Thermal management performance analysis and improvement for a commercial vehicle engine compartment through a 1D/3D co-simulation method

Abstract

The thermal management performance of a commercial vehicle engine compartment is crucial for improving overall vehicle performance and promoting green transportation. In this study, a one-dimensional (1D) and three dimensional (3D) CFD co-simulation method has been proposed for the modeling and simulation of thermal management of a commercial vehicle engine compartment. The steady-state temperature and velocity vector distribution in engine compartment has been obtained through 3D CFD approach. With data exchange between the cooling circuit and air conditioning circuit, the mathematical characterizations of the thermal management performance have been further investigated through 1D simulation and validated using test results. The comparison show that the obtained results for thermal management performance are consistent with test results, validating the accuracy of the co-simulation model. The results indicate an obvious thermal backflow phenomenon in the upper area of the intercooler module, causing a high outlet water temperature of the engine cooler. Thus, a deflector structure for eliminating the thermal backflow problem has been presented, and the heat dissipation effect has been analyzed. The co-simulation results show an improvement in cooling performance that the ATO value of cooling circuit decreased by 2.5% and intercooler constant of air conditioning circuit decreased by 12.1%. The proposed 1D/3D co-simulation method provides a reliable reference for developing the thermal management system of commercial vehicle engine compartment.