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The essential aspect of an automobile is its braking system. Brakes absorb the kinetic energy of the rotating parts, i.e., wheels, and dissipate this energy into the surroundings in the form of heat. This entire process is quite complex, and the brake disc is subjected to extreme thermal and structural stresses along with deformation, which might damage the disc. This paper presents a structural and thermal analysis of an Audi Q3 brake disc using an ANSYS 2021-R1. The present brake disc is designed using SOLIDWORKS software. Composite materials are added in the ansys material library by adding their respective characteristics. The thermal analysis mainly focused on temperature variation and directional heat flux. The structural study was conducted to understand the stresses developed during braking and the deformations observed.

In today's fast-paced lifestyle, people spend a maximum amount of time for traveling, leading to a heightened demand for thermal comfort. Automotive HVAC play a crucial role in providing conditioned air to ensure comfort while traveling. Evaluating HVAC systems performance including delivery systems, heat exchanger efficiency, air thermal mixing zones, and temperature distribution are essential to maintain fuel economy and modern vehicle styling. However, accurately predicting cooling/heating performance using CFD simulations poses challenges due to the complex nature of heat exchanger modeling, which demands substantial computational resources and time. This paper presents the development of CFD modeling capabilities for predicting temperature distribution at duct outlet grills for defrost mode. Additionally, it assesses heater performance under maximum hot conditions.

With the growing popularity of electric vehicles (EVs) Lithium-ion batteries (LIBs) exhibit unique characteristics such as long life, high specific energy, significant storage capacity, and remarkable energy density. The continual difficulty temperature non-uniformity over the battery surface and inside the battery pack, remains a major barrier in battery technology, significantly contributing to the tendency towards Thermal Runaway (TR). The hot gases discharged from a lithium-ion cell’s safety vent during a thermal runaway event carry flammable elements. If ignited, these gases heighten the potential for thermal runaway to spread to other cells within a multi-cell pack configuration. The study scrutinizes the effects of TR on the venting process. It explores contemporary approaches to minimize it, employing a variety of modeling methodologies such as Multiphysics, Computational Fluid Dynamics (CFD), and electrochemical-thermal, in addition to experimental methods.

Electric Trucks offer one of the most promising alternatives to vehicles in the field of transport of goods. In battery electric trucks, heat is generated by components present in the electric truck such as battery of the electric vehicle, electric drive system, Endurance Brake System etc. which require cooling and Thermal management system to control and monitor the cooling system. The thermal management system considered here includes two coolant tanks. The first coolant tank performs thermal management for the battery and Electric-Drive(e-Drive) components which can heat up to 600C and the second coolant tank performs thermal management for HPR circuit, and it is used to break the charging circuit to protect the battery getting charged beyond 100% using regenerative braking concept. HPR (High performance resistor) is the component which can heat up to ~950C and make sure the battery is not getting charged beyond the safe limits.

With the advent of electric vehicles and advance trends in power train there is an increasing demand in improving the overall cabin comfort level. This is especially true when it comes to electric vehicles as the major source of sound other than the external flows would be from the HVAC systems for the vehicle. The noise source can be further divided on structural noise and flow induced noise; the paper would be focusing on prediction of flow induced noise levels. Flow induced noise by the HVAC’s would be critical since there are significant advancements in the cabin insulations/materials from externally generated noise sources. Automotive HVAC system consist of complex flow paths, blower, flaps, ducts, and vents which are the main source of noise generation in HVAC systems. With packaging space beneath the IP been premium, changes proposed to improve the noise levels are expensive and are understood at later level/phase of product development cycle.

Residual thermal energy, a by-product of automobiles, contributes notably to climate change and global warming. This energy is produced as exhaust gases in vehicles with internal combustion engines and as heat from batteries and fuel cells in eco-friendly vehicles. A thermo-electric generator (TEG) can transform this waste heat into useful electrical energy. The efficiency of the TEG is influenced by several factors, including the properties of the materials used, the geometrical design (form factor), and the conditions under which it operates. In this study, we examine how the choice of materials for the semiconductors, electrodes, ceramics, and joining components influences the overall performance of the TEG. We evaluate the TEG’s performance based on output power, and efficiency. The findings from these measurements allow us to determine which material and its properties significantly impact the TEG’s performance.

In an electric vehicle, nevertheless, the primary component is the electric motor (e-motor). Understanding the thermal performance of the e-motor is paramount in ensuring the overall efficient functioning of the electric vehicle. Usually, the high-power e-motors are oil-cooled due to relatively high thermal loads. The e-motor thermal response is monitored under extreme conditions like warm-up cycle allowing the vehicle to move in a circular track multiple-times. In this condition, the vehicle undergoes heavy lateral and longitudinal accelerations, the e-motor speed varies and the consequent thermal losses from the rotor and stator components also vary accordingly. Importantly, the cooling oil sloshes rigorously that affects the heat removal capacity of the oil. The advanced capabilities of Computational Fluid Dynamics (CFD) allow to virtually simulate the warm-up cycle and capture the extremely transient thermal response of the e-motor in the given conditions.

This research study investigates the influence of undercover design on three critical aspects of vehicle performance: water entering into air intake filter, Aerodynamic performance, thermal performance on vehicle engine room components (Condenser, Radiator and Air Intake System). Undercover serves the purpose of protecting Engine, underhood components and also improves aerodynamics of the vehicle. Through CFD simulations, various undercover design configurations: Full Undercover, no undercover and half undercover cases are evaluated to assess their effectiveness in mitigating the water ingress into the air intake system. Additionally, we explore the implications of these design alterations on the thermal performance and aerodynamic drag.

The air supply system in a Fuel Cell Electric Vehicle (FCEV) provides the oxygen needed for the fuel cell to react with hydrogen. The air compressor, being the main component of the air supply subsystem, has the highest power consumption among all auxiliary loads in an FCEV. Therefore, efficient control of the air supply system is critical for improving fuel cell performance. The air supply system has a slow response to dynamic load changes. Due to its weak transient response, an overshoot in airflow can lead to an increase in auxiliary power loss, while an undershoot can cause a delay in meeting power requirements. Thus, reducing transients is a crucial factor in improving the overall system efficiency. In conventional control, the battery supplies additional power needed during dynamic load changes. During high dynamic load changes, there is frequent switching between the battery and the fuel cell. This frequent charging and discharging of the battery can impact its longevity.

Due to its affordability and environmental friendliness, triboelectric nanogenerators, or TENGs, are a promising and alluring energy harvesting technology. Here, time-dependent finite-element numerical simulations were used to study the performance of dielectric-dielectric TENGs operating in the contact-separation mode. The open-circuit voltage, short-circuit current, and ideal resistance were measured in order to assess the TENG's performance. The findings are consistent with the physical models that are now available for the short-circuit current, which show that the current increases (decreases) with the area of the TENG (the thickness of the material). The open circuit voltage differed from published models according to the area and thickness of the material; the causes for this discrepancy are provided. Because high load resistance values affect charge flow in the TENG cycle (transient state) and performance, a deeper understanding of their effects is also offered.

Nowadays, Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs) are becoming popular globally due to increasing pollution levels in the environment and expensive conventional non-renewable fuels. Li-ion battery EV’s have gained attention because of their higher specific energy density, better power density and thermal stability as compared to other cell chemistries. Performance of the Li-ion battery is affected by temperatures of the cells. For Li-ion cells, optimum operating temperature range should be between 15-35 °C [1]. Initially, small battery packs which are cooled by air were used but nowadays, large battery packs with high power output capacities being used in EV’s for higher vehicle performance. Air based cooling system is not sufficient for such batteries, hence, liquid coolant based cooling systems are being introduced in EV’s. Computational Fluid Dynamics (CFD) simulation can be used to get better insight of cell temperature inside battery.

Over the past few decades, there has been a notable increase in stakeholder’s attention on Earth's climate. The automotive industry, being a major contributor to this phenomenon, has been endeavoring to mitigate its impact through various measures. These efforts include reducing emissions in existing internal combustion engine (ICE) vehicles and promoting electric vehicles (EVs) as a feasible alternative for consumers. Despite these initiatives, there remains a persistent challenge in improving the fuel economy and driving range of vehicles. India, located along the Tropic of Cancer, experiences both tropical and subtropical climates. As a result, a substantial portion of the total heat absorbed is from solar radiation. The higher heat load necessitates extensive use of air conditioning (AC) systems, which significantly contributes to the overall power consumption of vehicles.

The selective catalytic reduction (SCR) is a technique, which is using in diesel engine to reduce harmful nitrogen oxide (NOx) emissions. SCR technique involves the injection of urea-water-solution (Water-urea solution) into the hot exhaust stream. The water first evaporates and then urea undergoes thermal decomposition. The thermal decomposition of urea produces ammonia, which reacts with the nitrogen oxides inside a SCR catalyst layers and nitrogen and water vapor are the final product. The production of ammonia from urea strongly influenced by the droplet size, residence time of the droplets inside decomposition chamber and exhaust gas temperature. During the combustion process of Diesel engines, Nitrogen oxide (NOx) is produced as a pollutant which is harmful for environment. Acceptance level of (NOx) is made more stringent in BS-VI and subsequent standards to regulate (NOx) levels. In SCR system NH3 reacts with (NOx) and converts N2 and H2O.

In the rapidly evolving landscape of electronic engineering, the reliability of electronic components under varying thermal conditions has emerged as a paramount concern. This paper presents an integrated approach for the reliability analysis of electronic components, emphasizing thermal impacts. Our methodology synergizes computational thermal analysis, experimental stress testing, and Failure Modes, Effects, and Diagnostic Analysis (FMEDA) to offer a comprehensive framework for assessing and enhancing component reliability, specifically focusing on a case study of motorcycle hand control switches. The approach begins with a detailed thermal simulation to identify potential hot spots and thermal gradients across electronic components under different operational scenarios.

The purpose of air conditioning (AC) duct packing is multifaceted, serving to prevent condensation, eliminate rattle noise, and provide thermal insulation. A critical aspect of duct packing is its adhesive quality, which is essential for maintaining the longevity and effectiveness of the packing's functions. Indeed, the challenge of achieving adequate adhesivity on AC ducting parts is significant due to the harsh operating conditions to which these components are subjected. The high temperatures and presence of condensation within the AC system can severely compromise the adhesive's ability to maintain a strong bond. Moreover, the materials used for these parts, such as HDPE, often have low surface energy, which further hinders the formation of a durable adhesive bond.

Automotive cooling module system consists of condenser, radiator and intercooler which is used for thermal management of vehicle. Condenser helps to reject cabin heat, radiator to reject engine heat and intercooler rejects charged air heat to ambient. CRFM (Condenser, Radiator and Fan module) is conventionally packaged under the bonnet of passenger vehicle. Fan circulate airflow through heat exchangers and has primary role of airflow delivery. While performing vehicle level thermal management duty, fan noise is generated from CRFM and fan noise is considered as an important design attribute of CRFM. Many researchers have done fan noise simulation at component level and very limited literatures at vehicle (system) level simulation are available. Customer perceives noise from outside of the vehicle and it is important to predict fan noise at vehicle level at various operating speeds. Such simulations are transient in nature and modeling complexity demands high computational cost.

Thermal management is paramount in electric vehicles (EVs) to ensure optimal performance, battery longevity, and overall safety. This paper presents a novel approach to improving the efficiency of cooling systems in automotive passenger vehicles, focusing specifically on battery circuits and e-motor cooling. Current systems employ separate pumps, degassing tanks, valves, and numerous mechanical components, resulting in complex layouts and increased assembly efforts. The primary challenge with the existing setup lies in its complexity and the associated drawbacks, including heat energy loss, increased weight, and space constraints. Moreover, the traditional approach necessitates a significant number of components, leading to higher system costs and maintenance requirements. To address these challenges, this paper proposes an integrated cooling system where the pump, degassing tank, and valves are consolidated into a single housing.

To understand effect of thermal hazards of LIBs during TR event, it is important to study flame propagation behaviour of LIBs during storage and transport applications. The process of flame propagation involves complex phenomena of gas phase behavior of LIBs. Present paper attempts a numerical investigation to portray this complex phenomenon. This paper investigates 18650 lithium cell considering two different chemistries NMC and LFP. A 3D numerical CFD model has been constructed to predict the gas phase behavior, threshold internal pressure, and cell gas venting of an 18650-lithium cell under thermal runaway conditions. The gas phase processes are modelled using the 4-equation thermal abuse model, while the cell's venting mechanism is modelled using Darcy's equation. Present work is divided into two parts: 1) Venting gas Internal pressure prediction 2) modeling thermal runaway event.

Proton exchange membrane (PEM) fuel cells are one potential green energy option for fuel cells, which are becoming more popular in the energy production industry. Despite the fact that it continues to draw a lot of interest, many obstacles, such as enhancing performance, boosting durability and reducing cost are impeding the fuel cells commercialization. Air/hydrogen feed has an impact on the fuel cell performance; as a result, the cathode side of the fuel cell supply manifold pressure must be regulated. Substantial power is used when operating at maximum load, and fuel cells may experience oxygen starvation due to inadequate air. Maintaining a quick and adequate air concentration in the fuel cell cathode is essential to avoiding oxygen starvation and maximizing durability.

For a three-wheeler, this research studies the aging effects on an LFP battery across a realistic three-wheeler commercial vehicle cycle simulated in GT-SUITE. The study evaluates how thermal management affects battery aging with different battery cooling methods and triggering temperatures for cooling activation. The three-wheeler analysis cycle includes a real-world drive cycle, followed by battery recharging, and then a rest period. This sequence repeats until the battery ages to 80% of its original capacity (end of life). Battery life is determined using various methods of battery cooling and the temperatures that trigger the activation of cooling mechanisms. Different heat transfer coefficients (HTCs) are derived or assumed based on the cooling method used.