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Heat management must allow the adjustment of optimal operating temperatures of all components of a vehicle. A comprehensive simulation model (KULI) will contain all components relevant for heat management. This includes heat sources, heat exchangers, fans, etc. Main aspects of the simulation are flow and heat transfer analysis. Not only the engine cooling system can be covered with this simulation tool, also the air-conditioning circuit including phase changing models is a part of it (KULI AC). To fulfill the needs of integrating various software tools to an overall simulation cluster an interface to a fluid flow 1-dimensional software (FLOWMASTER) was developed. The use of 1- dimensional methods and mesh flow theory for modeling the underhood air flow of vehicles is very efficient method. For complex flow patterns however it is desirable to use CFD analysis.

This paper introduces a novel design of an internal combustion engine heat transfer model within a comprehensive simulation environment. The modelling is based on a lumped mass parameters approach. The paper discusses an approach for a heat transfer model, implemented in MATLAB/SIMULINK, the coupling process and the physical interface. The methodology of implementing this model in a comprehensive simulation environment is presented. The calculation of the combustion process and the inner circuits for the water and oil loops, considered as boundary conditions for the Heat Transfer Model are performed using the 1D engine cycle simulation program BOOST i.e. the 1D cooling simulation program KULI. This results in a scalable and modular structure of the model, which in turn permits a flexible design of different engine types. In order to carry out a comprehensive thermal calculation, a coupled simulation with these three different models is performed.