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Multi-physical contact simulation in Vehicle applications

Schmid Michal, Tomek Petr, Hanus Petr

Production Engineering Archives

2022

Vol. 28, Iss. 4

369--374

Multi-physical contact behaviour is important in multiple disciplines related to the automotive industry. Nowadays battery-electric vehicles’ (BEV) thermal management systems deal with contact between bodies where mechanical, electric, and thermal interaction occurs. The battery thermal management itself is crucial for cell life, safety, and everyday vehicle performance. Thus, comprehensive and accurate simulation of the multi-physical contact is a vital part of vehicle development. The multi-physical contact is represented by two or more bodies under applied mechanical load and a current or heat conducted throughout the realized contact area. The amount of conducted current/heat or generated Joule heat is the function of the contact area as well as contact pressure, thus the structural simulation should be essential for such thermal management system simulations Most of the current full vehicle battery pack CFD cooling simulations simplified the multi-physical contact as ideal. Detailed contact modelling is time-consuming, hence not applicable for the full vehicle modelling. In this work, a feasible approach based on contact resistance curves was implemented. Furthermore, the work demonstrates the necessity of correct structural contact prediction for a joule heating and thermal solution.

Windshield Defrost Simplified CFD Model

Schmid Michal

Production Engineering Archives

2019

Vol. 25

8--11

The windshield defrost system, in general, is a vehicle safety feature. Thus, its restricted by variety of directives. However, the OMEs’ benchmark targets could be even more demanding as the deicing process is in addition also part of passengers comfort. From vehicle design point of view the wind-shield defrost system is typically connected to HVAC unit (Heating, Ventilation and Air Conditioning). In the technical solution the windshield is heated via hot air convection. Nevertheless, other methods are becoming more and more popular, like directly heated glass by hot wire ohmic heating (heated glasses). The defrost CFD model should predict the ice layer thickness in time and space and in environmental conditions defined according to appropriate directives and technical solution. The accurate and fast modelling technique is essential part of a vehicle development, especially nowadays, where the optimization techniques area widely used and requires hundreds of simulations runs. Modelling requests are even increasing with modern pure electric vehicles (EVs), were the thermal and energy management is more demanding compared to the classical internal combustion engine (ICE) vehicles. The aim of the work is to verify possibility to model the ice layer thickness with simplified approach, which could be beneficial from computational time burden.