ADVANCED THERMAL MANAGEMENT OF

DIESEL ENGINES

Submitted to Submitted by
Dr. Amir Fartaj Lovedeep Singh Sandhu
Inderjit Singh
Amandeep Sandhu
Raman Bhatoa
 Introduction
Combustion in the engine block produces energy. This energy is converted into
mechanical energy and waste heat in the exhaust and engine block metal.

The heat in the engine block metal is transferred to the coolant and mechanical
pump moves the coolant through the engine block.

The coolant leaves the engine block and passes through a two way valve.

Conduction and forced convection remove heat from the engine cooling system
when a mechanical fan moves air over the heat exchanger.
Schematic of standard diesel engine cooling system
 LIMITATIONS
1) Lack of Cooling System Control
The mechanical fan and coolant pump are driven directly by the engine via
a pulley arrangement.
Thus coolant fluid flow and coolant air flow are a function of engine RPM
only.
It leads to under-cooling and overcooling of engine.
The bypass valve has a wax pellet that expands as it warm up and contracts
as it cool down.
There is no direct control on functioning of bypass valve.
Inherent hysteresis in the expansion and contraction of the wax means that
large transients in coolant temperature is not avoided.
2) Reduced Cooling System Performance
The sandwiched arrangement of charge air cooler and jacket water heat
exchanger means that a high restriction is imposed on airflow.
Due to which pulley ratio is selected in order to attain higher fan speed to
overcome the reduction in airflow.
When the wax based valve is fully open, the restriction imposed is still
high. Thus , more power required to move fluid by coolant pump.

3) Parasitic loads
Every component that is running when it is not required represents a
parasitic load on the drive train and hence an unnecessary consumer of
excess fuel.
 ATMS MODELS

Full electric ATMS. The BLDC fans, BLDC pump and electronic valve are
controlled over a CAN network
 ATMS MODELS
Instead of one mechanical fan, there are several smaller fans driven
independently by brushless DC motors.

The wax based thermostat valve is replaced by an electronically controlled

valve and the mechanical pump is replaced by an electric one.

Control of all the components is implemented over a standard SAE J1939

CAN network.

There is no coolant air flow and coolant fluid flow restriction due to charge
air cooler and jacket water cooler are in series arrangement.
ATMS with an array of BLDC fans. All other components are the same as the
base system
ATMS with electric pump and electric valve
Dual mode coolant pump
 Dual mode coolant pump

The pump offers a high degree of freedom in operation

It can stop, run fully flexible in the range between minimum electric speed
(due to sensor less control) and maximum speed which depends on electric
motor size.

The dual mode pump provides support for the coolant flow requirements in
low and mid-engine loads.
 Merits of ATMS
Improve the coolant temperature regulation
Improve efficiency
Reduce fuel consumption
Reduce NOx emissions
Increase engine life
Aids in reduction of system warm up time
 CONTROL METHODS IN ATMS
PASSIVE CONTROL-
In conventional control cooling system, mechanical pump is directly
linked to engines crankshaft and power of pump is proportional to
engine speed.
A wax element thermostat is used in cooling system
Temperature of thermostat depends upon the top hose coolant
temperature.
Thermo fans are driven by engine
Limitations of passive control system
It decreases the efficiency of engine
Water pump always remains in on state
Due to belt driven system, wear and tear is more.
High parasitic power at high engine speed.
Possibility of undercooling and over cooling of system
Active control-
Electronic smart valve is used which gives sufficient scope of precise
control of thermostat.
It facilitates better cooling controlling of the coolant flow distribution
between radiator and bypass. It is further divided into two parts-
1. Mechanical water pump connected with camshaft and driven by engine.
2. Variable speed electric water pump and electric radiator fan.
Advantages of Active control
Increase engine durability
Reduction in the system warm up time
Ability to operate at higher mean temperature
 CONCLUSION
A thermal management development approach and its application to a
modern diesel powered vehicle have been presented.

Advanced thermal management systems (ATMS) have the potential to

increase the life of the vehicles engine cooling system components.

ATMS help to decrease fuel consumption as well as decrease carbon

emissions.
 References
Wenzel, W., Shutty, J., & Becker, M. (2014). Advanced Thermal Management of Diesel
Engines. Auto Tech Review, 3(9), 24-29. doi:10.1365/s40112-014-0734-3Staunton, N.,
Pickert, V., & Maughan, R. (2008).
Assessment of advanced thermal management systems for micro-hybrid trucks and
heavy duty diesel vehicles. 2008 IEEE Vehicle Power and Propulsion Conference.
doi:10.1109/vppc.2008.4677464