Truck & Off-Highway Engineering - December 2017 - 10
TECHNICAL INNOVATIONS
THERMAL MANAGEMENT | SIMULATION
Assessing a vehicle's cooling system performance
Off-highway OEMs historically have utilized simple 1-Dimensional analyses (either themselves or through their cooling system suppliers) to predict the
cooling performance of each vehicle's
engine system. These analyses produce
a low accuracy rate, which often results
in late design changes leading to delays
in the overall project.
To improve this situation, manufacturers
have a tool at their disposal in computational fluid dynamics (CFD). Using inputs
of temperatures, flows, restrictions, heat
transfer ability of coolers, and
3-Dimensional models of vehicle architecture, a 3D prediction of the cooling performance can be achieved. The 3D prediction
results in an overall systems design with a
higher success rate during validation.
JLG has been routinely using CFD software tools from industry-leading suppliers for more than five years, when developing new engine bay installations. The
introduction of so many new engine variants, including hybrid drives and global
emissions legislation variants, has driven
the need to get it right the first time while
managing even more variables.
The example described here is an extract from the analysis performed on a JLG
1500AJP Ultra Boom, launched in 2016.
CFD reveals design inefficiencies
There are often multiple coolers that
make up a system. Each of these coolers
must work together to provide the required level of performance for each part
of the system. By making sure that each
Previous predictions from 1D analyses provided a less-than-desirable
first-test success rate, closer to 70% on average. CFD has jumped that
average rate up to 90%.
10 December 2017
cooler is balanced with the proper airflow, preheat temperatures and more,
the desired performance of the system
will be achieved.
By utilizing CFD in the early stages of
the design process, engineers can iterate in a soft environment to achieve the
desired performance. By doing so, the
team can avoid changes in the validation portion of the design cycle which
are common when using 1D analyses.
Once an initial design of the cooling
system has been created, it is time to use
the CFD tool to analyze the efficiency of
each individual cooler. In this specific
case, the internal temperatures and cooler flows (constants, liquids and air) versus
the heat exchanger efficiencies (constants) are mapped as a heat rejection
from the system to the vehicle's environment based on the external cooler flows
(air), which the CFD tool is simulating.
CFD revealed the following about the
initial design of the cooling system:
* Engine liquid coolant was being
cooled to 110% of the requirement
* Engine charge air was being cooled to
only 75% of the requirement
* Vehicle hydraulics were being cooled
to 109% of the requirement.
While two of the systems were performing optimally, the engine charge air
cooler was below the requirement.
Based on the design, it was determined
that the engine liquid cooler needed to
Cooling system performance on the JLG 1500AJP Ultra Boom was
significantly improved through the use of CFD software tools.
TRUCK & OFF-HIGHWAY ENGINEERING
ALL IMAGES: JLG INDUSTRIES
JLG relies on CFD analyses when
developing new engine bay
installations, including that for
the JLG 1500AJP Ultra Boom
(shown).
Truck & Off-Highway Engineering - December 2017
Table of Contents for the Digital Edition of Truck & Off-Highway Engineering - December 2017
Truck & Off-Highway Engineering - December 2017
Contents
Navistar, VW pursue common electric powertrain, global connectivity platform
Technical Innovations
ZED Connect brings mobile-based ELD to improve safety and service
IAV brings variable valvetrains to heavy duty
Assessing a vehicle’s cooling system performance
Kohler engineers new 5400 engines for lower NVH, easier start-ups
Meeting truck autonomy hurdles head-on
Simulation key to additive manufacturing analysis
Making the case for battery electric fleet power
Electrified forklifts go big
Case IH Quadtrac CVX the first 4WD articulated tractor to offer a CVT
Original Equipment
Mack hits the highway with style and technology
Product Briefs
Companies Mentioned, Ad Index
Q&A
Truck & Off-Highway Engineering - December 2017 - Intro
Truck & Off-Highway Engineering - December 2017 - Truck & Off-Highway Engineering - December 2017
Truck & Off-Highway Engineering - December 2017 - Cover2
Truck & Off-Highway Engineering - December 2017 - Contents
Truck & Off-Highway Engineering - December 2017 - 2
Truck & Off-Highway Engineering - December 2017 - 3
Truck & Off-Highway Engineering - December 2017 - Technical Innovations
Truck & Off-Highway Engineering - December 2017 - 5
Truck & Off-Highway Engineering - December 2017 - 6
Truck & Off-Highway Engineering - December 2017 - ZED Connect brings mobile-based ELD to improve safety and service
Truck & Off-Highway Engineering - December 2017 - IAV brings variable valvetrains to heavy duty
Truck & Off-Highway Engineering - December 2017 - 9
Truck & Off-Highway Engineering - December 2017 - Assessing a vehicle’s cooling system performance
Truck & Off-Highway Engineering - December 2017 - 11
Truck & Off-Highway Engineering - December 2017 - Kohler engineers new 5400 engines for lower NVH, easier start-ups
Truck & Off-Highway Engineering - December 2017 - 13
Truck & Off-Highway Engineering - December 2017 - Meeting truck autonomy hurdles head-on
Truck & Off-Highway Engineering - December 2017 - 15
Truck & Off-Highway Engineering - December 2017 - 16
Truck & Off-Highway Engineering - December 2017 - 17
Truck & Off-Highway Engineering - December 2017 - 18
Truck & Off-Highway Engineering - December 2017 - 19
Truck & Off-Highway Engineering - December 2017 - Simulation key to additive manufacturing analysis
Truck & Off-Highway Engineering - December 2017 - 21
Truck & Off-Highway Engineering - December 2017 - Making the case for battery electric fleet power
Truck & Off-Highway Engineering - December 2017 - 23
Truck & Off-Highway Engineering - December 2017 - 24
Truck & Off-Highway Engineering - December 2017 - Electrified forklifts go big
Truck & Off-Highway Engineering - December 2017 - 26
Truck & Off-Highway Engineering - December 2017 - Original Equipment
Truck & Off-Highway Engineering - December 2017 - 28
Truck & Off-Highway Engineering - December 2017 - 29
Truck & Off-Highway Engineering - December 2017 - Mack hits the highway with style and technology
Truck & Off-Highway Engineering - December 2017 - 31
Truck & Off-Highway Engineering - December 2017 - Product Briefs
Truck & Off-Highway Engineering - December 2017 - 33
Truck & Off-Highway Engineering - December 2017 - Companies Mentioned, Ad Index
Truck & Off-Highway Engineering - December 2017 - Q&A
Truck & Off-Highway Engineering - December 2017 - 36
Truck & Off-Highway Engineering - December 2017 - Cover3
Truck & Off-Highway Engineering - December 2017 - Cover4
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