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Technical Paper

Thermal Management in Engine Compartment for Efficient Working of the Intercooler on a Rear Engine Vehicle

This paper is related to a vehicle with rear engine which is turbo charged and inter cooled. Due to packaging constraints the intercooler was placed in front of turbocharger and was exposed to hot air radiated out from the turbo charger. This was in turn reducing the efficiency of the intercooler. In such scenario, it is essential to shield the turbo charger from the intercooler for proper hot air management. Also rear engine vehicles don't have the benefit of ram air affect. This necessitates increasing the air entering in to the core of the intercooler. Both the above mentioned issues associated with such a vehicle was resolved by ensuring that the hot air from turbo-charge is guided away from the intercooler as well as the air flow to Intercooler is increased. Guiding or throwing out the hot air away from Intercooler was done by introducing a heat shield or a baffle between the two.
Technical Paper

Simulation of Intake System for Two Cylinder Naturally Aspirated In-Direct Injection Engine

This paper summarizes the approach towards the process of computational simulation of the intake system and its experimental investigation. It is an important aspect to improve breathing of the diesel engines for performance, torque smoothening and emissions. This can be achieved by optimizing intake system parameters such as plenum volume, diameters, length of ports & runners, etc., which directly correlates the volumetric efficiency, thereby the performance of the engine. Keeping the objective of improving volumetric efficiency to achieve low-end performance, the intake system design optimization has been done on a twin cylinder, four cycle, compression ignition, In-Direct Injection (IDI) engine. For the simpler intake system, the primary pipe length & diameter can be calculated by mathematical formula applying Helmholtz Resonator principle. But, for a complex intake system, simulation software is used here.
Technical Paper

High Voltage Battery (HVB) Durability Enhancement in Electric Mobility through 1D CAE

The public transport in India is gradually shifting towards electric mobility. Long range in electric mobility can be served with High Voltage Battery (HVB), but HVB can sustain for its designed life if it’s maintained within a specific operating temperature range. Appropriate battery thermal management through Battery Cooling System (BCS) is critical for vehicle range and battery durability This work focus on two aspects, BCS sizing and its coolant flow optimization in Electric bus. BCS modelling was done in 1D CAE software. The objective is to develop a model of BCS in virtual environment to replicate the physical testing. Electric bus contain numerous battery packs and a complex piping in its cooling system. BCS sizing simulation was performed to keep the battery packs in operating temperature range.
Technical Paper

Experimental Analysis of Prominent Factors Affecting Evaporator Frosting in a Mobile Air-Conditioning (MAC) System

In an automotive air conditioning system, evaporator is well designed for effective heat transfer between refrigerant and air flowing over the evaporator. This cold and dehumidified air obtained at evaporator is then supplied to passenger cabin. There are various parameters like air flow over evaporator, ambient temperature, humidity condition and condensate drain mechanism which can cause frost formation over the evaporator core. This study presents the probable causes of frost formation and their effects on the performance of evaporator and thus affecting overall performances of the automotive air conditioning system. In this study effect of variation in four major independent factors such as poor response of thermistor, undercharged refrigerant system and overcharged refrigerant system, drop in air flow by blower due to clogged air-filter, and also the effect of type of compressor has been studied.
Technical Paper

Thermal Management System and Performance Characteristics of Electric Vehicle

Thermal Management System (TMS) is equally or more important part of Battery Electric (BEV)/Hybrid Electric vehicle (HEV) than an internal combustion engine (ICE) vehicle. In an ICE vehicle, TMS ensures performance of power train/engine, after treatment/exhaust system and HVAC (Climate control) whereas it connected with safety and Range anxiety elimination additionally for the case of Electric Vehicle. Electric powertrain is not a new technology to the world but the technology is evolving in last few decades, to overcome the cost and make it commercially viable, charging infrastructural development and elimination of Range Anxiety. In last few years, Indian automotive industry has taken some major steps towards electrification journey for both passenger car and commercial vehicle. In BEVs, Battery Cooling or Battery thermal management System (BTMS or BCS) and Traction cooling system (TCS) are couple with nearly conventional HVAC circuit used in any ICE vehicle.
Technical Paper

Transient Hot Shut Down, CFD Simulation Technique for Underhood Thermal Management

During initial vehicle development stages thermal robustness is of prime importance. Vehicles are required to be validated for different drive cycles based on users driving patterns and also geographical road load database. Numerical simulations play key role in identifying critical thermal issues for different systems well in advance before physical validation. Hot shut down is one such case where thermal soak phenomenon plays vital role from thermal robustness point of view and there is a need to address this phenomenon using Computational Fluid Dynamics (CFD), which in turn will reduce the development time / testing efforts considerably. This condition is of utmost importance especially when vehicle is moving at higher gradients (uphill sections). In these critical conditions, hot engine compartment starves for cooling airflow despite the fact that fan is operating at maximum speed. The sudden stoppage of vehicle after this high thermal load is known as hot shut down.