Cooling System
(General and Radiator)
By Nurjanah
How to design cooling system for ev car
- During the design process, an extensive heat transfer analysis of the water side
and air side of a potential radiator was performed. Additionally, system resistance
curves and performance curves were calculated, plotted, and utilized in the
component selection process. A suitable fan and pump were selected and a
radiator was designed.
- After determining the critical cooling components, it was necessary to place the
components in effective locations within the vehicle. In addition to placing the
components, attachment tabs were designed to fix the cooling system to the
frame of the vehicle and to fix the fan to the radiator. An inlet duct for the radiator
was also created to direct air to the radiator and improve the performance of the
system
- Simulation and Testing
Note : Rough iDM 190 efficiency use to estimate the lossesat various operating point
for cooling study
Cooling system
Liquid Cooling System - Space Constraints: Radiators for EVs need to be
designed to fit within the available space
- a liquid cooling system is often employed to
manage the temperature of the battery pack and constraints of the vehicle while providing
the electric motor, radiator is used to dissipate sufficient cooling capacity.
heat from the coolant fluid circulating - Corrosion Resistance: Materials used in the
through the system. construction of the radiator should be
- Design : circulate a coolant fluid (usually a
mixture of water and antifreeze) through corrosion-resistant to ensure durability and
channels or pipes that run through the battery reliability over the vehicle's lifespan.
pack and the electric motor. The coolant - Energy Efficiency: While the radiator itself
absorbs heat from these components and does not consume energy, an efficient cooling
carries it to the radiator, where it is cooled by system contributes to the overall energy
airflow.
efficiency of the EV by minimizing the energy
Radiator required for thermal management.
- Maintenance: The design of the radiator should
- Efficiency: The radiator must efficiently
facilitate maintenance tasks such as cleaning
dissipate heat to maintain optimal operating
and servicing to ensure optimal performance
temperatures for the battery pack and electric
and longevity of the cooling system.
motor, ensuring performance and longevity.
Simulation
1. Heat transfer analysis (Ansys)
2. thermal responses and power consumptions of the cooling system, The
powertrain system of the vehicle is also modeled with Vehicle-Engine
SIMulation (VESIM)
Cooling Load Determination
Method 1 Method 2
The cooling load is the amount of heat that A more accurate method of
needs to be dissipated by the cooling system estimating the cooling load of
the vehicle is to consider the
- assume the overall drivetrain efficiency of estimated efficiencies of the
the vehicle and further assume that all motor and motor controller
inefficiencies result in heat generation
- For example, assume the vehicle has an - Referencing Table 1,
overall drivetrain efficiency of 75% and the efficiency of the
further assume that the 25% inefficiency Enstroj Emrax 228
is given off entirely to heat. motor is 93% to 98%
Understanding that the max power of the and the efficiency of the
system is 70.6 kW, the following equation RMS PM100DX motor
shows the determination of the cooling controller is 89%
load for this hypothetical scenario
power output is assumed to be constantly at a maximum
Cooling Load Determination
Method 3
Vehicle is rarely Calculations operating at full
power. The driver’s inputs are dynamic. To
accurately perform this analysis :
- Using OptimumG’s vehicle dynamics
simulation software Optimum Lap was
utilized. Optimum Lap is a powerful piece
of software that drastically reduces the
complexity of vehicle dynamics simulation
and analysis.
- Data need : tire data, motor curve data,
vehicle weight, drive type, and aero data
- Data output : vehicle velocity, longitudinal
and lateral acceleration, elapsed time,
motor speed, power output, and other
various information.
Cooling Load Determination
cont . method 3 - power lost to heat by the motor
From data Optimum G, we can get
- Motor curret
- Cooling load (kW) = Calculate all the
- Heat by motor controller
heat generate from the other
componen and summed it all
- Heat generate by motor calculated using the Note :
efficiency map provided by Enstroj (motor
supplier) P =power
V = voltage
I = current
- Inlet and outlet temperature
Cooling system design
Determine
= water flow inlet temperature
- Type of cooling system : liquid
= water flow outlet temperature
- Placement of the component = circuit
scematic (ex. From the calculation, motor = heat transfer
generates more heat and it requires a lower = mass flow rate of water
coolant temperature, so the motor was placed
= specific heat of water
at the beginning of the cooling circuit)
- Make water and temperature scematic
Step by step to select radiator
1. Determine Heat loss = size of the cabin, insulation, outside temperature, any
heat source
2. Select a suitable temperature = determine desired temperature for the cabin
3. Calculate required heat output = heat output of the radiator to maintain desire
temperature of the cabin
4. Radiator types
5. Radiator size
6. Simulate performance
7. Efficiency and cost
8. Installation considerations
Radiator
Automotive radiators consist
of two end tanks (inlet and
outlet), which hold the cooling
fluid, and a core. The core of a
radiator is comprised of tubes
and fins. The tubes run
lengthwise from tank to tank
and the fins are located in the
spaces between the tubes.
cross-flow and downflow radiators
A cross-flow radiator is a radiator in which
the fluid tanks are located on the sides of
the radiator core; the coolant flows across
the core of the radiator from tank to tank.
In a down-flow radiator, the tanks are
located on the top and bottom of the core
and the coolant flows through the core
from top to bottom.
Cross-flow and down-flow radiators of the
same measurements are equally effective
at dissipating heat, therefore the decision
between cross-flow and down-flow is
usually determined by fitment.
How radiator works
The fins serve the purpose of increasing
the heat transfer area of the radiator
without crippling the mass flow rate of air
across the radiator.
When the radiator is operating, coolant
flows through the tubes as airflows
through the core of the radiator and across
the fins. This airflow across and through
the radiator lowers the temperature of the
coolant. Therefore, an automotive heat
exchanger operates via the principle of
cross-flow convection.
multi-pass core
Example, A double-pass radiator
operates: the water in the tubes crosses
the radiator twice before reaching the Using this diagram, the area of the tubes, the area of the fins, and other
outlet. various specifications about airflow and water flow can be determined
Radiator data need ed
1. Radiator core type
2. Radiator type
3. Core size
4. Tank size
5. Thickness
6. Width
7. Material
8. Structure
Radiator selection
- Radiator size limit/max, according to
vehicle geometry
- Data from the previous calculation is
used to select radiator (cooling load,
temperature, etc)
- Radiator performance data from
suppliers/manufacturer (rate of heat
dissipation, water side pressure drop
based on core length, core height,
core depth, and fin)