Simulation And Test Research Of Thermal Management System For Hongyan C100 450 Truck

The research on vehicle thermal management system considers the heat transfer interaction in different systems including the engine cooling system, the intake and exhaust system, lubrication system, air conditioning system, and engine compartment with holistic perspective, in order to ensure components and systems running safely and efficiently, improve engine thermal efficiency and reduce environmental pollution. The thermal management system affects much of vehicle performance, such as engine performance, fuel economy, safety and reliability, aerodynamics, exhaust emissions and so on. With large tonnage, high-powered, heavy trucks becoming the main vehicles of the road transportation, thermal management performance of heavy-duty trucks has been put forward to higher requirements because of increasingly stringent energy saving regulations, harsh use conditions and complex driving environment. Therefore, the development of heavy-duty trucks’ thermal management system is often the focus in the vehicle development process.The thesis presents a research method “the engine test gaining modeling parameters- simulation to determine the optimal cooling system solution- thermal management performance test assessment” to research the thermal management system of Hongyan C100 450 truck, so that shortening the product development time, reducing the costs and providing an efficient and practical method of thermal management system design and development.Firstly, the C11 engine full condition heat balance bench test is established. Through the test, the heat distribution rule and heat dissipation performance itself of C11 engine are researched, and the simulation modeling parameters of thermal management system are obtained. And the effect of total calories whereabouts of fuel combustion is analyzed because of different engine load and speed.Secondly, the simulation theories about heat exchange circulation and engine compartment air flow are analyzed. And the heat pipe network model and the air circulation path model of Hongyan C100 truck are established with KULI software.Then, eight cooling system solutions are simulated with the simulation model and then the best cooling system solution is achieved for the C100 450 truck. The simulation results show that the best cooling system meets the cooling requirements of the vehicle under various engine conditions and harsh environments. And the factors of thermal performance are analyzed with the simulation results.Finally, thermal management performance test is proposed to assess the vehicle thermal management system and the comprehensive evaluation index is established for heavy-duty trucks’ thermal management performance assessment. The load trailer road test program is developed to assess comprehensively thermal management performance of the C100 450 truck. The results show that the cooling module matched by simulation has good thermal performance in road tests and the vehicle thermal management performance meets the design requirements. And then improvement measures are presented about the thermal management problems identified in test.