ME538/AEng566 Vehicle Thermal Management

Introduction

Prof. Dewey Dohoy Jung

Mechanical Engineering
The University of Michigan-Dearborn
Office: 2191 HPEC
Tel: (313) 436-9137
E-mail: dohoy@umich.edu

Vehicle Thermal Management

The goal of the thermal management in a vehicle is to
maintain proper operating temperatures of vehicle
components by actively controlling the heat flows with
dedicated thermal systems.
The vehicle cooling system and the climate control system
consist the vehicle thermal management system.
In conventional vehicles, the vehicle cooling system
maintains temperatures of the engine, intake charge air,
and transmission at proper levels.
The climate control system maintains the cabin
temperature by activating the Air-conditioning system or
heating system.
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Cooling System Requirements

Sufficient heat dissipation under all operating conditions to
maintain component temperatures and thermal stresses
below required limits for better performance, reliability and
durability
Even cooling of components and avoidance of local hot spots
Low parasitic power consumption for the operation of the
system
Low coolant mass and low thermal inertia of the system for
faster engine warm-up to normal operating temperature
Maintaining the lubricant temperature to reduce frictional
losses and avoid component wears
Sufficient energy supply for passenger compartment heating
at low ambient temperatures.
3

Climate Control System Requirements

Maintain comfortable cabin temperature and humidity.
Sufficient heating of the passengers cabin at low ambient
temperatures.
Defrosting/defogging
Optimal air flow distribution
Even (uniform) temperature through the cabin
Low energy demand for the operation of the system

System Overview: Engine Cooling System

Typical Structure of Cross Flow Compact Heat

Exchanger with Louvered Fins (Radiator)
Upper Water Tank
Coolant
Inlet

Pressure Cap

Coolant

Tube

Air
Coolant
Outlet
Lower Water Tank

Louvered Fin

Water Pump

Thermostat

Climate Control System

1. Belt driven Compressor
2. Pressure relief valve
(pressure side)
3. Dual pressure switch, sight
glass
4a. Pressure switch, electrical
connection to ECU
5. In-Line filter
6. Expansion tube (expansion
orifice)

A/C Compressor

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Expansion Valve

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Vehicle Thermal Management in Electric Drive Vehicles

(EDV)
In conventional vehicles the engine supplies most of the
accessory power for the cooling system and climate control
system typically mechanically through the accessory belt.
Engine driven accessory components: water pump, cooling
fan, A/C compressor
In EDVs including battery electric vehicles (BEVs), extendedrange electric vehicles, (EREVs), hybrid electric vehicles
(HEVs), and plug-in hybrid electric vehicles (PHEVs), the
engine is switched to on-and-off depending on the
configuration and power management strategy. Accordingly,
several engine driven accessories in conventional vehicles
should be driven by electrical motors to avoid any
interrupted operation.
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Mechanical vs. Electric Driven Accessories

Mechanically engine driven accessories are operated
based on the engine speed regardless of the actual needs.
Electrically driven accessories can be operated based on
demands. They needs control systems (sensors, actuators,
controller, and power source)
Examples: coolant pump/fan, power steering, A/C
compressor
Thermostat

Modified Thermostat

Radiator

Electric
Fan
Bypass

Radiator

By-pass

Mechanical
Fan

Mechanical Pump

Electric
Pump

Electric Controller

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Vehicle Thermal Management in Electric Drive Vehicles

(EDV)
In EDVs, vehicle thermal management system (VTMS) is
much more complicated because the electric power train
components such as generator, motor, power
management unit and battery have to be thermally
managed in addition to the engine cooling and air
conditioning system.

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Vehicle Thermal Management in Electric Drive

Vehicles (EDV)
HEVs have additional powertrain
components and they need dedicated
cooling circuits as a result of the
considerable heat rejections.
The additional powertrain components
have different cooling requirements:
different operating temperatures and
different operating modes based on
vehicle power management strategy.
Heat load on the CCS of HEVs is larger
than the heat load on the CCS of
conventional vehicles.

HEV
Control
Powertrain Target Temp.
Component
(oC)
Engine
120
Oil Cooler
Drive
Motor
Generator

130

Power Bus

70

Battery

45

95
95

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What fundamental knowledge should we have to

understand VTMS?
Thermodynamics
1st law of thermodynamics
Closed system
Open system

dE & &
= Q -W
dt
dEcv
= Q& cv - W&cv +
dt

m& h +
i

Vi 2
+ gzi
2

m& h
e

Ve 2
+ gze

Thermodynamic devices and machines

Fluid mechanics
Internal flow: piping system
Turbo machinery: Pump, fan, compressor

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What fundamental knowledge should we have to

understand VTMS?
Heat transfer
Conduction Fouriers law of heat conduction
Convection

Newtons law of cooling

Thermal Resistance Network

Fins and pipe flow
Heat exchangers
Log mean temperature difference method
EffectivenessNTU method

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Engine Cooling System Modeling using Matlab/Simulink

Drivetrain

Vehicle Dynamics
Fd, Fg, Fr

Ftr
Coolant flow & heat exchanges

Air flow
Thermostat
Cooling Fan

Vehicle grille
Radiator

Engine

Fan
Air

Cooling air flow

Coolant Pump

Bypass

Coolant
Pump

Radiator

Down stream

Coolant from Radiator

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