Efficient Volvo Bus Cooling System, Using Electrical Fans
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Efficient Volvo Bus Cooling System, Using Electrical Fans A comparison between hydraulic and electrical fans RITA BAILAO˜ MARTINS FERNANDES Master’s Degree Project Stockholm, Sweden June 2014 TRITA-EE 2014:xxx Abstract Economical and environmental factors together with energy policies towards more efficient sys- tems are the driving force for the development of the vehicle industry. Significant changes have been made to fulfill new emissions legislation but the basic internal combustion vehicle architecture has been kept. New emission treatment systems that increase the thermal loading of the cooling system had been added within the same package envelope as before, which means less space to place cooling fans and a greater need for airflow. Changes in the cooling system, namely the replacement of the hydraulic fan drive system by electrical fans is one of the energy efficient alternatives for several city buses under certain environments, like the ”typical red city buses”, well-known in the United Kingdom. In this thesis study, hydraulic fans are compared with electrical fans and a road-map of the benefits and drawbacks of the two systems is developed, based on real traffic performance performance data and the results of existing simulations and tests. In addition, new simulations are presented in order to find the most efficient design for the cooling system as well as a comparison of these results with previous ones. This road map will be used later by Volvo-Buses Group as a tool to better understand in which circumstances electrical fans can be beneficial, in terms of fuel consumption, noise production, cooling performance, control of the fans and associated costs. Keywords : hydraulic fan cooling system, electrical fan drive system, radiator, fan efficiency, fan shroud, static pressure, oil cooler, charge air cooler, built-in-resistance. 1 Part I Preface Dear reader of this thesis. This master thesis project is the final sign off of the last year of my master of science. It is based on engineering reports made by Volvo engineers, scientific articles and simulation results from Volvo GTT and Volvo Buses. The research was carried out from later January 2014 to July 2014, and presented in the end to Volvo AB and to KTH (Royal Institute of Technology), in Stockholm. The topic was based on the company’s request to analyze the current options for the fans of the bus cooling systems and to better understand electrical fans in terms of cooling performance. The master thesis project was carried out by Rita Fernandes as an intern, Reza Fakhrai as supervisor at the university Christer Kjellgren as supervisor at the company. The project was financed by the AB Volvo, namely by the department of Powertrain Development and conducted by the Cooling System group, with Charlotte Eldh as the line manager. The empirical research took place in Volvo Buses offices in Gothenburg, mostly located in Arendal. All of the co-workers: Chirster Kjellgren, Erik LindÃľn, Joel SÃűrborn, Eva BjÃűrk, Peter Gullberg, Erik Dahl, Dalibor Cuturic, Jessica LexÃľn, Stephan SchÃűnfeld and the remaining group are highly appreciated for their help and availability during the thesis work. Moreover the input from all the interviewees was crucial and without it, there would not be the possibility to get so quickly the results of this thesis. Also a special thanks to my friend Andrea who helped to feel home in this new city of Gothemburg and my Portuguese friends who guided me through all the aerodynamics concepts. It has been very nice to get to know you, and I hope to continue to learn more from you. Francisco, thanks for helping me with proper English. Finally, I would like to thank my family and all of my friends for their warm and kind support. At the end of the day, you have always been there for me. Thank You. Confidentiality clause Due to confidentially reasons, all the parts with sensitive information were deleted form this report. This includes all the tables, figures and graphs with valuable content for Volvo AB. A different and complete report of this thesis was delivered to Volvo AB, as well as a shorter version with the main results and recommendations. Gothemburg, July 2014 Rita Fernandes 2 Contents I Preface 2 II Introduction 8 III Objectives 9 IV Volvo Buses and cooling system 10 1 Thermodynamic and Heat Transfer fundamentals 10 1.1 Conduction . 10 1.2 Convection . 11 2 Bus Cooling System 11 2.1 Fan Systems . 12 2.2 Radiator . 13 2.3 Engine water pumps . 14 2.4 Charge air cooler . 15 2.5 Oil cooler . 15 2.6 Fans shroud . 15 2.7 Thermostats and other sensors . 15 2.8 Header Tank and Recovery System . 16 3 Hydraulic Fans 16 3.1 Coolant Temperature Sensor . 16 3.2 Hydraulic pump . 16 3.3 Pump control plate . 17 3.4 Control valve and check valve . 17 3.5 Hydraulic fan motor . 17 4 Electrical Fans 17 4.1 Radial, Axial fans and Diagonal fans . 19 4.2 How to select the right fan . 20 4.2.1 The total cooling requirements . 21 4.2.2 Static pressure . 21 4.2.3 Total System Resistance / System characteristic curve . 21 4.2.4 System Operating Point . 22 4.2.5 Stall effect and instability regions . 22 4.2.6 Efficiency of electrical fans . 22 V Modeling and analyzing electrical fans 23 5 What is limiting electrical fans 23 5.1 Fan blade types . 23 5.2 Fan Laws . 23 5.3 Influence of density . 24 5.4 Impact of Fan Diameter . 24 5.5 Series and Parallel Operation . 25 5.5.1 5 SPAL electrical fans (305 mm) vs 2 SPAL electrical fans (405 mm) . 28 5.6 Blade angle . 28 5.7 Distance between fan blades and fan ring . 28 3 5.8 Voltage imposed and consequences in fan curves characteristics . 28 5.9 Possible fan suppliers . 31 5.10 Pusher Fans vs. Puller Fans . 31 6 Evaluation of an electrical cooling system: London buses case: B5LH (hybrid) and B9TL 34 6.1 Exhaust gas recirculation (EGR) . 34 6.2 Real Data taken from Volvo Data Base (LVD) . 34 6.3 LAT and IMTD . 34 6.4 Derating . 35 VI Simulations and Tests 36 7 City-buses 36 7.1 Methodology . 36 7.2 AMESim . 36 7.3 Input Data . 37 7.4 Implementation . 37 7.5 Built-in-resistance . 37 7.6 Effect of removing the oil cooler . 39 7.7 Cooling performance: LAT and IMTD . 40 7.8 Separated CAC and radiator installation . 40 7.9 Effect of the fan shroud . 42 8 Coaches cooling performance using electrical fans 44 8.1 Cooling performance: LAT and IMTD . 44 VII Conclusions 45 VIII Recommendations and future work 47 4 List of Figures 1 Scheme of bus cooling system heat exchangers, air flow direction and respective pressure differences . 12 2 Scheme of a turbocharger.Adapted from [39]. 13 3 Scheme of a water pump. Adapted from [42]. 14 4 Scheme of hydraulic valves . 17 5 The effect of multiple fans on system pressure and flow rate. Adapted from [3]. 20 6 Change of static pressurer . 21 7 Sketch of fan and system curve. Adapted from [3] . 22 8 Stall: unstable zone in the fan curve . 23 9 Effect of an increase in fan diameter in air flow and static pressure . 25 10 The effect of multiple fans on system pressure and flow rate . 26 11 Lower duct pressure due to fans placed in series . 26 12 5 fan curves in a parallel configuration, with a diameter of 305 mm and 3750 rpm speed . 27 13 2 fan curves in a parallel configuration, with a diameter of 450 mm and 3750 rpm speed . 27 14 Different fan curves for the same system resistance . 28 15 A comparison between 2 real SPAL fans versus 5 small SPAL fans . 29 16 Dependency between pressure drop and blade angle. Adapted from [3]. 29 17 Fan ring location in the cooling module. Adapted from [3]. 30 18 Dependency between pressure drop and blade-ring distance. Adapted from [3]. 30 19 Effect of voltage in fan performance . 31 20 Sound level for different electrical fans . 33 21 5 electrical fans model: Heat stack (radiator and CAC) connected to 5 electrical fans . 38 22 Heat module: CAC, oil cooler and a radiator in the backside . 39 23 CFD calculations: case a) without oil cooler and case b) with oil cooler . 40 24 LAT change versus fan speed . 41 25 IMTD versus fan speed . 41 26 CFD model with fans . ..