COOLANT CIRCUIT ANALYSIS FOR RADIATOR FAN SELECTION FOR WATER COOLED MOTORCYCLE ENGINE.
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1 COOLANT CIRCUIT ANALYSIS FOR RADIATOR FAN SELECTION FOR WATER COOLED MOTORCYCLE ENGINE. Narendra Bansode R & D, Mahindra Two Wheelers Ltd. Gamma Technologies User s Conference, 23rd September
2 OBJECTIVE To study the Engine cooling system for radiator fan selection in different vehicle maneuver conditions. Problem Statement: The existing cooling fan on the radiator has 12V, 5A motor. It is required to reduce the total current rating of the electrical system. One way is to use lower current rated fan motor. The alternative fan available has 12V, 2.5A motor. New fan needs to provide sufficient cooling in all vehicle operating conditions. Both the fans are evaluated for different vehicle operating conditions. 2
3 METHODOLOGY Radiator Fan Performance map Radiator, Fan geometry and position Coolant Pump map CFD Engine cooling system Model 1D Analysis Radiator Fan Selection Engine Heat Rejection Vehicle Operating Condition 3
4 INPUTS Two radiator fans considered: 1. Fan A: Average speed : speed 1 Specifications: 12V, 5A 2. Fan B: Average speed : speed 2 Specifications: 12V, 2.5A Fan ON-OFF condition: ON-98 C Coolant Temperature OFF-94 C Coolant Temperature 4
5 INPUTS 5
6 INPUTS Engine Heat Rejection (kw) 6
7 USING COOL 3-D FOR MODELING COOLING SYSTEM OUTFLOW INFLOW 7
8 RADIATOR ASSEMBLY FROM COOL-3D 8
9 SIMULATION MODEL 9
10 ENGINE IDLING CONDITION Vehicle speed : 0 km/h. Engine speed:1500 rpm Ambient air temperature: 27 C Fan Speed: Fan A Fan Speed: Fan B 10
11 ENGINE IDLING CONDITION Vehicle speed : 0 km/h. Engine speed:1500 rpm Ambient air temperature: 27 C Engine out temperature for Fan: A FAN ON FAN OFF Engine out temperature for Fan: B FAN ON FAN OFF 11
12 OBSERVATION Fan A provides more cooling and runs for less duration while Fan B runs for more duration. Engine out coolant temperature remains below maximum allowable temperature. 12
13 HIGHWAY RUNNING CONDITION Vehicle speed : 100 km/h. Engine speed:8000 rpm Ambient air temperature: 27 C Engine out temperature for Fan: A Engine out temperature for Fan: B 13
14 OBSERVATION Both the fans do not start during entire cycle as Engine out coolant temperature remains below Fan start temperature. As vehicle speed is low coolant temperature goes on increasing but stabilize below Fan start temperature. 14
15 HILL CLIMBING CONDITION Vehicle speed : 40 km/h. Engine speed:8000 rpm Ambient air temperature: 27 C Engine out temperature for Fan: A Engine out temperature for Fan: B 15
16 OBSERVATION Both the fans do not start during entire cycle as Engine out coolant temperature remains below Fan start temperature. As vehicle speed is low coolant temperature goes on increasing but stabilize at below Fan start temperature. 16
17 SIGNAL START STOP CONDITION Vehicle speed : 40 km/h and 0 km/h. Ambient air temperature: 27 C 17
18 SIGNAL START STOP CONDITION Fan Speed: Fan A Fan Speed: Fan B 18
19 SIGNAL START STOP CONDITION Engine out temperature for Fan: A FAN ON FAN OFF Engine out temperature for Fan: B FAN ON 19
20 OBSERVATION Fan A provides more cooling and engine out coolant temperature decreases below Fan OFF temperature. This is not observed in Fan B. Engine out coolant temperature remains under maximum allowable limit in both the cases. 20
21 CONCLUSION Fan B performs well with acceptable deviation in cooling system operation compared to Fan A in all considered vehicle operating conditions. Engine out coolant temperature is maintained well below the coolant boiling point temperature. From the observations in each of above cases, Fan B is safely selected for cooling operation. 21
22
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