Global Light Vehicle Engine Cooling Market - Forecasts To 2030 - 2016 Q1 Edition - Technologies - Car Care Book

12/21/2016
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Globallightvehicleenginecoolingmarketforecaststo20302016
Q1Edition:Technologies
March21,2016carexhaustsystem
Definingtheelements
Atypicalcoolingsystemconsistsofanenginewaterjacket,thermostat,waterpump,radiator,coolingfan,
hoses,heatercore,oilcoolerandoverflow,orexpansiontank.Therearetwotypesofcoolingsystems:airand
watercooling.
Asthenamesuggests,aircoolingsystemsinvolvefanswhichblowairovertheengineblock.Accordingto
Bosch,heatabsorbedbytheengineoilisdispersedbyanaircooledoilcoolermountedatasuitablepositionin
theairstream.Thenoiseemissionlevelandtheinefficiencyinmaintainingconsistentenginetemperaturesare
consideredtobedisadvantagescomparedtoliquidcooledengines.Today,aircoolingismainlyusedfor
motorcycleenginesandinspecialapplications.Theoilcoolerisaheatexchangerthatusesanaircoolingsystem
tomaintaintheoptimisedoiltemperatureofvehicleoils,includingengineoilandautomatictransmissionoil.
Watercooledengines,ontheotherhand,havepassagesforthecoolanttopassthroughtheengine,absorbingthe
heatgeneratedsoitcanbereleasedthroughtheradiator.Thecooledfluidisrecirculatedaroundtheenginewhile
running.Watercoolinghasbecomethestandardinbothpassengercarsandheavydutyvehicles.Insteadofpure
water,coolantsarenowamixtureofwater(drinkingquality),antifreezeandvariouscorrosioninhibitors,says
Bosch.Anantifreezeconcentrationof3050percentraisesthecoolantmixtureboilingpointtoallowoperating
temperaturesofupto120Catapressureof1.4barinpassengercars.
AccordingtoBehr,thecoolingmoduleconsistsofanumberofenginecoolingcomponents,aswellasthe
condenserwhichformspartoftheairconditionercircuit.Themodulesareputtogetheraccordingtothevehicle
designconcept,reducingdevelopment,productionandlogisticsexpenses.
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Thermalmanagementmeansproductssuchasradiators,chargeaircoolersandoilcoolersthatuseamedium
(airorliquid)tocooltheheatthatisproducedbyavehicleengine.
Astheprimarycomponentofthecoolingmodule,theradiatorincludestheradiatorcore,thecoolanttankandall
theconnections.Theradiatorcoreitselfconsistsofafinnedtubesystemwithtubeheadersandsidesupports.
Thecoresofthecoolantradiatorsinpassengercarsarealmostexclusivelymadeofaluminium.Aluminium
radiatorsarealsobeingusedtoanincreasingextentinarangeofcommercialvehiclesworldwide.
Aluminiumreducesthetotalweightofaradiatorbyupto50percentcomparedwithnonferrousalloys.In
production,thecoolanttankistypicallyinjectionmouldedfromfibreglassreinforcedpolyamide.Agasketis
theninsertedbeforethetankisfittedonthetubeheaders.Theyarethencrimpedtoprovideatightseal.
AccordingtoBosch,therearetwobasicradiatorassemblyvariants:brazedradiators,andmechanicallyjointed
orassembledradiators.Forcoolinghighperformanceengines,orwhenspaceislimited,Boschreckonsthatthe
bestsolutionisabrazedflattubeandcorrugatedfinradiatorlayoutwithminimisedaerodynamicresistanceon
theairintakeside.Thelessexpensive,mechanicallyassembledfinnedtubesystemisgenerallyusedfor
applicationswithlesspowerfulenginesorwhenmorespaceisavailable.
Twotypesofaluminiumradiatorsareavailableaccordingtothedirectioninwhichthecoolantflows:thedown
flowtypeandthecrossflowtype:
*Thedownflowtypecoolingwaterpassesthroughthetubefromtheuppertank,dissipatesitsheatusingthe
aircomingthroughthefinsandflowstothelowertank.Abasicradiatorwherethecoolantflowsunderthe
effectofgravity.
*Thecrossflowtypecoolantpassesthroughthetubefromthesidetank,dissipatesitsheatusingtheair
comingthroughthefinsandflowstotheothertank.Withthisconfiguration,itispossibletomakethetank
smallerthanwiththedownflowtype.
Trendsinenginedevelopmentshowaconstantincreaseinspecificengineoutputpower.Thisdevelopmentisin
linewiththecurrenttransitionfromnaturallyaspiratedenginestosuperchargedenginesandultimatelyto
supercharged,intercooled(chargeaircooling)engines.
Chargeaircoolingrequirementsareincreasingduetohigherturbochargeroutlettemperaturesandpressures,
higherEGRrates,andrequestsbyOEMsforintakemanifoldtemperaturecontroltomanagecombustionand
exhausttemperatures.Chargeaircoolershelptoreduceemissionsindieselenginesbymakingturbochargedor
superchargedsystemsoperatemoreefficiently.Thesystemsaregenerallyusedtoincreaseenginepower.Sales
inNorthAmericaareprimarilytothetruckmarket,althoughthereisagrowingdemandalsointheoffhighway
market.Environmentalfactorshavebeendrivingthesalesgrowth.IntheUS,emissionsregulationsonheavy
truckstriggereddemandintheearly1990sfollowedbysimilarregulationsinEurope.Thematerialusedforboth
typesofchargeaircoolingistypicallyaluminium,althoughsomeairtanksaremadefromthermostableplastic
materials.
Therearetwobasictypesofchargeaircooling:
*directcooling(usingambientair)
*indirectcooling(usingacoolanttodissipateheattotheatmosphere).
AccordingtoBehr,incontrasttotheaircooleddirectchargeaircooler,theindirectchargecoolercanbe
mountedontheengine.Theairlinestothefrontendcanthisbeomitted.Thissavesinstallationspaceand
simplifiespackaging.Theindirectchargeaircooleriscooledviaaseparatelowtemperaturecoolantcircuit.The
chargeaironlytravelsashortdistancetothecooler,whichreducestheenclosedairvolumeandimprovesthe
dynamicperformanceoftheengine.
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Mostpassengercarsareequippedwithdirectchargeair/airheatexchangers.Thesecomponentsarefittedbefore
oralongsidetheradiators,orinthevicinityofthewheelcase.Forsuperchargedenginesincommercialvehicles,
mostarefittedwithanaircooledchargeaircooler.Thesearetypicallypositionedabovetheradiator,andare
capableofcoolingthechargeairto15Cabovetheambienttemperature.
AccordingtoBehr,thetrendistowardsindirectchargeaircoolingwhichispreferableintermsofpackagingsize
anddynamicresponse.Thecompanystates:Withindirectchargeaircooling,thechargeaircoolerisplaced
veryclosetotheengineratherthaninthefrontend.Theadditionallowtemperatureradiatorneededforindirect
chargeaircoolingisanintegralpartofthecoolingmodule.Duetothesmallerdepthofthelowtemperature
radiatorcomparedtoaconventionalchargeaircooler,morespaceisavailableinthefrontend,whichcanthen
beusedforpedestrianprotection,forexample.Thelocationclosetotheengineallowsshorterchargeairlines,
cuttingthepressurelossbyabout50percent.Thehigherdensityofthecooledchargeairandlowerpressureloss
meansthereismoreairavailabletotheengineforcombustion.Theresult:improvedengineresponse.Stricter
emissionregulationswillleadtoincreaseddemandforindirectchargeaircoolingdesignconceptsfortrucks.
Thatmeanschargeaircoolerswillhavetowithstandhighpressuresandtemperatures,particularlyforheavy
trucks.Withourstrengthoptimizedchargeaircoolers,wewillbeabletomeetthisrequirement,and
developmentwillcontinuetofocusonstrengthimprovements.
Incooledexhaustgasrecirculation(EGR),theexhaustgasiscooledviaacoolingsystemandthenmixedwith
freshintakeair.Behrpointsoutthatthisreducestheoxygenavailableinthecylinderchargeandthecombustion
temperaturedrops.Theresultislessnitrogenoxideintheexhaust.Cooledexhaustgasrecirculationreduces
emissionsintheengineanddoesnotrequireanyadditionalreductionagents,suchasurea.Afurtheradvantage,
notesBehr,isthatcarandtruckmakerscancombinecooledexhaustgasrecirculationwithotherpollutant
reducingsystemsthussignificantlyundercuttingtheemissionlimitsapplicabletoday.Valeopointsoutthat
recentdevelopmentsofEGRcoolingsystemsforgasolineenginesachievehighercompressionratios,forfuel
savingsof57percent.
Aheatexchangerisadeviceusedtotransferheatbetweenliquidsandgasesofdifferenttemperatureandmainly
consistsofthreeparts:tubesthroughwhichcoolingwaterorrefrigerantflows,atankthatholdssuchfluid,and
foldedfinsforheatexchange.Vehiclesusevariousheatexchangersincludingaradiatortocooltheengine
coolant,aheatercoretowarmthecabinair,acondensertocooltheairconditionerrefrigerant,andan
evaporatortocoolthecabinair.Theseheatexchangerssignificantlyaffectthefuelefficiencyandefficiencyof
theairconditioningsystem.
Driversofchange
Demandsonpowertraincoolingproductperformance,packagingandcostarecontinuallyincreasing.As
automakersexpecteconomicalsolutionsthathelpreduceemissionsfromcarsandtrucks,
ArnaudGandon,chiefengineer,globalpowertraincoolingandheatexchangers,DelphiThermal,believesthat
thereareseveralfactorsdrivingchangesinthepowertraincoolingsector.
Fromatechnologystandpoint,theincreasingdemandformorediesel,turbochargedenginesandhybridsis
drivingnewandimprovedtechnologyalongwithmoreefficienttransmissionsthatsometimesrequireheatingas
wellascooling.
Fromapackagingpointofview,Delphiexpectsthattherewillbeaneedtocombineheatexchangerslikethe
combicooleraswellaswideruseofchargeaircoolers.Thereisalegislativepushtocapturetheheatfromthe
exhaustanduseitforcabinheatingortransmissionheating.Forhybrids,thereisalsoaneedforanewheating
sourcelikeanimmersionPTCheaterwhichdriveselectronicsforoperationandsafety.
Innovations
Heatexchangers
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DensodevelopslowcostheatexchangersfortheIndianautomotivemarket
DensohasdevelopedfourlowcostheatexchangersdesignedfortheIndiaautomotivemarket.Itsradiator,
heatercore,condenserandevaporatoraremanufacturedonasingleproductionline.Conventionally,the
companywouldhavetomanufactureeachproductonseparateproductionlines.Densosaysthisnewmethodhas
improveditsmanufacturingefficiencyevenatasmallproductionquantity.
Forexample,Densomadeimprovementstotheformingmachine,whichallowedittocombinetheproductionof
twodifferentkindsoftubesusingonesinglemachine.Conventionallythetwotubeshollowtubesforradiators
andheatercores,andpressureresistanttubeswithcorrugatedinternalstructureforevaporatorsandcondensers,
wereproducedusingseparatemachinesduetothedifferenceinthetubesstructure.
ThefourheatexchangersareusedintheToyotaEtios,amongothermodels.
Visteonsinternalheatexchanger(IHX)
Visteonhasdevelopedaninternalheatexchanger(IHX)thatincreasescoolingpower.Itusesanovelcoaxial
tubedesignintegratedintherefrigerantcircuitforenhancedautomotiveairconditioningsystemperformance.
Theinternalheatexchanger,whichreplacesapartofthesuctionandliquidrefrigerantlinesinatraditional
R134asystem,exchangesenergyinacounterflowarrangement.Whencombinedwithtuningoftheexpansion
devicesettings,theIHXincreasessystemcoolingperformanceupto14%andimproveoperatingefficiencyup
to12%dependingonthebasesystemandthermalexpansionvalvesettings.Appliedtothenewneardropin
refrigerantR1234yf,thetechnologydeliverssimilarperformanceimprovements.
WebastodevelopsLiquidHeatGenerator
Webastohasdevelopedadevicethatrapidlyheatsenginecoolantinextremecoldconditions.Webastoclaims
thatitssocalledLiquidHeatGeneratorwillsavefuel,cutemissionsandimprovedrivercomfort.Thebelt
drivendevicemountstothefrontoftheengineandquicklyheatsthecoolantbyrapidlyswirlingitinarotor.
Thefastheatingofthecoolantmeansthatthevehiclesinteriorheaterandwindshielddefrostercanbefully
operationinaboutthreeminutes,downfromtenminutesinavehiclewithoutsuchadevice.
Indirectchargeaircooling
Thetrendtowarddownsizing,thatis,reducingdisplacementwhilemaintainingperformance,butwithbetterfuel
economy,isoneofthemainapproachestotheongoingdevelopmentofthecombustionengine.
Inpractice,downsizingmeansturbocharging,andthereforerequireseffectivecoolingofchargeairbecausehot
chargeairpresentsdisadvantages,suchaslowerdensity,greaternitrogenoxideformationduetohigher
combustiontemperature,increasedtendencytoknockingingasolineengines,andagreaterthermalloadonthe
enginecomponents.
Uptonow,chargeairisstillprimarilycooleddirectlywithexternalair.Thismeansthatitisfedtothefrontend
ofthevehicleafterexitingthecompressor,thenflowsthroughadirectlycooledchargeaircooler,andisthen
returnedtotheengine.
Mahlepointsoutthatindirectchargeaircoolinghasanumberofadvantages.
Fortheindirectvariant,thechargeairiscooledbyacoolant,whichisthenrecooledbyexternalairina
separatelowtemperaturecoolantcircuit.Theindirectchargeaircoolercanbelocatedclosetotheengine,
betweenthecompressorandthethrottlevalve.Despiteitsgreatercomplexity,indirectchargeaircoolinghas
distinctadvantagesoverconventionaldirectcooling:
*Improvedpackaging:theLTcoolerrequiredcanbemademorecompactforthesamepoweroutput,thus
openingupcriticalinstallationspaceinthefrontendofthevehicle.Atthesametime,thelargevolumecharge
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airhosesusedfordirectchargeaircoolingarereplacedbymuchthinnercoolantlines.Thissimplifies
integrationoftheengineinvariousvehicles.
*Lowerpressureloss:dueitsreducedvolume,indirectchargeairhasupto20percentlesspressureloss.This
resultsingreaterdensityrecoveryandhighervolumetricefficiencyinthecylinder.
*Greaterthermalinertia:incaseofasuddenchangeinload,suchasunderstrongaccelerationonthefreeway,
theenginehascoolerairavailableforasignificantlylongerperiodoftime.Thishasapositiveeffecton
performance,andisevidentinthedynamicresponsivenessoftheengine.
Forthesereasons,anddespitethegreatercomplexityofthesystem,indirectchargeaircoolingisbeingused
evermoreoften,eveninhighvolumeproductionmodels.
Inthenextstep,saysMahle,indirectchargeaircoolinghasshiftedclosertotheengine:theintegratedindirect
chargeaircoolerisinstalledintheintakepipe.Thiseliminatesallthechargeairlines,andamplifiesthebenefits
ofindirectchargeaircooling.
MahledevelopsintakepipesandBehrdesignsthematchingchargeaircoolers.
Moreuseofelectronics
Generallyspeaking,inrespectoffueleconomy,thereatrendtowardmoreuseofelectronicstotrytomore
closelymonitorenginetemperatureformaximumefficiencyi.e.usingelectronicthermostatsandelectronic
waterpumpstocompletelytakecontroloftheheatrejectionitself.Butthereisalwaysatradeoffthecarmaker
mustmakebetweenaddingweightandcost(throughelectronics)andsavingfuel.
GabrieleMaione,R&Dmanager,enginecoolingsystemsandcomponents,DensoThermalSystemsSpA,adds
thatfueleconomyisattractingmoreandmoreinterestfromcarmakers.Thisislargelyduetothenew
environmentallawsthatfixlimitsonpollutantemissionsandincurfinesforanytransgression.Carmakersand
suppliersareconsideringaverywiderangeofdevicestoreducefuelconsumption.Electronicscanhelpthe
enginetemperaturetowarmupfaster,forexample,toreducefrictionandcoldstartproblems.Workingtogether,
carmakersandsuppliersareevaluatingtheeffectsofsuchdevicestounderstandboththebenefitsandthecosts.
Thisisnotonlyrelatedtofueleconomyuseofthesedeviceshasalsosomeindirectbenefits.Forexample,the
electricalwaterpumpcanavoidoverheatingatengineshutdown.
Onbalance,weshouldexpecttoseefurtherinnovationincoolingsystemsandcomponentsduetothetrends
notedhere.Thechallengeforsupplierswillbetomeetdemandsfromautomakersforimprovedengine
efficiencyandoutput,aswellasrespondtorisingproductionofdieselvehiclesanddirectinjectionand
turbochargedgasolinevehicles.Intermsofsocialtrendsandlegalregulations,thesupplysectorwillcontinueto
facedemandsforimprovedfuelefficiencyduetosurginggasolinepricesandstricterfuelconsumption
regulations,aswellasformorecompactandthinnerradiatorsandotherpartsinresponsetothemorestringent
legislationdesignedtoprotectpedestrians.
Oilcoolers
Theoilcoolerisaheatexchangerthatusesanaircoolingsystemtomaintaintheoptimisedoiltemperatureof
vehicleoils,includingengineoilandautomatictransmissionoil.Asthenamesuggests,oilcoolersarerequired
inordertomaintainthetemperatureoftheoilitselfneededforthecorrectandsafeoperationoftheengine.
Vehicleswithautomatictransmissionsandhighlystressedmanualtransmissionsrequiretransmissionoilcoolers.
Oilcoolingcanbeachievedbyaircooledheatexchangersorcoolantbasedoilcoolers.Thelatterinvolves
simplifiedoilcircuitsandlowercostcomparedtotheoilairsolutionswhichofferhigherperformancesanddo
notresultinadditionalthermalloadfortheradiator.Anaircooledoilcooleraretypicallyfittedwithan
additionalfan.Coolantcooledoilcoolerscanbeincorporatedinthecoolanttankorengineblock,orfitted
externallyontheengine,transmission,coolingmoduleoroilfilterhousingasrequired.
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Forsometime,aircooledtransmissionoilcoolershavebeenusedtosupplementthecoolingfunctionperformed
bywatercooledoilcoolers.However,therehasbeenatrendtofreeuptheusageoftheradiatorfluidforcooling
peripheralfunctionssuchastransmissionoil.Thishastheadvantagesofminimisingthesizeofboththewater
coolingradiatorandthelinestoandfromthetransmission.
Duetothetypicalserviceconditionsofoilcoolersintermsofpressure(upto15bar)andtemperature(upto
150degreesC),theycannotbemechanicallyassembledbutbrazed.
Foritspart,Modinedevelopsandmanufacturesliquidtoliquidlayeredcoreoilcoolers(LCOCs)whichare
engineeredtoreducethehighoilandfueltemperaturesencounteredintodaysvehicles.Typicalapplications
includecommercialandspecialtyvehicle,agriculture,construction,andindustrialequipment,includingretarder
transmissionoilcooling.Thecoolersaremadeofaluminiumoreithercopperornickelbrazedstainlesssteel
usingcontrolledatmosphereorvacuumbrazing.Stainlesssteelconstructioneliminatestheneedforexternal
coating(e.g.Ecoat)forcorrosionprotectionandprovidesincreaseddurabilityandperformance.
Other
AisinSeikiselectriccoolingpump
AisinSeikisaysithasdevelopedasmaller,cheaperelectriccoolingpump.Carstraditionallyusemechanical
watercoolingpumps,whichhaveaflowratedependentontheenginespeed.Electriccoolingpumpsoffer
greatercontroloverthewaterflowallowingsignificantfueleconomies,particularlyimportantinviewofrising
environmentalconcerns.Howeverelectricpumpsaretraditionallymuchlargerthantheirmechanical
counterparts.Aisinselectricpumpusesanewlyshapedimpellertoimproveperformance.Inaddition,the
designpositionsthecomponentssothatboththemotorefficiencyandthecentrifugalpumpmutuallybenefit.
Thepumpalsousesfewercomponents,allowingittooccupylessspace.
Aluminiumenginecoolingpartsfortrucks
KustomCoolingProducts,(KCP)isofferinganaluminiumradiatorandairconditionercondenserlinefor
trucks.Thecompanyclaimstheseproductsare100percentaluminiumincludingthecore,sidesupportsand
tanks.Thecorefeaturesawavystylefinbuiltinabarandplateconfiguration.Aluminiumallowsmuchhigher
operatingtemperaturesandsincethetubesthemselvesarethickerthanOE,itallowsforbetterthermalstress,
vibrationandshockabsorption.
BorgWarnerThermalSystemssuppliesnovelfanforFreightliner
BorgWarnerThermalSystemsissupplyingVisctronicfandrivesasoptionalequipmentforFreightlinerCascadia
truckspoweredbyDD13andDD15engines.TheelectronicallycontrolledVisctronicfandrivesoperateonly
whenneededandattheappropriatespeed.
Tomeetstringentemissionsregulations,todaysheavydutycommercialtruckenginesrunathigher
temperatures,makingcoolingsystemsacriticalenginecomponent,saidBorgWarnerThermalSystemsDaniel
CasaSanta.[The]Visctronicfandrivesresponddirectlytoenginedemands,deliveringprecisecoolingtokeep
truckfleetsrunningmoreefficiently.Throughspecificallycalibratedsoftware,thefandrivecommunicateswith
theengineselectroniccontrolunittocontinuouslydeterminetheenginescoolingneeds.
Coolingsystemsealant
RisloneisofferingitsvehiclecoolingsystemsealantinCentralandSouthAmerica.Thecompanyssocalled
LiquidCopperBlockSealandRadiatorStopLeakisdesignedtosealmajorcoolingsystemleaksinvehicle
gaskets,radiators,heatercores,intakemanifolds,blocks,headsandfreezeplugs.Thecompanysaysthesystem
iseasytousethedriverpoursthebottleintotheradiator,idletheengineforfiveminutes,cool,topoffwith
coolant,andcontinuesonhisorherjourney.
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Fordsactivegrilleshutter
CertainFordmodelsuseactiveaerodynamicfeaturestocutdrag,resultinginfuelsavingsandreduced
emissions.Forexample,Fordsactivegrilleshutterusesavariableshuttersystemtoblankofftheflowofairto
thecarscoolingsystem,andwhenfullyclosedcanreduceaerodynamicdragbyuptosixpercent.
Mountedinthegrilleapertureaheadoftheradiator,Fordsactivegrilleshutterfeaturesmotorisedhorizontal
vaneswhichcanrotatethrough90degreestoblocktheairflow.
Controlledbythecarselectroniccontrolunit,thevanescanberotatedinto16differentpositionsfromfully
closedtofullyopendependingontheamountofcoolingairrequired.
SKFsEngineFanSupportModule
SKFisofferingitssocalledSKFEngineFanSupportModule,anintegratedunitforcoolingoftruckengines.
Claimedbenefitsincludehighrobustness,lowweightandreducedapplicationcosts.Newtechnologies,suchas
twostageturbochargers,highpressurefuelsystemsandhighrateexhaustgasrecirculation,arerequiredfor
truckstocomplywithnewregulationsrequiringloweremissions.Thesetechnologiesdemandefficientcooling
oftheengine.ThemoduleisproducedinLchow,Germanyanddistributedbycertifieddistributors.
Solutionsforalternativepowertrains
Behr
BehrAmericahasdevelopedanumberofitselectricandhybridelectricvehicletechnologiesandengine
mountedcomponentsfordownsizedengines.Morespecifically,Behrdemonstrateditsnewstorageevaporator
developedforvehiclesequippedwithstartstopsystems.Hybridvehiclesareequippedwithastartstopfunction
thatshutsofftheenginewhenthevehicleisstoppedoridling,reducingemissionsandloweringfuel
consumption.Someofthatfuelconservationisduetotheairconditioningcompressorbeingswitchedoffas
well.Indoingthat,however,temperatureinsidethevehiclerisesquicklymakingituncomfortablefor
occupants.Toalleviatethatcondition,Behrengineershavedevelopedastorageevaporatorwhichhelpsmaintain
cabintemperaturesandairflowupto95percentofallidlestopsincitytraffic.Theairflowingintothevehicle
isadequatelycooledbythelatentmedium,evenduringvehiclestops.
Behralsoshowcaseditsenginemountedcomponents,includingchargeaircoolersforturbochargedenginesand
enginemountedchargeaircoolersforgasolineengineswhichsupportenginedownsizing.
Dana
InOctober2014,Danaintroducedanewaluminiumcoolingtechnologyforelectricandhybridvehicles.The
suppliersaiditisusingtheefficiencyofaluminiuminitsLongbrandofintegratedcoolingplatesthatimprove
heattransferofinsulatedgatebipolartransistor(IGBT)switches.ThislatestadditiontoDanasthermal
managementportfolioprovidescustomerswithitisclaimedoptimised,compactcoolingcomponentsto
addressthehighheat,highpowerdemandsofelectricandhybridvehicles.TheIGBTcoolingplateswillbe
manufacturedatDanasfacilityinCambridge,Ontario,withproductionexpectedtobegininearly2015.
Valeo
ValeoisinvolvedinatechnologypartnershipwithLeroySomer,JohnsonControls,GKN,MichelinandLeoni
topooltheirskillsandexpertisetoofferautomakersacompleteelectricdriveline.Valeoisinvolvedintwo
majordrivetrainfunctions:controlelectronicsandthevehiclesheatmanagement.Thesupplierhasexpertise
coveringtheoperationofthemotor,vehiclesafety,batteryautonomyandclimatecontrolforpassengers.More
specifically,Valeohaspushedbackthetechnicalboundariesinthethermalmanagementarena.
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Electricvehicleshaveanumberofthermalmanagementneedswhicharemorecomplexthanthoseofaninternal
combustionenginevehicle.Thesystemmustcooltheelectricmotorandelectronicsandprovidethermal
comfortforpassengersbothinallyearround.Italsoimpactstherangeofthevehicle,andbatterydurabilityand
reliability.
Foritspart,Valeohasdesignedanewarchitecture,withthreefluidloopsoperatingatdifferenttemperatures.
Themainwaterloopcoolsthedrivetrainandheatsthecabin,therefrigerantloopcoolsthecabinandthethird
loop,alsoawaterloop,providesthermalmanagementforthebattery.
Anelectricvehiclemustofferthesamelevelofthermalcomfortasaconventionalvehicle.Sinceelectricmotors
generateverylittleheat,Valeohasthereforedevelopedathermalaccumulatorthatcanstoreheatwhenthe
vehicleischargingatthegridchargingpoint.Itisathermallyinsulatedboxcontainingaspecialmaterialwhich
storestheheatandredistributesitthroughawatercircuitconnectedtothevehiclesheatingsystem.The
completesystemincludesaheatingresistanceandawaterpump.Thesystemmeansthatthecabincanbeheated
foracertaintimewithoutdepletingthebattery.Asaresult,theadditionalrangegeneratedbythisconcept
representsabout10percentinoneurbanjourneyatanoutsidetemperatureofaround0C.
Valeoisalsodevelopingotherssolutionsadaptedtodifferenttypesofvehicleandusage,torestricttheenergy
requiredforcabinheating.Thesesolutionsofferdifferenttradeoffsbetweentheamountofenergyrecovered,
thecomplexityofthesolutionitselfandtheadditionalcostincurred.
Morespecifically,thermalmanagementofthelithiumionbatteryisofimportance,sincethisiswhatdetermines
thebatteryscapacitytostoreanddeliverenergy,itsdurabilityandreliability.Thebatterysoptimaloperating
temperatureisbetween20Cand30C,whatevertheconditionsofuse(charging,running)andoutside
temperature,andthistemperaturemustbeevenlydistributedacrossallcells,inordertoguaranteehomogenous
ageing.
EMPsuppliesminiHybridcoolingsystemtobusmaker
EngineeredMachinedProductsInc(EMP)issupplyingitselectrifiedcoolingsystemstobusmakerNewFlyer
IndustriesInc.Themodularkitreplacestheconventionalcoolingsystemondieselpoweredandnaturalgas
engines.UseoftheminiHybridcoolingsystemscanimprovefueleconomyupto10percent,accordingto
EMP.TheminiHybridisadropincoolingmodulethatreplacesaconventionalhydraulicsystemwithanarray
ofelectricfansdevelopedbyEMP.Thesystemincludesanaircooledbrushlessalternator.EMPhasbeen
developingitselectrifiedcoolingsystemsince2006.
Thermalmanagementsystemsforhybridvehicles
Designingthermalmanagementsystemsforhybridvehiclesrequiresspecialconsiderations.Thethermal
comfortofvehicleoccupantsmustbemaintainedevenwhentheengineisatastandstill.Tomaintainthermal
comfortforpassengersinthesummermonths,Behrhascreatedanevaporatorwithacoolingbattery.Thisso
calledstorageevaporatorpreventsthecabinfromheatingupwhenthecompressoridles.
Thefasteracoldvehiclereachesitsoperatingtemperature,thefasteritcanbeginstartstopoperation.
Manufacturerssaythisiswhyalloftheresultingwasteheatshouldbeusedtoheattheengineandnot
dischargedoutside.Somesolutionsforthefastestpossiblewarmupincludeexhaustgasheattransfer,which
usesexhaustgasheattowarmuptheenginecoolant,aswellasshuttingdownthemaincoolantcircuitduring
thewarmupphase.
Startstopphasescanrepresentabout20percentofdrivingtimeinurbantraffic.Duringthewintermonths,say
manufacturers,itisimportantthatthecabinissufficientlyheatedduringthesephases.Thesameappliesfor
solelyelectricoperationoverlongerdistances.Becausethecombustionengineisnotrunning,theenergyfor
heatingmustcomefromadifferentsource.Forexample,residualheatfromtheenginecanbeusedoran
auxiliaryheatingsystem.
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Coolingofhighperformancebatteriesalsorequiresnovelsolutionssincethenecessarytemperaturelevelhereis
toolowforaconventionalcoolingcircuit.Foritspart,DensoCorphasdevelopedanewhighoutputpower
controlunit(PCU)andbatterycoolingsystemforhybridvehicles.TheproductsareinstalledontheLexus
LS600handLS600hL.ThehighoutputPCUconsistsofaboostconverterthatraisesthemainbatteryvoltage
(288V)uptothemaximumsystemvoltage(650V),andthetwoinvertersthatconvertdirectcurrent(DC)into
alternatingcurrent(AC)todrivethemaintractionmotors.DensoclaimsthatitsnewPCUcanproducehigher
outputpowerbyabout60percentperunitvolume,comparedtothesuppliersconventionaltechnology,thus
improvingthehybridsystemperformance.ForthisPCU,Densodevelopedanewstructuretohandlethe
increasedcoolingrequirements.TodeliverahigherPCUoutput,saysDenso,thepowerdevicesmusthandle
morepower,resultinginmoreheatgenerationbythedevices.Usingaconventionalcoolingstructurewhere
powerdevicesaremountedhorizontallyonacoolingunitthroughaheatsinksothatonlythesidefacingthe
coolingunitisthroughaheatsinksothatonlythesidefacingthecoolingunitiscooledmadeitdifficultto
adequatelycoolthehigherpowerdevices,saysDenso.Inthecompanysnewcoolingstructure,thepower
devicesaresandwichedbetweentwoheatsinksandinsertedinlayersbetweenstackedcoolingtubes.This
structureallowsbothsidesofthepowerdevicestobecooled,whichimprovesthecoolingperformance.
Lithiumionbatteriesoperatewithanoptimumperformanceandlongservicelifeonlywithinanarrow
temperaturerangebetween10Cand40C.Forthisreasons,theyposeaspecialcoolingchallenge.Ambientair
isnotsufficienttocoolthebatteries.Instead,batterycoolingmustbeintegratedinthevehiclesairconditioning
circuit.Foritspart,Behrhasahybridbatterycoolingsolution.
Tomorrowshybridvehiclesandcoolingsystems
Delphireportsthat,giventheemergenceofhybridelectric/ICenginesystems,theimplicationsforthermal
managementsystemsforbotharesignificant.Delphistates:Thereisawiderangeofpossiblehybridvehicle
configurationsandtheimportantimplicationsforthermalmanagementsystemdesigndependuponthepower
splitbetweenelectricandICenginedrive.Sincetheelectrictractionmotorrejectssignificantlylessheatthanan
equivalentpowerICenginethenthehigherthefractionofelectricpowerthelowerwillbetherequirementfor
coolingairflow.Thecoolingrequirementfortheelectricdriveperunitpowerisapproximatelyhalfthatofthe
ICengine.However,thehybridvehiclesystemswillhaveasignificantincreaseincomplexityneedingseparate
coolingsystemsforICengine,tractionmotor/generatorandinverterdrive,batterypackandtransmission
system.
Packagingconcerns
Packagingthecoolingsystemiscertainlyamajordriverofinnovation.Giventhepressureonsuppliersto
squeezehigherperformingproductsandsystemsintoasmallerspaceunderthebonnet,radiatorshavegradually
becomesmallerinsize.Forexample,amodernaluminiumradiatorisabouttwothirdsthesizeofaunit
producedinthelate1970s.Thehighcostoffuel,particularlyinEurope,meansthatdesignersareseekingways
ofreducingtheairflowinthecar,whichisleadingtowardstheuseofsmallerheatexchangers.
Pedestrianimpactregulationsandinsurancetestsarebecomingevermorestringent,saidGabrieleMaione,
R&Dmanager,enginecoolingsystemsandcomponents,DensoThermalSystemsSpA.Carmanufacturersand
suppliersthereforehavetojoineffortstofittheincreasingnumberofcomponentsunderthebonnet,andmeet
Europeanregulations.Todoso,Densoisstudyingnewheatexchangerswithhigherspecificheatrejection,i.e.
higherheatexchangedpersurfaceunit.Thismayleadtosmallerheatexchangersthatcanbemoreeasilyfitted
intothefrontend.Enginemodulefixationsalsohavetobechangedtoaiddamagereductionandserviceability.
Moreover,Densoisdevelopingindirectexchangers(e.g.watercooledCAC)thatcanbepositionedunderthe
bonnettomakethefrontendmodulesimplerandlighter.
Notonlyareautopowertraincoolingpartsbecomingsmallerbutthereisacleartrendtowardmorecomponent
integration.Forexample,combiningthecondenserandradiatorcansavespaceandhelpcutcosts.Modularity
playsanimportantroleinpackagingenginecoolingsystems.Thisapproachcan,ofcourse,helpcutcostsand
simplifytheentireinstallationontheassemblyline.
9/11
12/21/2016
Densohasdevelopedaradiatorthatis40percentsmallerandlighter,comparedtoDensospreviousradiators.
Theradiatorsreducedsizetranslatesintogreaterdesignflexibilityftallationintheenginecompartment.This
alsohelpsmakethevehiclesaferintheeventofafrontalcollisionbecausethereducedsizeallowsforalarger
impactorcrashzone,saidAkioShikamura,seniorexecutivedirofDensosThermalSystemsBusinessGroup.
Inaddition,theradiatorstankismadeofaplantderivedresin,whichDensohasbeenmassproducingsince
2009,makingtheradiatorgreenerandenvironmentallycleanertraditionalradiators.Thenewradiatorisonly
16mmwide,butequalinperformancetotheconventional27mmwideradiators,resultinginasubstantialsize
andweightreduction.Thedesignchangeallowstheradiatorto10percentmoreefficientheatradiationthan
Densosconventionalradiators.Thenewlydeveloped16mmwideradiatorisinstalledintheLexusGS.
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Global Light Vehicle Engine Cooling Market - Forecasts To 2030 - 2016 Q1 Edition - Technologies - Car Care Book

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