ANALYSIS OF ENGINE SPLIT COOLING SYSTEMS FOR INTERNAL COMBUSTION ENGINES: FOCUS ON TEMPERATURE DISTRIBUTION AND PERFORMANCE OPTIMIZATION
DOI:
https://doi.org/10.11113/jm.v48.577Keywords:
Split cooling system, internal combustion engine, thermal management, emission efficiencyAbstract
This research focuses on the optimisation and analysis of internal combustion engine (ICE) split cooling systems to enhance thermal management, improve engine efficiency, and reduce emissions. Split cooling systems separate the coolant circuits for the cylinder head and engine block, allowing for differential cooling that maximises warm-up time and operational efficiency. A one-dimensional flow model of the cooling system was developed using GT-Suite simulation software to analyze coolant flow, pressure drops, and temperature distribution across a range of engine speeds (from 1,000 rpm to 5,000 rpm). The simulation results indicate that the split cooling system accelerates the warm-up process, with the cylinder head temperature reaching 260°C compared to 250°C for traditional systems, representing a 10°C improvement in thermal efficiency. Additionally, the split system exhibited a 20°C higher piston temperature (210°C versus 190°C) during warm-up. This configuration enables the use of a higher compression ratio and improved thermal efficiency. The study identifies the limitations of conventional cooling systems in managing heat at elevated engine outputs. In contrast, the split cooling system demonstrates a more uniform temperature distribution and maintains superior performance under increased engine loads. Validation of the simulation results against design targets confirms that split cooling systems significantly enhance engine performance and thermal management, with implications for broader automotive thermal management applications. Future research should focus on on-road testing and further applications to advance engine efficiency and sustainability.
References
Naderi, A., et al., A smart load-speed sensitive cooling map to have a high-performance thermal management system in an internal combustion engine. Energy, 2021. 229: p. 120667.
Thomaz, F., et al., Thermal management of an internal combustion engine focused on vehicle performance maximization: A numerical assessment. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 2021. 235(8): p. 2296-2310.
Romero, C.A., et al., Strategies for reducing automobile fuel consumption. Applied Sciences, 2024. 14(2): p. 910.
Balakheli, M.M., et al., Analysis of different arrangements of combined cooling, heating and power systems with internal combustion engine from energy, economic and environmental viewpoints. Energy Conversion and Management, 2020. 203: p. 112253.
Osman, A., M.A. Hussin, and S.F. Zainal Abidin, Testing and Development of an Enhanced and Cost Effective Engine Split Cooling Circuit. SAE Technical Papers, 2015. 2015-April(April).
Germany, H. and FORD-Werke. A High-Resolution Warm-Up Simulation Model for a Gasoline Engine with Advanced Thermal Control. 2011.
Schmidt-Troje, D., et al., Virtual development of the BMW Z4 cooling system. MTZ worldwide, 2003. 64(1): p. 2-5.
Seider, G., et al., A numerical simulation strategy for complex automotive cooling systems. 2001, SAE Technical Paper.
Jalal, R.I.A., et al., Simulation of bypass electric water pump to reduce the engine warm-up time. Journal of Mechanical Engineering and Sciences, 2021. 15(3): p. 8241-8252.
Cipollone, R. and D. Di Battista, Performances and opportunities of an engine cooling system with a double circuit at two temperature levels. 2012, SAE Technical Paper.
Vdovin, A., Cooling performance simulations in GT-Suite. 2010.
Kim, K., et al., Active coolant control strategies in automotive engines. International Journal of Automotive Technology, 2010. 11(6): p. 767-772.
ASSANIS, D., Control strategy of electric coolant pumps for fuel economy improvement. International journal of automotive technology, 2005. 6(3): p. 269-275.
Cipollone, R., et al., Development of Thermal Modeling in Support of Engine Cooling Design. 2013, SAE International.
Jawad, B., K. Zellner, and C. Riedel, Small Engine Cooling and the Electric Water Pump. 2004, SAE International.
Osman, A., et al., Design and Simulations of an Enhanced and Cost Effective Engine Split Cooling Concept. 2013, SAE International.
Osman, A., M.K.A. Muhammad Yusof, and M. Rafi, Vehicle Testing and Development Involving a Simplified Split Cooling with Integrated Exhaust Heat Recovery and Reuse. SAE Technical Papers, 2016. 2016-April.
Chen, X., et al., Study of different cooling structures on the thermal status of an Internal Combustion Engine. Applied Thermal Engineering, 2017. 116: p. 419-432.
Heywood, J.B., Internal combustion engine fundamentals. (No Title), 1988.
Stone, R., Introduction to internal combustion engines. Vol. 3. 1999: Springer.
Cipollone, R., D. Di Battista, and A. Gualtieri, Head and block split cooling in ICE. IFAC Proceedings Volumes, 2012. 45(30): p. 400-407.
Osman, A., R. Mohd Razali, and N. Nurdin, Powertrain Warm-Up Optimization Involving Simplified Split Cooling with Integrated Exhaust Heat Recovery and Reuse. 2018, SAE International.
Liu, G., et al., Benefit of Coolant Control Module for Thermal Management on SUV. 2017, SAE International.
Lee, H., et al., Control for Electrical Coolant Valve in Engine Thermal Management Module. 2017, SAE Technical Paper.
Luptowski, B.J., et al., Development of the Enhanced Vehicle and Engine Cooling System Simulation and Application to Active Cooling Control. 2005, SAE International.
Brace, C., et al., Integrated cooling systems for passenger vehicles. 2001, SAE Technical Paper.
Minovski, B.B., L. Lofdahl, and P. Gullberg, A 1D Method for Transient Simulations of Cooling Systems with Non-Uniform Temperature and Flow Boundaries Extracted from a 3D CFD Solution. 2015, SAE International.
Minovski, B.B. and L. Lofdahl, Study of software integration for transient simulation of future cooling system for heavy truck application. 2014, SAE Technical Paper.
Soujanya, C., V. Sundaram, and S. Sathish Kumar, Simulation of split engine cooling system. SAE Technical Papers, 2015.
Ap, N.-S. and M. Tarquis, Innovative engine cooling systems comparison. 2005, SAE Technical Paper.
Downloads
Published
How to Cite
Issue
Section
License
Copyright of articles that appear in Jurnal Mekanikal belongs exclusively to Penerbit Universiti Teknologi Malaysia (Penerbit UTM Press). This copyright covers the rights to reproduce the article, including reprints, electronic reproductions or any other reproductions of similar nature.
