Vehicle Thermal Management

Vehicle thermal management is gaining increased importance as more vehicle systems require cooling.

The challenge involves providing the optimum cooling, which meets the requirement with minimum power consumption, reduced frontal area to reduce aerodynamic drag, and a compact system with minimum weight.

Vehicle terminal management involves:

• Engine cooling
• Cabin Cooling /HVAC
• HV Battery cooling
• Power electronics cooling
• E-Machine Cooling
• Hydrogen fuel cell thermal management

Even though EV thermal management has gained more popularity recently, the underlying principles are similar to conventional cooling systems:

• Air cooled
• Liquid/coolant-cooled with the radiator
• Refrigerant cooling

The basic cooling system design includes matching the heat rejection to the system's cooling capacity in worst-case conditions.

Different development stages involve:

• 1D- Simulation
• Design
• 3D-Simulation
• Development test in worst-case conditions (RWUP)

For a conventional engine, the heat rejection capacity of the radiator should be equal to the sum of the heat rejection of the engine (typically 30% of total energy generated due to burning of fuel) plus heat rejection from other systems like (HVAC, Intercooler, etc).

For EV vehicle motor, power electrons and HV batter must be maintained at optimum temperature for best performance and durability.

HV battery cooling is very important in India's current scenario of fire…