JSS MAHAVIDYAPEETHAJSS ACADEMY OF TECHNICAL EDUCATION NOIDA

Department Of Manufacturing Technology

DESIGN, FABRICATION AND ANALYSIS OF AUTOMOBILE RADIATOR TEST RIG USING MATLAB

Supervised By :

Mr. VISHNU TIWARIAssistant Prof.MT Department

Presented By :

Sharang Bhardwaj 1109141043Aayushi 1109141002Shishir Tripathi 1109141044Sanchit Agrawal 1109141040

(8th Sem Students)

Group no.4

MAIN DIVISION OF PROJECT1. Estimation of cost and availability of the components.2. Design of the engine cooling system in MATLAB .3. Assembling of the different components to prepare test rig.4. Analysis of rig values for different parameters of the system.5. Simulate the system, compare and formulate the results.

INTRODUCTION

HEAT GENERATED IN THE VEHICLE

DUE TO COMBUSTION

STROKE

POWER TO DRIVE THE VEHICLE AND ITS ACCESSORIES

HEAT IS CARRIED OFF INTO THE ATMOSPHERE

THROUGH EXHAUST SYSTEM

REMAINING REMOVED FROM THE ENGINE BY

COOLING SYSTEM

AUTOMOBILE RADIATORA radiator is a type of heat exchanger. It is designed to

transfer heat from the hot coolant that flows through it to the air blown through it by the fan.

TESTING SET UP OF AUTOMOBILE RADIATOR

• Reservoir with heating element• Pump• Rotameter• Thermocouples• Radiator• Fan• Coolant bottle

WORKING PRINCIPLE• The pump sends the fluid into the engine block, where it makes its way

through passages in the engine around the cylinders. Then it returns through the cylinder head of the engine.

• The thermostat is located where the fluid leaves the engine. The thermostat sends the fluid back to the pump directly if the thermostat is closed.

• If it is open, the fluid goes through the radiator first and then back to the pump.

• There is also a separate circuit for the heating system. This circuit takes fluid from the cylinder head and passes it through a heater core and then back to the pump.

• There is normally also a separate circuit for cooling the transmission fluid built into the radiator. The oil from the transmission is pumped by the transmission through a second heat exchanger inside the radiator.

PROCEDURE• Fill the reservoir with the coolant upto indicated level.• Switch on the power supply,and then switch on the heating element.• Allow the coolant to get heated up to 60-90 degree celcius.• Switch on the fan and the pump.• Note down the electricity consumed by fan and pump by energy

meter.• Note down the discharge of the coolant from flowmeter.• Note down the inlet and outlet temperature/ by varying pump

discharge.• Plot the graph between discharge vs. temperature.• Plot the graph between inlet and outlet temperature.

COMPONENT SPECIFICATIONSMaruti Alto:

•Size: 300*335*23 mm•Make: SUZUKI•Model no. DL-A039•Material: CopperMaruti 800•Downward flow type•Cu tubes, Cu plates•37 plates, dia of tubes-10mmCapacity= 3lit.Cooling fan•Rpm: 1200-2400 rpm•220/240 V•Single phase AC

Water Pump•Submersible pump •165-220V/50 Hz•Power -19W•Output -1100 L/HEnergy wire• 1 phase, 2 wire•AC 240V , 50Hz•I (max)- 30A Heating elements•Power = 2000W, 1500WReservior•Material: Stainless steel•Capacity: 25-30L

∆t= time taken(s)Z= energy meter reading(W)Ƞₒ= overall efficiency (%)Ƞ= thermal efficiency(%)h= convective heat transfer coefficient (w/m2 °C)∆Q= heat loss (W)

CALCULATIONS• Temperature Difference ∆T = T1 – T2• Thermal ƞ= ∆T/T1• Overall ƞₒ=( m*Cp* ∆T)/ z• Q= h*A*∆TWhere,T1= temp at inlet(°C)T2= temp at outlet (°C)M= mass of the coolantCp= specific heat at constant pressureQ= dischargeP= Power of pumpῥ=density of water (kg/m3)g= acceleration due to gravity (m2/s)H= head of the pump(m)∆T= temp diff (T1-T2)

Water meter•Dia of inlet & outlet- 15 mmFrame•Material: Mild steel•Angle size: 1``Pipes and fittings•Diameter – 0.5`` and 1``

COST ESTIMATION

•Radiators : Rs.2500-3000•Cooling fan: Rs.300•Energy meter: Rs.300•Water meter: Rs.600•Container: Rs. 560•Water pump: Rs.120•Heating element:Rs.180•Frame: Rs.1500•Pipes and joints: Rs.850•Electrical boards and switches: Rs.500

•TOTAL:Rs.8000

RADIATOR SPECIFICATION USED IN THE MATLAB

• Size: (300*335*23) mm• Make: SUZUKI• Model no. DL-A039• Material: Copper• Downward flow type• Cu tubes, Cu plates• 37 plates, dia of tubes-10mm

ENGINE COOLING SYSTEM MODEL

ENGINE MODEL

OUTPUT

FLUID DENSITY IN THE SYSTEM

PARTS PURCHASED

• Radiator: Accent Camry Petrol version• Submersible pump• Inverter Circuit for efficient running of the radiator fan at

high current.• Step down Transformer • Emulsion heating rod• Alcoholic Thermometer

Steps involved in the removal of radiator from the car

1. Remove the Radiator Filler Cap and Detach the Radiator Reservoir Hose.

2. Detach the Driver's side Fan and ECT Switch Connector.

3. Detach the Passenger side Fan Connector.

4. Disconnect the Supply and Return Transmission Fluid Lines from the Transmission .

5. Remove the four 10mm bolts that secure the two cooling fan shrouds. Then pull up and out the passenger

side Cooling Fan Shroud to expose the ECT Temperature Control Wire Harness Strap.

6. Disconnect the ECT Wire Harness Strap from the Strap Mount.  Then disconnect the ETC Wire Plug from

the Water Temperature Sending Unit.

7. Drain the Coolant

8. Disconnect the Upper and Lower Radiator Hose

9. Unbolt the two Upper Radiator Support Mounts, remove the mounts and pull the radiator up from its

lower support mount

10. With the old radiator out, remove the a) Lower Radiator Hose b) Supply and Return Transmission Oil

Lines c) Water Temperature Sending Unit d) Lower Radiator Support Mounts if detached from their sockets.

INVERTER CIRCUIT

1. Step down transformerA varying current in the transformer's primary winding creates a varying magnetic flux in the core and a varying magnetic field impinging on the secondary winding. This varying magnetic field at the secondary induces a varying electromotive force (EMF) or voltage in the secondary winding.

2. Voltage Regulator

• A voltage regulator is designed to automatically maintain a constant voltage level. A voltage regulator may be a simple "feed-forward" design or may include negative feedback control loops. It may use an electromechanical mechanism, or electronic components. Depending on the design, it may be used to regulate one or more AC or DC voltages.

Alcoholic Thermometer• The alcohol thermometer is an

alternative to the mercury-in-glass thermometer and has similar functions. Unlike the mercury-in-glass thermometer, the contents of an alcohol thermometer are less toxic and will evaporate away fairly quickly. An organic liquid is contained in a glass bulb which is connected to a capillay of the same glass and the end is sealed with an expansion bulb.

Assembly of the Complete Rig

S.NO Inlet Temp Ti(°C) Outlet Temp TO(°C)

Time (sec)

1 70 62 602 75 67 1203 80 68 1804 85 71 2405 90 74 300

OBSERVATIONS AND CALCULATIONS9.1USING WATER AS FLUID9.1.1OBSERVATION TABLE

S.NO Inlet Temp Ti(°C) Outlet Temp TO(°C)

Time (sec)

1 70 62 60

2 75 67 120

3 80 68 180

4 85 71 240

5 90 74 300

OBSERVATIONS AND CALCULATIONS

USING WATER AS FLUID

OBSERVATION TABLE

S.NO Temp(ΔT)°C ɳt

1 8 11.42

2 8 10.67

3 12 15

4 14 16.47

5 16 17.78

CALCULATION TABLE(ΔT) = Ti - TO

ɳt = ΔT/ Ti

USING COOLANT AT 50% DILUTION

OBSERVATION TABLES.NO Inlet Temp Ti(°C) Outlet Temp

TO(°C)Time (sec)

1 65 54 60

2 70 57 120

3 75 60 180

4 80 61 240

5 85 64 300

6 90 66 360

CALCULATION TABLE

S.NO Temp(ΔT)°C ɳt

1 11 16.92

2 13 18.75

3 15 20

4 19 23.75

5 21 24.7

6 24 26.67

(ΔT) = Ti - TO

ɳt = ΔT/ Ti

USING COOLANT AT 75% DILUTION

S.NO. Inlet temp Ti(°C) Outlet temp TO(°C)

Time (sec)

1 65 58 60

2 70 63 120

3 75 66 180

4 80 69 240

5 85 72 300

6 90 76 360

OBSERVATION TABLE:-

CALCULATION TABLE

S.NO Temp(ΔT)°C ɳt

1 7 10.72

2 7 10

3 9 14.66

4 11 13.75

5 13 15.29

6 14 15.56

(ΔT) = Ti - TO

ɳt = ΔT/ Ti

CONCLUSIONS

USING WATER AS FLUIDInlet Temperature(x) versus Outlet Temperature(y):

Thermal Efficiency versus Change in Temperature

Inlet Temperature versus Thermal Efficiency

50% DILUTION LEVEL

• Inlet Temperature versus Outlet Temperature

Thermal Efficiency versus Change in Temperature

Inlet Temperature versus Thermal Efficiency

75% DILUTIUON LEVEL

• Inlet Temperature versus Outlet Temperature

Thermal Efficiency versus Change in Temperature

Inlet Temperature versus Thermal Efficiency

FURTHER WORK

• Analysis of rig values for different parameters of the system.

• Simulate the system, compare and formulate the results.

GANTT CHART

References1. J P Yadav and Bharat Raj Singh,”Study on performance

evaluation of automotive radiator “.S-JPSET:ISSN:2229-7111,Vol.2,issue 2.

2. F. G. Tenkel, “Computer Simulation of Automotive Cooling Systems,” SAE Paper 740087, 1974 in page no. 19.

3. J.C. Corbel, “An Original Simulation Method for Car Engine Cooling Systems: A Modular System,” SAE Paper 870713, 1987 in page no. 27.

4. W. Eichlseder, G. Raab, J. Hager and M. Raup, “Quasi-Steady Calculation of Cooling Systems with Forecast on Unsteady Calculations,” SAE Paper 954042, 1995 in page no. 29.

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