Thermal management of IC engines and vehicle systems

Temperature management is an essential part of optimising any Internal Combustion Engine (ICE) as well as predicting complete vehicle system performance including heat exchangers and cooling fans.

With the focus shifting to electric and hybrid electric vehicles, thermal analysis now extends beyond traditional ICE to include their performance with alternative e-fuels (including hydrogen) and their use as part of hybrid propulsion systems. These developments require R&D resources to improve overall efficiency, whilst reducing engine emissions, friction, oil consumption and Noise, Vibration, Harshness (NVH).

The heat generated by an ICE has a significant effect on both the performance of the system and its structural integrity. Accurate prediction of temperatures throughout a powertrain structure is vital for the successful design of the engine components and of the overall system. Component failure due to thermal loading at the prototype stage is not only costly but could impact on the time scales for delivering the engine. Key focus areas for thermal analysis include warm-up from cold to optimum conditions, powertrain integrity, piston performance and durability.

Similarly for hybrid and electric systems, both solid and fluid components can be modelled to develop an effective cooling system and improve the heat flow to heat exchanger packs.

In the initial stages of development, physical prototype modelling is expensive, requiring virtual simulation tools to answer many of the 'What ifs' before committing to a chosen design path. Detailed thermal models are vital in the assessment overall performance and reducing emissions, friction, oil consumption and fuel usage.