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The paper presents the development of a proposed rear powertrain cooling system of a minivan. The packaging of cooling system is finalized such that the radiator faces towards the rear of the vehicle bumper which is opposite to the conventional rear cooling system (i.e. radiator faces towards the front of the vehicle). In the small minivan, the space ahead of the engine is used as a floor for passenger foot. Due to these space constraints, the cooling system has no choice, but to move rear of the vehicle and above the departure plane to meet packaging requirements. Furthermore, in the conventional rear cooling system, in front of the radiator, there is engine and exhaust system, which heats up the air going to the radiator and reduces radiator cooling performance. Thus the cooling system is placed such that the radiator faces the rear bumper to draw in cooler air.

This paper reports a study on Charge air cooler effectiveness, Air intake pressure drop, Acceleration Performance and Rise over ambient temperature of a utility vehicle for different layouts of Inter cooler, radiator, condenser and fan module in order to finalize an efficient Power train cooling system layout. The main objective is effective utilization of front end opening area, eliminating inter cooler heat load on the radiator, so that radiator size, fan size and fan motor wattage can be optimized to achieve desired cooling performance requirements with the cooling system (CRFM) module. Effect of the intercooler effectiveness, Intake pressure drop, Vehicle acceleration performance and Rise over ambient temperature are studied and both the advantages and disadvantages of the proposals are discussed to finalize the better position of inter-cooler along with other engine cooling components.

The Technical paper present the mathematical model that predicts the radiator thermal performance curves for different airflow and coolant flow. This model was modeled using the signal library of AMEsim software. The model accepts the inputs of radiator parameters such as Air flow, Ambient temperature, Core size, Tube pitch, FPDM, No of rows, Louver pitch, Fin thickness, Louver angle Tube section data, Tube thickness, Coolant lpm, Max allowable coolant temp. The output of this model is the Radiator Performance Curve. This model is quick tool to work out approximate size of radiator to start system level packaging, Hence the Product Development time can be saved in Radiator Sizing.