Introduction to Cooling Airflow Systems Web Seminar RePlay
Vehicle functional requirements, diesel emission regulations, and subsystem thermal limits all have a direct impact on the design of a powertrain cooling airflow system. Severe duty cycles, minimal ram air, fouling, and sometimes unconventional package layouts present unique challenges to the designer. This course introduces many airflow integration issues and vehicle-level trade-offs that effect system performance and drive the design. The goal of this course is to introduce engineers and managers to the basic principles of diesel cooling airflow systems for commercial and off-road vehicles. Participants will learn about vehicle/product constraints, integration issues, cooling airflow, system resistance, fans, shrouds, radiators, coolers, estimating heat rejection, thermal recirculation, and overall system performance. Basic concepts will be reinforced with examples and a cooling performance calculation of a diesel cooling system.
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OEM and supplier engineers and managers who are involved with vehicle cooling systems, or who interface with vehicle program management on these issues, will benefit from this web seminar. Graduate-level students interested in cooling systems will also find it instructive.
What will you learn
- Define vehicle requirements and many cooling airflow system integration issues
- Describe heat exchanger sizing considerations, design alternatives, and thermal effectiveness
- List fan/shroud aerodynamic design parameters, guidelines, and installation effects
- Apply the fan laws to evaluate alternative designs
- Calculate fan operating point and airflow using component pressure-loss coefficients
- Estimate engine heat rejection to coolant, including Exhaust Gas Recirculation (EGR)
- Calculate steady-state thermal performance of a diesel cooling airflow system
Course structure
Session 1: Vehicle Perspective
- Overview Typical Cooling Airflow Systems
- Design Drivers
- A Classification of Vehicle Cooling Systems
- Industrial Air-cooled Heat Exchanger Assemblies
- Impact of System & Sub-system Requirements
- Thermal Recirculation
- Design Challenges
Session 2: Key Concepts – System Heat Transfer Equation and Pressure Losses
- 1st Law of Aerodynamics
- Radiator Heat Transfer Equation
- Definition of Standard Air
- Airflow Terminology and Standard Cubic Feet per Minute (SCFM)
- Bernoulli’s Equation and Ram Pressure
- Pressure Loss Coefficient
- Vehicle Air Flow Restrictions – Flow Energy Losses
- Construct a System Pressure Loss Curve
Session 3: Fan Airflow
- Fan Classification and Specific Speed
- Fan Characteristic Curve and System Matching
- Air Performance Test Chambers (AMCA)
- Axial Fan Systems, Pusher and Puller
- Exercise the Fan Laws to Evaluate Design Alternatives
- Shroud Design Considerations
- Vehicle Installation Effects – Fan Position, Tip Clearance, Radiator Proximity
Session 4: Fan and Ram Airflow Map
- Ram Airflow
- Flow Energy Balance Equation
- Fan Operation with Ram
- Ram Total-Pressure Recovery
- Calculate System Loss Curve, Fan Operating Point and Cooling Airflow
Session 5: Compact Heat Exchangers
- Thermal Classification of Heat Exchangers
- Compact Heat Exchangers in Vehicle Applications
- Radiator Effectiveness and Louvered Fins
- Charge Air Coolers, Performance Calculation Against Requirements
- Air-Side Fouling Study and Heat Exchanger Design Considerations
- Thermal Accumulation Calculation
Session 6: Estimating Powertrain Heat Rejection
- SAE Dynamometer Gross Power Test Procedures
- Dynamometer Data on Engine Heat Rejection
- Brake Mean Effective Pressure (BMEP), A Power Density
- Specific Heat Rejection (SHR) Characteristic Curve
- EGR Heat Rejection to Coolant
- Evaluation of Diesel Cooling System
- Tools and Methods for System Development
Materials Provided
- 90 days of online single-user access (from date of purchase)
- 12 hours of instructor-delivered content
- Course workbook (downloadable, .pdf\’s)
- Online learning assessment
- Instructor follow up to your content questions
- 1.2 CEUs* (upon completion of all course modules and satisfactory assessment score)
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