Multiple Heat Exchanger Cooling System for Automotive Applications – Design, Mathematical Modeling, and Experimental Observations

The design of the automotive cooling systems has slowly evolved from engine-driven mechanical to computer-controlled electro-mechanical components. With the addition of computer-controlled variable speed actuators, cooling system architectures have been updated to maximize performance and efficiency. By switching from one large radiator to multiple smaller radiators with individual flow control valves, the heat rejection requirements may be precisely adjusted. The combination of computer regulated thermal management system should reduce power consumption while satisfying temperature control objectives. This research focuses on developing and analyzing a multi-radiator system architecture for implementation in ground transportation applications. The premise is to use a single radiator during low thermal loads and activate the second radiator during high thermal loading scenarios. Ground vehicles frequently use different radiators for each component that needs cooling (e.g., engine blocks, electronics, and motors) since they have different optimal working temperatures. The use of numerous smaller heat exchangers adds more energy-management features and alternative routes for carrying on with operation in the event of a crucial subsystem failure. Moreover, despite cooling systems being designed for maximum thermal loads, most vehicles typically operate at a small fraction of their peak values. To study and examine the planned multi-heat exchanger cooling system concepts, various computer simulations and experimental tests were performed. A nonlinear state space model, featuring input and output heat flow paradigms, was developed using a multi-node resistance-capacitance thermal model. The heat removal rate from the radiator(s) was estimated using the -NTU method as downstream fluid temperatures were not required. The system performance was studied for two driving cycles proposed by the Environmental Protection Agency (EPA) – urban and highway driving schedules. The computer simulation was validated using the laboratory setup in the High Bay Area of Fluor Daniel Engineering Innovation Building. The configuration features computer controlled variable speed electric motor driven coolant pump and independent variable speed fans for each radiator to provide desired fluid flow rates. The pump and fan power consumptions are approximately 0.8-1.2 kW and 0.4-3.2 kW, which corresponds to coolant and air flow rates of 0.2-1.5 kg/s and 0.5-1.75 kg/s, respectively. Two servo motor-controlled gate valves limit the coolant outlet from each radiator. Various thermocouples and a magnetic flow sensor record test data in real time using a dSpace DS1103 data acquisition control system. Designing and analyzing a nonlinear control architecture for the suggested system was the last phase in the study process. A nonlinear controller equipped TMS should offer higher energy efficiency and overall system performance. Three controllers—sliding mode, stateflow, and classical—were designed and implemented in Matlab/Simulink and placed onto the dSpace hardware. The sliding mode controller is recommended for high performance applications since it offers steady temperature tracking, 5oC, an acceptable response time, 120 sec, but suffers from frequent changes in fan speed. The stateflow controller exhibited the fewest fan speed oscillations, the fastest response time, 88 sec, and the smallest temperature offset, 3oC, it is advised for use in common passenger vehicle applications. Both controllers need around six minutes to warm up. The traditional controller, meanwhile, had the quickest warmup, 600 sec, but the slowest response time, 215 sec. Nonlinear cooling systems are essential for maintaining component temperatures which will enable vehicle reliability, and maximize performance given the focus on hybrid and electric vehicles

Transdisciplinarity seen through Information, Communication, Computation, (Inter-)Action and Cognition

Similar to oil that acted as a basic raw material and key driving force of industrial society, information acts as a raw material and principal mover of knowledge society in the knowledge production, propagation and application. New developments in information processing and information communication technologies allow increasingly complex and accurate descriptions, representations and models, which are often multi-parameter, multi-perspective, multi-level and multidimensional. This leads to the necessity of collaborative work between different domains with corresponding specialist competences, sciences and research traditions. We present several major transdisciplinary unification projects for information and knowledge, which proceed on the descriptive, logical and the level of generative mechanisms. Parallel process of boundary crossing and transdisciplinary activity is going on in the applied domains. Technological artifacts are becoming increasingly complex and their design is strongly user-centered, which brings in not only the function and various technological qualities but also other aspects including esthetic, user experience, ethics and sustainability with social and environmental dimensions. When integrating knowledge from a variety of fields, with contributions from different groups of stakeholders, numerous challenges are met in establishing common view and common course of action. In this context, information is our environment, and informational ecology determines both epistemology and spaces for action. We present some insights into the current state of the art of transdisciplinary theory and practice of information studies and informatics. We depict different facets of transdisciplinarity as we see it from our different research fields that include information studies, computability, human-computer interaction, multi-operating-systems environments and philosophy.Comment: Chapter in a forthcoming book: Information Studies and the Quest for Transdisciplinarity - Forthcoming book in World Scientific. Mark Burgin and Wolfgang Hofkirchner, Editor

Innovation in manufacturing through digital technologies and applications: Thoughts and Reflections on Industry 4.0

The rapid pace of developments in digital technologies offers many opportunities to increase the efficiency, flexibility and sophistication of manufacturing processes; including the potential for easier customisation, lower volumes and rapid changeover of products within the same manufacturing cell or line. A number of initiatives on this theme have been proposed around the world to support national industries under names such as Industry 4.0 (Industrie 4.0 in Germany, Made-in-China in China and Made Smarter in the UK). This book presents an overview of the state of art and upcoming developments in digital technologies pertaining to manufacturing. The starting point is an introduction on Industry 4.0 and its potential for enhancing the manufacturing process. Later on moving to the design of smart (that is digitally driven) business processes which are going to rely on sensing of all relevant parameters, gathering, storing and processing the data from these sensors, using computing power and intelligence at the most appropriate points in the digital workflow including application of edge computing and parallel processing. A key component of this workflow is the application of Artificial Intelligence and particularly techniques in Machine Learning to derive actionable information from this data; be it real-time automated responses such as actuating transducers or informing human operators to follow specified standard operating procedures or providing management data for operational and strategic planning. Further consideration also needs to be given to the properties and behaviours of particular machines that are controlled and materials that are transformed during the manufacturing process and this is sometimes referred to as Operational Technology (OT) as opposed to IT. The digital capture of these properties and behaviours can then be used to define so-called Cyber Physical Systems. Given the power of these digital technologies it is of paramount importance that they operate safely and are not vulnerable to malicious interference. Industry 4.0 brings unprecedented cybersecurity challenges to manufacturing and the overall industrial sector and the case is made here that new codes of practice are needed for the combined Information Technology and Operational Technology worlds, but with a framework that should be native to Industry 4.0. Current computing technologies are also able to go in other directions than supporting the digital ‘sense to action’ process described above. One of these is to use digital technologies to enhance the ability of the human operators who are still essential within the manufacturing process. One such technology, that has recently become accessible for widespread adoption, is Augmented Reality, providing operators with real-time additional information in situ with the machines that they interact with in their workspace in a hands-free mode. Finally, two linked chapters discuss the specific application of digital technologies to High Pressure Die Casting (HDPC) of Magnesium components. Optimizing the HPDC process is a key task for increasing productivity and reducing defective parts and the first chapter provides an overview of the HPDC process with attention to the most common defects and their sources. It does this by first looking at real-time process control mechanisms, understanding the various process variables and assessing their impact on the end product quality. This understanding drives the choice of sensing methods and the associated smart digital workflow to allow real-time control and mitigation of variation in the identified variables. Also, data from this workflow can be captured and used for the design of optimised dies and associated processes

Smarter–lighter–greener : research innovations for the automotive sector

This paper reviews the changing nature of research underpinning the revolution in the automotive sector. Legislation controlling vehicle emissions has brought urgency to research, so we are now noticing a more rapid development of new technologies than at any time in the past century. The light-weighting of structures, the refinement of advanced propulsion systems, the advent of new smart materials, and greater in-vehicle intelligence and connectivity with transport infrastructure all require a fundamental rethink of established technologies used for many decades—defining a range of new multi-disciplinary research challenges. While meeting escalating emission penalties, cars must also fulfil the human desire for speed, reliability, beauty, refinement and elegance, qualities that mark out the truly great automobile

Development of a virtual reality milling machine for knowledge learning and skill training

Current methods of training personnel on high cost machine tools involve the use of both classroom and hands on practical training. The practical training required the operation of costly equipment and the trainee has to be under close personnel supervision. The main aim of this project is to reduce the amount of practical training and its inherent cost, time, danger, personal injury risk and material requirements by utilising a virtual reality technology. In this study, an investigation into the use of Virtual reality for training operators and students to use the Milling Machine was carried out. The investigation has been divided into two sections: first the development of Milling Machine in the 3D virtual environment, where the real machine was re-constructed in the virtual space. This has been carried out by creating objects and assembling them together. The complete Milling machine was then properly modelled and rendered so it could be viewed from all viewpoints. The second section was to add motion to the virtual world. The machine was made of functions as for the real machine. This was achieved by attaching Superscape Control Language (SCL) to the objects. The developed Milling machine allows the users to choose the material, speed and feed rate. Upon activation, the virtual machine will be simulated to carry out the machining process and instantaneous data on the machined part can be generated. The results were satisfactory, the Milling Machine was modelled successfully and the machine was able to perform according to task set. Using the developed Virtual Model, the ability for training students and operators to use the Milling Machine has been achieved