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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

DFSS to Design Engine Cooling System of Small Gasoline Vehicle with Rear Engine

In automobile design, a rear-engine layout mainly espoused for small entry-level cars and light commercial vehicles for three reasons - packaging, traction, and ease of manufacturing. The aim of this paper is to strategize cooling system of rear-mounted engine of a small gasoline car. Radiator and cooling fan packaged close to engine at rear of the car for simple packaging. Efficient thermal management ensured by robust overheat protection stratagem using EMS software. DFSS, a disciplined problem prevention approach that helps in achieving the most optimum design solution and provides improved and cost effective quality products; is used to finalize an optimum design based on the analysis of the various tests carried out as per DOE [1]. This paper is about designing a distinctive cooling system of a car having rear-mounted engine with rear radiator but front mounted HVAC system [2].
Technical Paper

Transient 1D Mathematical Model for Drum Brake System to Predict the Temperature Variation with Realistic Boundary Conditions

Brake system is the most important system in the vehicle considering the overall vehicle safety and speed control. Brake applications are repetitive during a city traffic and hilly terrain on downhill gradient. Frequent braking gives rise to an overheating of the brake drum and its components. Braking operations at high temperature gives rise to problems like reduced deceleration due to loss of brake pad friction characteristics, pad softening and sticking to drum, pad distortion and wear etc. All these factors collectively result in deterioration of the braking performance and reduction of brake pad durability with time. Till date most of the thermal analysis performed for brake drum heating are through physical testing using brake system prototypes and by means of CFD tools. These methods are time consuming and expensive. There is a need for an alternative method to reduce physical trials and prototype building and reduce dependency on CFD analysis.
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.