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Improvements in microprocessor-based electric motor drives have opened up new opportunities for advances in automotive thermal management. For light trucks and SUV's, secondary cooling systems can provide benefits of improved heat rejection, variable temperature control, packaging flexibility, improved warm-up, and reduced primary cooling system power consumption. Of particular attraction are the relatively low power consumption, 12 V operating voltage, and size of the electric drive components. This paper details the design and testing of two separate systems; the first being a controlled transmission cooling/heating system on a 1999 Chevrolet Tahoe; the second being an independent EGR cooling system on a 2004 Ford Excursion.

Electronic thermal management reduces pump and fan power consumption through gains in controllability and efficiency, and also provides for additional control of heat rejection management and variable control of coolant, oil, and engine temperatures. This paper represents the design, bench testing, and wind-tunnel vehicle testing of an advanced system comprised of an electric pump, electronic water flow proportioning valve, 42V alternator, 36V starter, and an electronic control system which commands the performance of the valve, pump, and fan clutch in relation to the cooling demand on a 1999 Volvo VN tractor equipped with a Cummins N14 engine. System design and test data are compared from both the stock cooling system and the advanced thermal management system (ATMS).

The replacement of the mechanical water pump and wax-based thermostat with an electric pump and electric flow control valve provide the opportunity for improved engine thermal management and climate control. This paper investigates various cooling system flow circuits and their effects on heater performance, subsequently optimizing passenger comfort and engine warm-up. An electric pump and 2-way electric flow control valve were installed on a large SUV, and both the warm-up and flow performance were evaluated for several circuits-including a heater core boost pump, modified flow circuit designs, and differing pump speeds-and compared to the base cooling and HVAC systems. The Advanced Thermal Management System (ATMS) is shown to increase engine warm-up, cabin warm-up, and heater performance.