump and the pick-up tube to prevent the tonal noise. Test data are also included to demonstrate the accuracy of the CAE simulation.
2017-03-28
Technical Paper
2017-01-1087
Pengfei Zang, Zhe Wang, Yu Fu, Chenle Sun
Abstract The Linear Internal Combustion Engine-Linear Generator Integrated System (LICELGIS) is different from conventional crank-based engine for reducing frictional losses by eliminating the crankshaft. Thus, the LICELGIS piston stroke is not constrained geometrically and the system compression ratio is variable. During steady-state operation, the LICELGIS converts the fuel chemical energy into electric power with piston assembly reciprocating motion, which can be used as a range-extender in hybrid electric vehicles. The LICELGIS scavenging process is prerequisite and key for the system steady-state operation, which has remarkable influence on mixture gas and, eventually, on engine combustion performance. In order to achieve high scavenging performance, a LICELGIS is investigated in this paper. The LICELGIS motion characteristics and scavenging process were analyzed.
2017-03-28
Technical Paper
2017-01-0627
Bo Yang, Peter Woyciesjes, Aleksei Gershun
Abstract In this paper, new test results in the use of electrochemical techniques to measure corrosion in extended life engine coolants are presented. Corrosion protection performance of the engine coolants (including both fresh coolants and simulated used coolants) for typical cooling system metals under heat rejecting and heat accepting surface corrosion conditions for both general corrosion and localized corrosion are measured under conditions similar to the ones encountered in vehicle engine cooling systems as a function of immersion time. Fleet tests of the coolants were also conducted. They are used to provide support on the electrochemical test methodologies adopted. The effective use of electrochemical techniques to aid the development of the next generation of extended life coolant technologies with improved corrosion protection performance and a longer service life will be demonstrated and discussed.
2017-03-28
Technical Paper
2017-01-0337
Kalyan S. Nadella, Yi Zhang
Abstract Ensuring durability is one of the key requirements while developing cooling modules for various powertrains. Typically, road surface induced loads are the main driving force behind mechanical failures. While developing the components, road load accelerations are utilized in CAE simulations to predict the high-stress regions and estimate the fatigue life of the components mounted on the body. In certain scenarios where components are mounted to the body and attached to the engine with hoses, the components can experience additional loads associated with engine vibration. This attachment scheme requires a different analysis methodology to determine fatigue life. In the proposed paper, we look at the effect of engine motion (EM) on the fatigue life of internal transmission oil cooler (ITOC) which is mounted on the body through radiator and is simultaneously connected to the engine using a steel pipe.
2017-03-28
Technical Paper
2017-01-0620
Chandrakant Parmar, Sethuramalingam Tyagarajan, Sashikant Tiwari, Ravindra Thonge, S Arun Paul
Abstract The engine compartment of passenger car application contains various source which radiates the produced heat and raises the temperature level of the compartment. The rise in compartment temperature increases the body temperature of individual component. The rise in body temperature of critical components can endanger the durability or functionality of the specific component or a system in which it operates. The aim of this paper is to strategize thermal protection of the rear mounted engine and its components of a vehicle having radiator and cooling fan mounted in front. An additional ventilation fan with speed sensor is fitted alongside rear mounted engine and a unique monitoring technique framed in the EMS ECU to protect critical components like HT cables, alternators, ECUs, wiring harness etc. from thermal damage. The EMS continuously monitors the engine speed, vehicle speed and the PWM signal of ventilation fan to ensure the intended operation of the ventilation fan.
2017-03-28
Technical Paper
2017-01-0631
David C. Ogbuaku, Timothy Potter, James M. Boileau
Abstract The need to increase the fuel-efficiency of modern vehicles while lowering the emission footprint is a continuous driver in automotive design. This has given rise to the use of engines with smaller displacements and higher power outputs. Compared to past engine designs, this combination generates greater amounts of excess heat which must be removed to ensure the durability of the engine. This has resulted in an increase in the number and size of the heat exchangers required to adequately cool the engine. Further, the use of smaller, more aerodynamic front-end designs has reduced the area available in the engine compartment to mount the heat exchangers. This is an issue, since the reduced engine compartment space is increasingly incapable of supporting an enlarged rectangular radiator system.
2017-03-28
Technical Paper
2017-01-0629
John Kuo, George Garfinkel
Abstract Thermal modeling of liquid-cooled vehicle traction battery assemblies using Computational Fluid Dynamics (CFD) usually involves large models to accurately resolve small cooling channel details, and intensive computation to simulate drive-cycle transient solutions. This paper proposes a segregated method to divide the system into three parts: the cells, the cold plate and the interface between them. Each of the three parts can be separated and thermally characterized and then combined to predict the overall system thermal behavior for both steady-state and transient operating conditions. The method largely simplifies battery thermal analysis to overcome the limitations of using large 3D CFD models especially for pack level dynamic drive cycle simulations.
2017-03-28
Technical Paper
2017-01-0624
Jiaxin Liu, Sicheng Qin, Yankun Jiang, Shumo He
Abstract In this work, a XD132 Road Roller from XCMG in China was employed as a research basis to study the heat exchange performance of the heat dissipation module under varied working conditions. The module in the XD132 consists of a cooling fan and three radiators. At first, the numerical investigation on the elementary units of radiators was performed to obtain Colburn j factor and Fanning friction f factor, which were used for the ε-NTU method to predict the radiator performance. The fan was numerically tested in a wind test tunnel to acquire the performance curve. The performance data from both investigations were transformed into the boundary conditions of the numerical vehicle model in a virtual tunnel. A field experiment was carried out to validate the simulation accuracy, and an entrance coefficient was proposed to discuss the performance regularity under four working conditions.
2017-03-28
Technical Paper
2017-01-0152
Gang Liu, Zheng Zhao, Hao Guan, Chunhui Zhang, Dingwei Gao, Yongwei Cao
Abstract Advanced technology of thermal management is an effective method to reduce fuel consumption. There are several different technologies for coolant control, for example, electric water pump, split cooling and coolant control module. Through 1D thermal management simulation, coolant control module was chose for the test due to the best benefit for fuel consumption under NEDC cycle. 1D thermal management simulation model includes vehicle, cooling system, lubrication system and detailed engine model with all friction components. Coolant control module is designed to fix on 2.0L turbocharger GDI gasoline and to control 5 coolant ways, including radiator, by-pass, engine oil cooler, cabin heater and transmission oil cooler. The prototype is designed and made. The function and strategy is verified on designed test-bed. The vehicle with coolant control module is running under NEDC cycle.
2017-03-28
Technical Paper
2017-01-0139
Fei Dong, Liuwendi Hou, Zhenlong Xu, TaoTao Cao
Abstract The objective of this present research is to investigate the influence of bubble waiting time coefficient on subcooled flow boiling heat transfer in internal combustion engines and propose an approach to predict its value. The three-dimension simulated cooling jacket structure of valve bridges for forced water-cooling system was developed respectively. The numerical model for subcooled flow boiling based on two-fluid approach was established and calculated. Numerical results suggest that the bubble departure diameter increases with the increasing wall superheat or decreasing inlet subcooling. And the proportion of the quenching heat flux gradually rises and its peak value is delayed along the direction of the higher wall superheat when the subcooling degree increases. The bubble waiting time coefficient has been found to have a significant impact upon the boiling heat transfer.
2017-03-28
Technical Paper
2017-01-1078
Walid Ashraf, Sherif Khedr, Aya Diab, Hashim Elzaabalawy
Abstract A throttle valve is one of the main components of the intake system of a vehicle and is used to control the air flow rate into the combustion chamber at different engine speeds. Consequently, it has considerable effect on the engine power and performance especially at high engine speeds. The butterfly throttle valve is more common in commercial vehicles due to its simplicity. However, the butterfly throttle plate may affect the engine performance by incurring some pumping losses at high engine speeds even with the plate at wide open throttle (WOT) position. Hence it is proposed in this research work to replace and compare the performance of a spark ignition engine butterfly throttle valve to a newly designed barrel-shaped one with regards to the induced air mass flow rate. The main benefit of the proposed barrel-shaped throttle valve is the elimination of the flow restriction at WOT and high engine speeds.
2017-03-28
Technical Paper
2017-01-1083
Chawin Chantharasenawong
Abstract This study focuses on achieving a lower overall lap time at SAE Formula Student competition through a modification to the standard intake system. The lower lap time is achieved by widening the range of engine RPM which produces torque higher than 90% of the maximum value and lowering the engine RPM corresponding to the maximum torque. An intake system with ‘variable runner length’ is introduced to the 2015 racecar of KMUTT team. The values of intake lengths are determined from the wave equation with the goal of producing over 90% of the maximum torque of the baseline configuration over a range of engine RPM. Computer simulations are performed to determine the pressure at engine entry at various runner lengths. Finally, a prototype variable runner length intake system with linear motor actuators is constructed and installed on the racecar. Chassis dynamometer tests are performed to determine the engine torque for 3,000 – 10,500 RPM at all interested runner lengths.
2017-03-28
Technical Paper
2017-01-1081
Chongzhi Zhong, Tieqiang Fu, Chunbei Dai, Taiyu Zhang, Ke Wu, Wangwen Gu
Abstract In order to study the single cavity and double cavity canister work performance, the L/D, as well as the similarities and differences among the diameter of the adsorption mouth, purge mouth and air mouth have been studied. At the same time, the work performance of ORVR canister and common canister is also studied. The results demonstrate that the similar of L/D, efficient work ability and efficient adsorption rate of the double cavity canister is better than the single cavity canister. The bigger of L/D, the stronger work ability of the canister. However, the excessive increase of the L/D is not conducive to the canister desorption, instead resulting in the increase of RARCP. The adsorption mouth diameter of common canister is generally smaller or similar to the purge mouth, while for ORVR canister the adsorption mouth diameter is bigger than the purge mouth and similar to air mouth.
2017-03-28
Technical Paper
2017-01-1088
Katherine Randall, Cody Bradford, Jeremy Ross, Jeremy Church, Nolan Dickey, Adam Christian, Matthew Dunn
Abstract High frequency variations in crankcase pressure have been observed in Inline-four cylinder (I4) engines and an understanding of the causes, frequency and magnitude of these variations is helpful in the design and effective operation of various engine systems. This paper shows through a review and explanation of the physics related to engine operation followed by comparison to measured vehicle data, the relationship between crankcase volume throughout the engine cycle and the observed pressure fluctuations. It is demonstrated that for a known or proposed engine design, through knowledge of the key engine design parameters, the frequency and amplitude of the cyclic variation in crankcase pressure can be predicted and thus utilized in the design of other engine systems.
2017-03-28
Technical Paper
2017-01-0623
Zun Wang, Yi Zhang, Christophe lenormand, Mohammed Ansari, Manuel Henner
Abstract Radiator thermal cycle test is a test method to check out the robustness of a radiator. During the test, the radiator is going through transient cycles that include high and low temperature spikes. These spikes could lead to component failure and transient temperature map is the key to predict high thermal strain and failure locations. In this investigation, an accurate and efficient way of building a numerical model to simulate the transient thermal performance of the radiator is introduced. A good correlation with physical test result is observed on temperature values at various locations.
Viewing 1 to 30 of 2535