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Vehicle Cooling a Compact Guide for the Workshop 02

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Vehicle Cooling a Compact Guide for the Workshop 02 Vehicle cooling A compact guide for the workshop 02 What is thermal management? Thermal management includes ensuring the optimal engine tem- The components in these two assemblies, which interact with perature in all operating conditions as well as heating and cooling each other, often form a unit. This booklet covers modern cooling the vehicle cabin. A modern thermal management system there- systems and their technical background. In this context, we also fore consists of engine cooling and air conditioning components. deal with the principles of operation, causes of failure, character- istic features, and diagnostic options. Disclaimer/picture credits The information in this document has been compiled by the publisher on the basis of details provided by automobile manufacturers and importers, in addition to other sources. Great care has been taken to ensure the accuracy of this information. However, the publisher assumes no liability for any errors or the consequences thereof. This applies to the use of data and information that proves to be incorrect or has been misrepresented, or errors that have been inadvertently introduced during the compilation of the data. Without prejudice to the above, the publisher accepts no liability for any loss of profit, goodwill, or any other resulting loss, including economic loss. The publisher accepts no liability for damage or operational disruption resulting from nonobservance of the training document and the specific safety instructions. The pictures shown in this booklet are mostly supplied by MAHLE and MAHLE Service Solutions. 03 Contents Modern cooling systems Intake air and temperature management Integrated system—passenger cars 4 Air temperature control Integrated system—commercial vehicles 5 for the combustion process in the engine 27 Design of a modern cooling module 5 Subsystems of intake air temperature management (ATM) 28 Battery temperature management for hybrid vehicles 31 Cooling: a retrospective view Engine cooling with water 6 PTC auxiliary heaters Modern engine cooling 7 Design and function 33 Performance and spontaneity 34 Cooling systems Operational safety 35 Actuation 35 The engine cooling system 8 New developments 35 Radiator 9 All-aluminum radiator 11 Expansion tank 12 Diagnostics, maintenance, and repair Thermostats 13 Coolant pumps 14 Coolant, antifreeze, and corrosion protection 36 Electric coolant pumps 15 Radiator maintenance 37 Cabin heat exchangers 16 Bleeding the system when filling 38 Typical damage 39 Engine fans Electronically controlled cooling Visco® fans 17 The electronic Visco® clutch 18 Coolant temperature level 42 Electric radiator fans 19 Coolant distributor housing 43 Coolant control unit 44 Electronic control: Overview 45 Other cooling systems Controlling the coolant temperature when heating is required 46 Oil coolers for engine, transmission, Map-controlled thermostat 48 and hydrodynamic retarders 20 Power steering cooling 21 Fuel cooling 21 Technical information 50 Direct charge air cooling 24 Indirect charge air cooling 25 Cooler for exhaust gas recirculation (EGR) 26 04 Modern cooling systems Modern cooling systems Integrated system— values can be affected by an increased operating temperature, leading to faulty engine control. In addition, in engine variants passenger cars such as direct injection, both diesel and gasoline, which gener- ate only a small amount of heat, the cooling system must warm All of the heat generated by an engine and its dependent sys- the vehicle occupants in winter and cool them in summer. All tems must be dissipated. Today, the operating temperature of an these factors must be considered when developing a thermal engine is only permitted a small tolerance in order to control oper- management system. Added to this is the requirement for higher ation and ambient temperature (engine and interior). Emissions performance and efficiency in a smaller installation space. 05 1 9 8 2 3 4 7 5 6 Integrated system— 1 Pressure shroud with electrically driven fan commercial vehicles 2 Power steering cooler 3 Air conditioning condenser module This is a typical example of the current status of thermal manage- ment in commercial vehicles. We will look at both segments— 4 Module frame passenger cars and commercial vehicles—below. 5 All-aluminum radiator Design of a modern cooling module 6 Transmission oil cooling 7 Suction shroud for engine fans This is a typical example of the current status of a cooling mod- ule. It consists of the radiator, engine oil cooler, air conditioning 8 Module frame cover condenser, transmission oil cooler, power steering cooler, and 9 Engine oil cooler radiator/air conditioning condenser fan. 06 Cooling: a retrospective view Cooling: a retrospective view Engine cooling with water As engines evolved, a coolant regulator or thermostat was used. The water circulation through the radiator was controlled depend- ing on the coolant water temperature. In 1922, it was described The temperatures generated during fuel combustion (up to as follows: “The purpose of these devices is to warm up the 2,000°C) are harmful to the operation of the engine. That is why engine quickly and prevent it from cooling down.” We are already the engine is cooled to operating temperature. The first type of talking about a thermostat-controlled cooling system with the fol- cooling using water was thermosiphon cooling. The heated, lowing functions: lighter water rises through a manifold into the upper part of the cooler. It is cooled by the airstream, sinks to the bottom, and n Short warm-up time flows back to the engine. This circuit remains in operation as long as the engine is running. The cooling was supported by fans—so n Operating temperature kept constant no control was possible. Later, the water circulation was acceler- ated by a water pump. Weak points: n Long warm-up time n Low engine temperature during the cold season BEHR wind tunnel 1937 07 MAHLE climatic wind tunnel today To cool an engine, use is now made of the fact that pressurized Modern engine cooling water starts to boil not at 100°C but at 115°C to 130°C. So the cooling circuit is under a pressure of 1.0 to 1.5 bar. We are The thermostat and the resulting “short-circuited” coolant cir- talking about a closed cooling system. For this purpose, the sys- cuit brought about a crucial improvement in engine cooling. As tem has an expansion tank that is only about half filled. Instead long as the desired operating temperature of the engine is not of just water, a mixture of water and coolant additive is used as reached, the water does not flow via the radiator, but passes the cooling medium. We are now talking about coolant that has back into the engine by a short route. Only when the desired antifreeze properties as well as an increased boiling point and operating temperature is reached does the thermostat open the protects engine and cooling system components from corrosion. connection via the radiator. To this day, all systems have featured this control. The operating temperature of the engine is of vital importance not only for performance and consumption, but also for low emissions. radiator manifold since 1922 thermostat engine water pump Around 1910 with water pump 08 Cooling systems Cooling systems The requirements placed on the cooling system are: The engine cooling system n Shorter warm-up phase With the engine compartment becoming more and more com- n Rapid cabin heating pact, housing the components and dissipating the enormous amounts of heat poses a significant challenge. In order to cool n Low fuel consumption down the engine compartment, high demands are placed on n Improved component service life modern cooling systems. As a result, there has recently been great progress in the field of cooling. All engine cooling systems are based on the following components: n Radiator n Thermostat n Coolant pump (mechanical or electrical) n Expansion tank n Lines n Engine fan (V-belt driven or Visco®) n Temperature sensor (engine control/display) 8 4 5 6 3 1 Radiator 1 2 Coolant pump 3 Radiator fan 7 4 Thermostat 5 Heat exchanger 2 6 Heat exchanger valve (optional) 7 Engine 8 Airflow 09 Radiator Radiator Advantages: n Precise fitting for easy installation Engine cooling began in 1905. The combustion temperature in the n Optimal efficiency engine at that time was around 600°C to 800°C. Steel radiators were used around the turn of the century until about 1938; after n Tailored to customer specifications (OEM) that, metal radiators (copper/brass) appeared. Disadvantage: high weight and limited supply, meaning a high material price. Typical design Requirements for the radiator: The oil cooler can also be a separate component of the radia- tor. The individual parts are assembled to give the radiator its n High power density shape. The cooling takes place via the cooling fins (core matrix), n Adequate strength whereby the air takes heat from the coolant as it flows through. The coolant flows from top to bottom, called downdraft, or from n Long-lasting corrosion resistance right to left or vice versa (crossflow). Both variants must have n Low manufacturing costs enough time and a sufficiently large cross section to allow the air to cool the coolant effectively. n Environmentally sound production Design: n Water tank made of GFP = glass fiber-reinforced polyamide n Increasingly from aluminum Task: n To cool the coolant in the engine circuit 10 Cooling systems 5 4 1 Water tank 3 2 2 Oil cooler 1 1 3 Seals 4 Cooling fins (core matrix) 5 Side plates 6 Base 3 6 7 Cooling tube 7 5 6 Designs mechanically joined or brazed. The tech- nical performance data for the two pro- There are two typical designs: brazed and duction processes is virtually identical. mechanically joined. Both types are used However, the mechanically joined version with downdraft cooling.
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