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The significance of thermal management performance in electric vehicles (EVs) has grown considerably, leading to increased complexity in thermal systems and a rapid rise in safety and quality-related concerns. The present real-vehicle-based development methods encounter several constraints in their approach when dealing with highly complex systems. Huge number of verification and validation work To overcome these limitations and enhance the thermal system development process, a novel virtual development environment established using the XiLS (X in the Loop Simulation) methodology. This XiLS methodology basically based on real-time coupling between physical thermal system hardware and analytical models for the other systems of vehicle. To control vehicle model and thermal system, various options were realized through hardware, software and model for VCU (Vehicle control unit) and TMS (Thermal management system) control unit.

The automotive industry’s journey towards fully autonomous vehicles brings more and more vehicle control systems. Additionally, the reliability and robustness of all these systems must be guaranteed for all road and weather conditions before release into the market. However, the ever-increasing number of such control systems, in combination with the number of road and weather conditions, makes it unfeasible to test all scenarios in real life. Thus, the performance and robustness of these systems needs to be proven virtually, via vehicle simulations. The key challenge for performing such a range of simulations is that the tire performance is significantly affected by the road/weather conditions. An end user must therefore have access to the corresponding tire models. The current solution is to test tires under all road surfaces and operating conditions and then derive a set of model parameters from measurements.

In order to align with net-zero CO2 ambitions, automotive OEMs have been developing increasingly sophisticated strategies to minimise the impact that combustion engines have on the environment. Intelligent thermal management systems to actively control coolant flow around the engine have a positive impact on friction generated in the power cylinder by improving the warmup rate of cylinder liners and heads. This increase in temperature results in an improved frictional performance and cycle averaged fuel consumption, but also increases the piston to liner clearances due to rapid warm up of the upper part of the cylinder head. These increased clearances can introduce piston slap noise and substantially degrade the NVH quality to unacceptable levels, particularly during warmup after soak at low ambient temperatures. Using analytical techniques, it is possible to model the thermo-structural and NVH response of the power cylinder with different warm up strategies.

Seat Heater testing methods traditionally rely on a human subject to provide normal contact, load, and thermal conditions. This creates a thermal environment closer to what an actual customer might experience but it also introduces a variation from individual subject’s seating posture, body size, and metabolic differences. This paper describes the development and initial testing results of a passive, heated seat testing manikin (or HANIKIN) that is intended to replace human subjects for more meaningful, repeatable objective testing.

An EGR system has been significantly used in order to cope with reinforced exhaust gas regulation and enhancement of fuel efficiency. For the well-designed EGR cooler, performance analysis is basically required. Furthermore, boiling prediction of the EGR cooler is especially essential to evaluate durability failure of abnormal operating conditions in DPF. However, due to intrinsic complexity of detailed 3-dimensional heat transfer tubes in the EGR cooler, no precise technique of boiling prediction has been developed. Therefore, this research had been performed in order to fulfill 3 goals: (1) development of 3-dimentional performance prediction technique including boiling occurrence, (2) generation and validation of a new evaluation index for boiling, (3) development of an optimized EGR cooler for suppressing boiling. In order to increase analysis accuracy and reduce analysis efforts at the same time, 3-dimensional single-phase flow analysis was developed.

This paper presents a method of controlling the seat heater using intentional oscillations between multiple, independently controlled temperatures (each with its own tolerance range). The amplitude and frequency of these oscillations can be changed based on secondary trigger events such as changes in the interior temperature. The benefits of using this technique to heat the seat surface are improved thermal sensation and reduced energy usage over the typical drive time.

Increasing compression ratio is essential for developing future high-efficiency engines due to the intrinsic characteristics of spark-ignited engines. However, it also causes the unfavorable, abnormal knocking phenomena which is the auto-ignition in the unburned end-gas region. To cope with regulations, many researchers have been experimenting with various methods to suppress knock occurrence. In this paper, it is shown that cooling the combustion chamber using coolants, which is one of the most practical methods, has a strong effect on knock mitigation. Furthermore, the relationship between thermal boundary and coolant temperatures is shown. In the beginning of this paper, knock metrics using an in-cylinder pressure sensor are explained for readers, even though entire research studies cannot be listed due to the innumerableness. The coolant passages for the cylinder head and the liner were separated to examine independent cooling strategies.