DESIGN AND DEVELOPMENT OF AUTOMOTIVE ENGINE COOLING SYSTEMS GOAL OF COURSE; Provide the basic fundamentals for a systematic approach in the design and development of automotive, highway truck, agricultural, military, construction equipment vehicle cooling systems that meet all customer expectations. OBJECTIVE: The objective of the two day intensive seminar is to study the different components of the Automotive Cooling System and to demonstrate how they may be combined to produce an effective, high quality system at low cost. Emphasis is placed on safety, quality, timing and cost. The effect of the engine cooling system on engine design and durability is also discussed. The importance of communication and interaction with different engineering groups and discplines, including manufacturing, are stressed to minimize warranty and to enable meeting all engine cooling functional objectives and costs within the packaging constraints under the hood. AUDIENCE: Although the seminar is directed to engine cooling designers, technicians and engineers, its purpose is to also inform and familiarize engine cooling basic and advanced concepts to those disciplines that interface with engine cooling design and development. These would include program management, CFD, engine-transmission-drive line design, aero and thermodynamcis, engine control systems, fuel economy, emissions, manufacturing, field testing and analysis and scientific laboratories. PHILOSOPHY OF DESIGN. The customer's confidence in the overall vehicle performance as well as the cooling system is the basis of design. The cost of the engine cooling components and their functionality as a system to meet all engine cooling and relative vehicle objectives are also a part of the design basis. DESIGN PROCEDURE: The seminar is divided into four sections, Hardware, Fundamentals, Design and Development. The students are first introduced to the various components, their function and their location in the engine cooling system. Fundamental heat transfer equations and concepts are then presented. A model is specified based on the vehicle operating characteristics. The radiator, fan and oil cooler are sized and selected to meet required fluid stream temperature and flow objectives. The AC condenser and charge air cooler are added to the model and the radiator and fan are resized and selected to meet the added heat load of these componets. The coolant pump, de-aeration system, thermostat, pressure cap, plumbing, drive train, drag coefficents and rolling resistance, trailer frontal area, vehicle and trailer weights and grade are incorporated as part of the model and the affect of these components and variables on the engine cooling system are evaluated. The front end system resistance and fan curves are used to determine air flow. The engine coolant system resistance curves and pump throttling curves are used to determinve coolant flow. The advantages and disadvantages of different radiator types and air moving devices are evaluated and a selection is made based on optimum performance and minimum cost within given packaging constraints. The selected radiator is characterized for effectiveness and for overall, outside and inside heat transfer coefficients. Supplier fan curves and heat transfer device performance curves are corrected to represent their actual performance in the vehicle. DEVELOPMENT PROCEDURE: The students are introduced to different development tests required to finalize the engine cooling design. The importance of first doing an analytical analysis of the expected results and then confirming the resulsts in an environmental chamber, wind tunnel or in the field is emphasized. The comparison of actual performance to ideal performance is studied. The test and development procedures discussed include: a. air flow non-uniformity correction. b. determination of the front end mass air flow. c. characterize the coolant pump in the vehicle. d. determine de-aeration ability. e. determine front end system resistance to air flow. f. determine coolant flow system resistance. g. determine vehicle wheel HP and tractive effort curves. h. the use of a towing dynamometer. i. determine engine heat rejection to the coolant at peak power. j. use of the climatic chamber and wind tunnel. k. field tests. ASSOCIATED AREAS: OEM and Supplier relations and responsibilities on how to most effectively accomplish the goals of designing and developing an engine cooling system within cost and timing constraints is presented. Warranty and cost reduction issues are discussed. INSTRUCTOR'S EVALUATION: An evaluation of the seminar is provided as part of a Summary Report submitted to the seminar requestor.