A New Design Rule of Engine Coolant Pump in ICEs Focused to Energy Consumption Reduction

M. Di Bartolomeo, Davide Di Battista, R. Cipollone, F. Fremondi, Umberto Camagni
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Abstract

Engine thermal management systems represent a promising solution to improve the efficiency of current Internal Combustion Engines (ICE) and sustain the transition towards a net zero scenario. The core component of an engine thermal management system is the electric pump, which can adjust the coolant flow rate according to the engine thermal needs. This possibility opens to newer design choices, which can contribute to non-negligible energy savings. In this study, three electric coolant pumps with different maximum efficiencies have been investigated to understand the influence of the design operating conditions on the pump energy absorption. A reference vehicle equipping a 130 HP downsized gasoline engine has been considered. An experimental test bench with a copy of the engine and its cooling circuit has been reproduced, and the electric pumps have been tested at a wide range of rotational speeds and thermostat lifts to obtain their characteristic maps. Once their performances were known, the vehicle was run in three driving cycles consisting of different shares of rural, urban and highway sections, acquiring data from the Electronic Control Unit (ECU). These data have been used to calculate the operating condition and energy absorption of the mechanical pump originally equipped by the vehicle and the electric pumps. The results have been evaluated using a statistical approach, normalizing the instantaneous efficiency by using their maximum efficiency values. The results show that all the electric pumps have lower energy absorption compared to the conventional mechanical actuation, with a reduction of up to 77% of the energy absorption. Considering the vehicle's fuel consumption and the lower heating value of gasoline, the potential reduction of CO2 specific emissions is 1 g/km. The statistical analysis approach showed that the design operating conditions have a higher influence than the maximum pump efficiency. The best performances are achieved through the electric pump with the lowest efficiency, showing a decrease in energy absorption between 10 % and 50% compared to the other electric prototypes, depending on the driving profile.
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以降低能耗为重点的内燃机车发动机冷却液泵设计新规则
发动机热管理系统是提高当前内燃机(ICE)效率和维持向净零(net zero)方案过渡的一种有前途的解决方案。发动机热管理系统的核心部件是电动泵,它可以根据发动机的热需求调节冷却剂流量。这种可能性提供了更新的设计选择,有助于实现不可忽略的节能效果。在这项研究中,对三种最大效率不同的电动冷却剂泵进行了调查,以了解设计工作条件对泵能量吸收的影响。参考车辆配备了一台 130 马力的小型汽油发动机。我们复制了一个带有发动机及其冷却回路副本的实验测试台,并在各种转速和恒温器升程下对电动泵进行了测试,以获得其特性图。一旦知道了它们的性能,车辆就在三个驾驶循环中运行,包括不同比例的农村、城市和高速公路路段,从电子控制单元(ECU)获取数据。这些数据被用来计算车辆最初配备的机械泵和电动泵的运行状况和能量吸收情况。计算结果采用统计方法进行评估,使用最大效率值对瞬时效率进行归一化处理。结果表明,与传统的机械驱动相比,所有电动泵的能量吸收都较低,最多可减少 77% 的能量吸收。考虑到车辆的油耗和较低的汽油热值,二氧化碳的具体排放量可能减少 1 克/公里。统计分析方法表明,设计运行条件比最大泵效率的影响更大。效率最低的电动泵可实现最佳性能,与其他电动原型相比,其能量吸收率降低了 10% 至 50%,具体取决于驾驶情况。
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