Simulation, experimentation, and collaborative analysis of adjacent heat exchange modules in a vehicular cooling system

A cooling system consisting of several heat exchange modules is a necessary part of an automobile, and its performance has a direct effect on a vehicle’s energy consumption. Heat exchangers, such as a charged air cooler (CAC), radiator, oil cooler, or condenser have different structures and can be arranged in various orders, and each combination may produce different effects because of interactions among them. In this study, we aimed to explore the principles governing interactions among adjacent heat exchangers in a cooling system, using numerical simulation and experimental technology. 3D models with different combinations were developed, compared, and analyzed comprehensively. A wind tunnel test platform was constructed to validate the computational results. We found that the heat dissipation of the modules was affected slightly by their relative position (the rules basically comply with the field synergy principle), but was independent of the modules’ spacing within a certain distance range. The heat dissipation of one module could be effectively improved by restructuring, but with a penalty of higher resistance. However, the negative effect on the downstream module was much less than expected. The results indicated that the intensity of heat transfer depends not only on the average temperature difference between cold and hot mediums, but also on the temperature distribution.