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Technical Paper

Maximizing FCEV Stack Cooling Performance: Developing a Performance Prediction Model Based on Machine Learning for Evaporative Cooling Radiator

2024-04-09
2024-01-2586
Recently, regulations on automobile emission have been significantly strengthened to address climate change. The automobile industry is responding to these regulations by developing electric vehicles that use batteries and fuel-cells. Automobile emissions are environmentally harmful, especially in the case of vehicles equipped with high-temperature and high-pressure diesel engines using compression-ignition, the proportion of nitrogen oxides (NOx) emissions reaches as high as 85%. Additionally, air pollution caused by particulate matter (PM) is six to ten times higher compared to gasoline engines. Therefore, the electrification of commercial vehicles using diesel engines could potentially yield even greater environmental benefits. For commercial vehicles battery electric vehicles (BEVs) require a large number of batteries to secure a long driving range, which reduces their maximum payload capacity.
Technical Paper

Research on Thermal Control of High Voltage Electronic Control System in Dual Hybrid Vehicles

2024-04-09
2024-01-2400
The hybrid system's thermal strategy is centered around controlling the cooling of the motor, inverter, DCDC and evaporator. In this electric drive circuit system, the water temperature sensor is positioned at the radiator outlet rather than within it. Consequently, when determining the required air volume for radiator cooling and water demand for sub-components of the electric drive circuit, an estimation of the inlet water temperature becomes necessary. This estimation relies on a heat transfer formula that converts heat released by circuit sub-components into their contribution to temperature rise within the circuit plus the outlet temperature from the previous round through the radiator to determine inlet water temperature. The inverter's heat transfer power depends on voltage and current levels. Adjusting motor torque leads to rapid changes in current flow while maintaining a low speed for optimal flow rate through the electric drive pump.
Technical Paper

A Preliminary Study on the Evaporative Cooling System for FCEV

2024-04-09
2024-01-2406
The existing FCEV have been developed with only a few vehicle models. With the diversification of both passenger and commercial FCEV lineups, as well as the increasing demand for vehicle trailer towing, there is a growing need for high-capacity fuel cell stacks to be applied in vehicles. However, at the current level, there are limitations and issues that arise, such as insufficient power output and reduced driving speed. As a results, the importance of thermal energy management has been increasing along with the increase in required power. Traditional cooling performance enhancement methods have mainly focused on developing increased hardware specifications, but even this approach has reached its limitation due to package, cost and weight problem. Therefore, it is essential to develop a new cooling system to solve the increases in heat dissipation.
Technical Paper

Efficient Design of Shell-and-Tube Heat Exchangers Using CAD Automation and Fluid flow Analysis in a Multi-Objective Bayesian Optimization Framework

2024-04-09
2024-01-2456
Shell-and-tube heat exchangers, commonly referred to as radiators, are the most prevalent type of heat exchanger within the automotive industry. A pivotal goal for automotive designers is to increase their thermal effectiveness while mitigating pressure drop effects and minimizing the associated costs of design and operation. Their design is a lengthy and intricate process involving the manual creation and refinement of computer-aided design (CAD) models coupled with iterative multi-physics simulations. Consequently, there is a pressing demand for an integrated tool that can automate these discrete steps, yielding a significant enhancement in overall design efficiency. This work aims to introduce an innovative automation tool to streamline the design process, spanning from CAD model generation to identifying optimal design configurations. The proposed methodology is applied explicitly to the context of shell-and-tube heat exchangers, showcasing the tool's efficacy.
Technical Paper

Numerical Investigation on Heat Dissipation Performance of Multi-Fan Cooling Module

2024-04-09
2024-01-2587
To study the heat dissipation performance of the multi-fan cooling module composed of multiple fans and a radiator, numerical models of the radiator and the multi-fan cooling module were established, and heat dissipation performance prediction analysis and application analysis were conducted. In modeling, the Effectiveness-Number of Transfer Units (ε − NTU) method is used to predict the heat dissipation performance of the radiator. The aerodynamic performance of the fan at any speed is obtained by the similarity theorem using the data obtained from the tests at a certain speed. The influence between the fan and the radiator was established by using the flow addition scheme. To validate the established model, heat dissipation performance using 36 radiators and 11 multi-fan cooling modules is measured, and the measured data are compared with the calculations.
Standard

Nickel Wire and Ribbon 99Ni

2024-04-01
CURRENT
AMS5555G
This specification covers a nickel in the form of round wire and rectangular ribbon.
Technical Paper

Optimization of Cooling Air Flow for Improved Heat Dissipation through Radiator

2024-01-16
2024-26-0042
Environmental Protection Agency (EPA) study indicates that a typical passenger vehicle emits about 4.6 metric tons of carbon dioxide per year. The Automotive industry facing a challenge of meeting stringent CO2 emission targets of 95g per kilometer for passenger car application. Thermal efficiency of internal combustion engine is one of the crucial technical parameters, which plays an important role in meeting CO2 emission targets. Global Automotive industry tends to achieve for cleaner, lower emission, low noise & improved performance for automotive products. Engine Overheating is affecting thermal efficiency & thus brake specific fuel consumption of the vehicle. Radiator is one of the critical components in Engine cooling system, which will ensure optimum operating range of internal combustion engine through precise control on coolant flow rate by Thermostat valve. Heat dissipation through radiator is directly proportional to volumetric mass flow rate of atmospheric air.
Technical Paper

Predictive under Hood Thermal Management Model

2024-01-16
2024-26-0272
In the automotive industry, thermal management plays a very important role to solve the problems of energy saving and emission. The under hood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc.
Technical Paper

HVAC NVH Refinement in Electric Vehicle

2024-01-16
2024-26-0206
Customers expect more advanced features and comfort in electric vehicles. It is challenging for NVH engineers to reduce the vibration levels to a great extent in the vehicle without adding cost and weight. This paper focuses on reducing the tactile vibration in electric vehicle when AC is switched ON. Vibration levels were not acceptable and modulating in nature on the test vehicle. Electric compressor is used for cabin cooling and battery cooling in the vehicle. Compressor is connected to body with the help of isolators. Depending upon cooling load, the compressor operates between 1000 rpm and 8000 rpm. The 1st order vibration of compressor was dominant on tactile locations at all the compressor speeds. Vibration levels on steering wheel were improved by 10 dB on reducing the dynamic stiffness of isolators. To reduce the transfer of compressor vibration further, isolators are provided on HVAC line connection on body and mufflers are provided in suction and discharge line.
Technical Paper

Computational Study on the Influence of the Radiator in Vehicle Overall Performance

2024-01-08
2023-36-0045
One of the key components in engine cooling system design in internal combustion vehicles is the radiator, which is responsible not only for regulating the engine coolant temperature but also for the required airflow crossing the grille openings. Considering different construction techniques and materials, the radiator design and its characteristics influence the overall vehicle performance. This work proposes a study on the influences of the radiator in the overall performance of a conceptual vehicle design, when considering different parameters. The main radiator characteristics evaluate in this study are the construction type, heat exchange thin number and tube number in different configuration arrays. Virtual cfd simulations are used to perform this study, where the drag influence in verified in three velocities: 40, 60 and 80 kph and compared with a baseline vehicle.
Technical Paper

Numerical Analysis and Optimization of Heat Transfer for FSAE Radiator for Various Sidepod Designs

2023-11-10
2023-28-0055
Heat transfer optimization is a crucial aspect of the design process for Formula Student race cars, particularly for the radiator, usually housed in a side pod. For the car to operate at peak performance, a well-designed radiator-sidepod system is essential such that it can dissipate heat generated by the engine faster, for the car to run in optimal performance. Testing the car physically for various radiator-sidepod design iterations is a very difficult task, also considering the costs to manufacture the radiator-sidepod setup. The objective of this study is to develop a comprehensive methodology for analysing heat transfer through radiator setup using Computational Fluid Dynamics and to validate it through experimental investigations, to enhance performance and efficiency of the radiator setup. It further explains how to find out its heat transfer efficiency, and to choose the right radiator-sidepod setup, giving optimal performance.
Technical Paper

Influence of Iron and Manganese on the Mechanical Properties and Microstructure of a Recycled EN AC-43200 Aluminium-Silicon Alloy

2023-11-05
2023-01-1880
The work investigates the effect of different Iron and Manganese contents in ad-hoc cast specimens made from recycled EN AC-43200 alloy. Tensile tests and metallographic analyses coupled with energy dispersive X-ray spectroscopy measurements are carried out to elucidate the interplay between the microstructure and the quasi-static properties of the Aluminium-Silicon alloy under investigation. A strong correlation between the composition and morphology of Fe/Mn -based intermetallic precipitates and tensile properties is demonstrated. Moreover, it is found that specific intermetallic phases are present only for certain, relative and/or absolute contents of Fe and Mn.
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