An experimentally-verified temperature control simulation model for spray evaporative cooling of vibrating powertrain parts. (May 2021)

• Record Type: Journal Article
• Authors: Jose, J. Thalackottore; Sarmadian, A.; Dunne, J.F.; Long, C.A.; Pirault, J.-P.; Rouaud, Cedric
• Is Part Of: International journal of heat and mass transfer. Volume 170(2021)
• Publication Date: 2021-05
• Subjects: Spray evaporative cooling -- Vibrating surfaces -- Temperature control system simulation -- Hardware based experimental verification -- Automotive and aerospace; Heat -- Transmission -- Periodicals; Mass transfer -- Periodicals; Chaleur -- Transmission -- Périodiques; Transfert de masse -- Périodiques; Electronic journals; 621.4022
• DOI: 10.1016/j.ijheatmasstransfer.2021.121041
• Languages: English
• ISSNs: 0017-9310

Abstract

Highlights: A hypothesis is tested, that a dynamic correlation model for spray evaporative cooling of a flat test-piece exposed to vibration, can be used as a reasonable model for spray evaporative cooling of component parts with curved cooling surfaces in non-horizontal orientation. A second hypothesis is also tested, that the transient heat diffusion properties of a particular 3-dimensional component part body can be replaced by a 1-dimensional (1D) equivalence. An experimental test facility has been built in hardware, to generate real data, the accuracy of test-piece surface temperature control simulation to be tested, in which the temperature of two particular instrumented test-pieces exposed to vibration (from a shaker) is controlled by spray evaporative cooling. Detailed comparisons of temperature control via hardware and simulation are given for the two test-pieces under static and dynamic conditions. The paper shows that temperature control of a hardware-based control system using spray evaporative cooling of powertrain parts can be confidently simulated. Abstract: A new simulation capability is presented to enable the performance of a hardware-based temperature control system to be assessed in thermally-managing heat-generating automotive vehicle powertrain parts. Temperature control is assumed to involve spray evaporative cooling of powertrain parts exposed to vibration. Two hypotheses are proposed to enable construction of a practical simulation that is both accurate and computationally efficient. The first is that a dynamic correlation model for single-nozzle spray evaporative cooling of a flat test-piece exposed to vibration, can be used as a reasonable model for multiple-nozzle spray evaporative cooling of component parts with curved cooling surfaces of non-horizontal orientation. The second is that the transient heat diffusion properties of a particular 3-dimensional component can be replaced by a 1-dimensional (1D) equivalence. To test this hypothesis, Finite Element models for two representative parts have been constructed and used to demonstrate the quality of the 1D heat diffusion equivalence, for which a fast Finite Difference solution can be exploited. To test the accuracy of test-piece surface temperature control simulation, an experimental test facility has been built in hardware, in which the temperature of two instrumented test-pieces exposed to vibration (from a shaker) are controlled by spray evaporative cooling. Each test piece is electrically-heated and the hardware control system is configured using PID control, for which appropriate gains are selected. Detailed comparisons of temperature control by hardware and simulation are given for the two test-pieces under static and dynamic conditions. Good agreement is generally obtained between simulated surface temperatures compared with measurements taken from both test-pieces. The paper shows that temperature control of a hardware-based control system using spray evaporative cooling of powertrain parts can be confidently simulated.