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Michael Pagel - Model-based diagnosis of electronic cooling fan drive systems

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Michael Pagel

Model-based diagnosis of electronic cooling fan drive systems

Series: Mess-, Steuerungs- und Regelungstechnik

Volume 1262 2018

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The Engine Cooling Fan System S. 18-39

„… 18 3 The Engine Cooling Fan System Up to a few years ago, the main task of the engine cooling …” „… for increasing the overall e ciency is the transition of the former mechanically driven engine cooling …” „… fan to one which is driven by an electrical drive. The output power delivered by the cooling fan is …”

Introduction S. 1-7

„… monitoring. Malfunction or failure of the engine cooling fan or the coolant pump, e.g., can cause damage to …” „… for diagnosing a bearing damage, whereas Xie et al. (2012) base their health assessment of a cooling …” „… on engine cooling fans is very scarce. The importance of these devices, however, has grown …”

Titelei/Inhaltsverzeichnis S. I-X

„… -, Steuerungs- und Regelungstechnik Reihe 8 Model-based diagnosis of electric cooling fan drive systems Pa …” „… _Reihe_08_1262_Umschlag.pdf · Seite 2 2 Model-based diagnosis of electric cooling fan drive systems Vom …” „… cooling fan drive systems Dip.-Ing. Michael Pagel, Bad Liebenzell Mess-, Steuerungsund Regelungstechnik …”

Summary and Outlook S. 118-121

„… for electrically driven engine cooling fans has been made. As is illustrated in Figure 6.1, the focus …” „… and resource saving implementation. After an introduction of the engine cooling fan and derivation of …” „… bench. The algorithms can not only be used for engine cooling fans, but are suitable for all continuous …”

Fault Detection and Diagnosis of the electrical motor: Online Parameter Acquisition S. 40-98

„… angle, which is determined during a power-o run of the engine cooling fan by measurement of the …” „… the engine cooling fan is almost utilized to full capacity during normal motor operation, the …” „… ) capacitor. Applying the aforementioned procedure to the engine cooling fan requires the actual motor …”

Fault Detection and Diagnosis: Application S. 99-117

„… reference for fault detection when the engine cooling fan is operated in the car. In this work, two di erent …” „… EoL-stages of the engine cooling fan are considered. 1. The rst stage happens in the plant of the supplier …” „… in the plant of the car manufacturer with the complete engine cooling fan module (i.e. electrical …”

Bibliography S. 127-137

„… , pp. 2734 2752. Simonin,M., S. Burgold, B. Gessier, and M. Ponchant (2008). Modular front-end cooling …” „… Cooling System Component Interactions . PhD thesis. Texas, USA: Graduate Faculty of Texas Tech University …” „… Reihe 8 Model-based diagnosis of electric cooling fan drive systems Pa ge l M od el -b as ed d ia …”

doi.org/10.51202/9783186262080

VDI Wissensforum GmbH - International Conference on Gears 2019

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VDI Wissensforum GmbH (ed.)

International Conference on Gears 2019

Series: VDI-Berichte

Volume 2355 2019

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B. Karpuschewski, D. Sackmann, M. Kochig, M. Beutner, F. Welzel Potentials and limits of gear hobbing with cooling lubricants S. 1591-1602

„… Potentials and Limits of Gear Hobbing with Cooling Lubricants Prof. Dr.-Ing. habil. Prof …” „… gear. Besides its potential for dry machining, gear hobbing is widely applied with cooling lubricant …” „… different cooling lubricants. Determining the wear behaviour depending on the cooling strategy the fly tooth …”

H.-J. Dennig, S. Winterberg Test stand for internally cooled metal gears S. 1263-1266

„… efficient. Smaller mass moments of inertia and optimized design for cooling, lubrication and tooth meshing …” „… gear steels offer great potential. For example, an integrated cooling system (Fig. 1) can reduce the …” „… internal cooling channels A typical failure mode which can be influenced by such a cooling principle is …”

P. Barreiro, J. Hoffmeister, J. Hermes, A. Bronner New improvement opportunities through applying topology optimization combined with 3D printing to the construction of gearbox housings S. 1823-1834

„… cooling of gearboxes can be improved by increasing the housing’s surface and integrating customized …” „… cooling channels into the housing structure. Thus, the relevant friction points cool down by an oil …” „… noise into airborne sound [21]. Since the cooling channels integrated in the housing structure had to …”

G.-T. Weber New possibilities for dry hard finishing of internal gears S. 1659-1664

„… use of cooling liquids. Scudding processes lead to a process specific feed mark pattern on the tooth …” „… , compared to other hard finishing processes, allow Profilator to abolish cooling liquids. This paper will …” „… internal and external gears with a geometrically defined cutting edge without the use of cooling liquids …”

J. Lotz, B. Bouche, R. Thiele Sensorless evaluation of the ideal timing for oil-change S. 1053-1064

„… slows down the cooling process in gear units for industrial applications. The acceleration of the …” „… heating process or deceleration of the cooling process can be explained by the fact that both the gearbox …” „… . 2355, 2019 1055 In the case of geared motors, the heating/cooling process is generally …”

J. Lohmiller, J. Hoffmeister, J. Hermes Conventional high-strength nodular graphite iron as a substitute for austempered ductile iron (ADI) S. 877-892

„… transformation during cooling down to the isothermal austemper level. Even more expensive is the treatment in a …” „… cast-on samples may not represent the mechanical properties from castings since cooling conditions differ …” „… castings. Dhonau’s casting technique is characterized by the extensive use of cooling chills and no use of …”

C. M. Illenberger, T. Tobie, K. Stahl Flank load carrying capacity of oil-lubricated high performance plastic gears – Analysis of the pitting development in back-to-back tests S. 1379-1390

„… improve cooling of the plastic gear the oil is held back by a barrage that establishes an oil level at …” „… the shaft centers. Heating cartridges and cooling pipes in the gear housing as well as an external …” „… , 7] oil injection oil level plastic test gear cooling pipe VDI-Berichte Nr. 2355, 20191380 All …”

V. Heuer, D. Bolton Lean heat treatment for distortion control S. 1749-1764

„… in much more homogenous cooling-conditions [Sti95, Heu12]. Significant reductions of distortion by …” „… inhomogeneous cooling conditions. Three different mechanisms occur during conventional liquid quenching …” „… cooling conditions cause tremendous thermal and transformation stresses in VDI-Berichte Nr. 2355 …”

R. Weidig, H. J. Weimar Powertrain NVH improvement with high-performance polymer gears S. 1421-1430

„… applications Resistance to engine and transmission oils, cooling agents, fuels, AdBlue® and other …” „… each cooling phase down to significantly below 0 °C the engine was at standstill. Enhanced …”

H.-W. Raedt, T. Wurm, A. Busse Lightweight forging initiative III: transmission lightweighting potential based on design and material concepts in a split-axle hybrid vehicle and a heavy-duty truck S. 1777-1786

„… cost-efficiency of steel materials (e.g. through controlled cooling from the forging heat) to be increased even …” „… ) 1.7136. This generates a higher core strength directly through cooling from the warm forging heat than …”

M. R. Mauntz, J. Peuser Deep online oil analysis of dielectric parameters for life time enhancement of industrial gearboxes – Identification of critical operation conditions for reduction of failure rates S. 245-256

„… monitoring of an offshore wind turbine installation with WearSens® in the cooling bypass of a Siemens SWT …” „… , b) WearSens® base sensor installation in the existing cooling bypass and c) sensor communication …”

A.-K. Wiemann, M. Stein, K. Kniel Temperature influence on involute gear measurements S. 1557-1566

„… seven additional surface temperature sensors monitored the workpiece temperature. Within the cooling …” „… up at 0.1 K, because of an exponential temperature cooling progression. After this process, a …”

M. Zapf, J. Klose, F. Zanger, V. Schulze Analysis of process forces and surface topography when manufacturing case-hardened gears by double flanked hard skiving S. 1647-1658

„… heat by a cooling liquid is often not necessary. Hard cutting materials at risk of thermal shock such …” „… as CBN even require dry machining. The elimination of VDI-Berichte Nr. 2355, 2019 1649 cooling …”

M. Yilmaz, T. Lohner, K. Michaelis, K. Stahl Minimizing gear friction with water-containing gear fluids S. 669-680

„… = 8.3 m/s without cooling or heating of the gearboxes. For each lubricant, new gear pairs were used in …” „… at KS7 and vt = 8.3 m/s without cooling or heating the gearboxes and relates to a stationary …”

A. Miltenović, M. Banić, V. Miltenović Prediction of heat generation of crossed axis gearbox S. 583-594

„… without additional cooling. Temperature distribution between heat source and surface of gearbox is …”

K. Smrczkova Wear resistant plastics – Bespoke plastic compounds for plastic gears S. 1345-1356

„… under water or cooling liquid with low abrasion and good sliding properties [1, 2]. The ALCOM® WP …”

K. Mukaiyama, M. Nakagawa, T. Hirogaki, E. Aoyama Investigation of meshing phenomenon of hypoid gears with different offsets via high response infrared video thermography S. 505-516

„… speed [min-1] 20 mm 10 mm 0 mm VDI-Berichte Nr. 2355, 2019 509 such as cooling because of the peripheral …”

D. Mevissen, C. Lopenhaus, T. Bergs Calculation of mixed friction conditions in large-scale rolling-sliding contacts for different surface structures S. 555-568

„… or by the choice of the lubricant. The main purposes of the lubricant are the cooling of the system …”

Titelei/Inhaltsverzeichnis S. I-XXVI

„… Technology, Karlsruhe Potentials and limits of gear hobbing with cooling lubricants …”

doi.org/10.51202/9783181023556

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VDI Wissensforum GmbH (ed.)

ELIV 2023

Series: VDI-Berichte

Volume 2423 2023

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A. Heise Plug & Play High-Performance Computer (HPC) and Fluid Cooling Solution S. 159-168

„… Plug & Play High-Performance Computer (HPC) and Fluid Cooling Solution Scalable HPC solution …” „… including flexible fluid cooling pad allows an easy, drip-free connection to vehicle's cooling circuit …” „… and higher density of Systems-on-Chip (SoC) bring more heat losses. Fluid cooling is the method of …”

B. Budaker Modular High Power DC/DC Platform for FC-Applications S. 711-XVIII

„… products, is the “Semiconductor Power-Conversion Unit” or as we call it “SCU – Semiconductor Cooling Unit …” „… development. The main part of our SCU is a PIN-Fin-Cooler for best cooling performance. Special design and …” „… manufacturing capabilities allow us to achieve an optimized and homogeneous cooling performance throughout the …”

T. Hackl, L. Roslaniec Multi-level GaN inverter for highest HV EV performance and efficiency – comparison of 2-level and 3-level inverter topology S. 247-252

„… this results in less cooling demand and increased performance as well as driving range. The …” „… highly efficient and affordable powertrain platform solutions. This solution reduces the cooling system …”

S. Miller, L. Nicoletti A Holistic Approach for Designing a Battery Electric Vehicle Thermal Management System S. 77-90

„… the HV network and is actively cooled by a cooling plate composed of 12 parallel channels (dark blue …” „… battery and cooling plate (left) and the corresponding battery model in Simscape Battery (right). The …” „… . Finally, the four-way valve can switch between a parallel and a serial cooling strategy based on the …”

T. Huck, A. Achtzehn Towards the next step in vehicle E/E architectures S. 185-198

„… , visible by minimal sharing of resources, for example only with a common cooling and power management of …” „… , however, come at the cost of a more complex zone controller design; providing sustainable cooling can be …” „… both ADAS and infotainment) or to benefit from a common cooling and power supply (premium segment …”

O. Meyer, B. Böhlen Mastering the software update complexity of modern vehicles S. 199-210

„… ccmfw2.0 ccmfw2.0Cooling Management Firmware cmsfw1.0 cmsfw1.0 cmsfw1.0 cmsfw1.0 cmsfw1.0 …” „… ccmfw2.0 ccmfw2.0 ccmfw2.0 ccmfw1.0 ccmfw2.0 ccmfw2.0 ccmfw2.0 ccmfw2.0 ccmfw2.0Cooling Management …” „… ccmfw1.0 ccmfw2.0Cooling Management Firmware cmsfw1.0 …”

Titelei/Inhaltsverzeichnis S. I-XVI

„… Architecture – StrategyPlug & Play High-Performance Computer (HPC) and Fluid Cooling Solution 159A. Heise …”

N. Pfullmann Electrified commercial vehicle trailers – how to turn a conventional trailer into a hybrid vehicle S. 703-710

„… to change, though. In a first step, diesel generators to power the cooling unit of a reefer trailer …”

doi.org/10.51202/9783181024232

VDI Wissensforum GmbH - PIAE Europe 2023

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VDI Wissensforum GmbH (ed.)

PIAE Europe 2023

Series: VDI-Berichte

Volume 2418 2023

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M. Barbolini, F. Naudin Cooling pipes for high performance application based on PPS S. 123-128

„… Cooling pipes for high performance application based on PPS Dr.-Ing. Marco Barbolini, Roechling …” „… context, the cooling circuit represents a system which will also be crucial for future generations of …”

R. Hofer, M. Jacobi 26% weight savings in an automotive headlight housing due t o MuCell® foaming technology S. 383-388

„… or hot spots in the mold need unnecessarily long cooling. After demolding, these areas swell due to …” „… model was built with the real cooling system in order to VDI-Berichte Nr. 2418, 2023 385 optimally map …”

S. Weidmann, T. Hoffmann, M. Duhovic, J. Weber, P. Mitschang Cutting-edge joining processes for TP-FRPC and multi-material structures made of TP-FRPC and metals S. 673-688

„… residual stresses induced in the component during the forming process and the cooling phase are also …” „… . Cooling makes it possible to generate a temperature gradient that rises toward the joining zone, which …” „… described in [1]. Air cooling was modeled by applying an analytical model based on Hofmann et al. coupled to …”

Entwicklung Leichtbau-Unterfahrschutz für BEVs in FVK-Bauweise Development of a lightweight underride guard for BEVs in FRP S. 61-72

„… cooling time a component can be removed in its final contours from the positive mold. Process parameters …” „… , such as pressing force and cooling time requirements, have so far been determined experimentally …” „… guard is designed to be at a defined distance from the overlying cooling system or battery box. In the …”

T. Weyer Decorative and Functional Front Panels for BEVs – MEZZOTM Plus Panel S. 547-552

„… vehicle. One area greatly impacted is the front end, especially from a cooling requirements perspective …” „… . Traditionally, open air flow front grilles that provided engine cooling and HVAC needs can be greatly reduced in …”

W. Schijve, R. Bhairi, F. Becker, K. Fischer, M. Emonts Multi-material options for future fire and impact resistant battery casings S. 395-412

„… would result to the cooling system, typically located below the batteries. Or at an even higher level of …” „… cooling fluid are overmoulded on the bottom laminate. In a second operation surface treated aluminium …” „… sheets are welded to these flow channel ridges to form a closed integrated cooling plate structure …”

F. Wazula, H. Tattko, A. Sumfleth Star panel of the Mercedes Benz EQS – New design meets new challenges S. 33-46

„… validated the temperature control of the tool. The cooling layout was designed by the toolmaker and …” „… incorporated into the simulation. Fig. 3.2 shows the result at the end of the cooling time, showing a very …”

F. Meißen, H. Gleich The next level of polymer parts in CAE – From the process to the process chain, from the individual part to the assembly S. 355-362

„… the cooling of the hybrid materials (Fig. 4). When comparing this simulation with the real crash …”

Titelei/Inhaltsverzeichnis S. I-XII

„… Wegbereiter für HV-Batteriesysteme der nächsten Generation 113J. Haspel, C. Höfs, Envalior, DormagenCooling …”

C. Bouvatier, S. Oener Lower stiffener of the Porsche 992 GT3 in PAIM technology S. 1-16

„… projectile: ca. 180 bar  Cooling time: 85 s (due to the complex geometry) As a result, due to project …”

M. Fischer Smart front and rear panels by purposefully combined plastic processing S. 479-494

„… predominantly influenced by the cooling time of the thermoplastic resin end the curing time of the PUR …”

D. Braun, E. Kougioumtzi, O. Geiger, M. Prinz From Scrap Tires to Door Handles S. 427-436

„… condensed into pyrolysis oil by controlled cooling. Pyrolysis oil that meets specifications can then be …”

T. Köppl, Florian Dresel Reducing the carbon footprint of materials and processes for soft-touch applications S. 149-158

„… part. It is readily apparent that this processes of heating up and cooling down again is not …”

S. Lang, C. Niermann Sustainably high-quality! Are recyclates the only way to reduce CO2? S. 159-182

„… into account. The center of the cooling system is often a central distributor, which simultaneously …” „… made of cooling systems in electric vehicles. Compared to PA66 the polymer performs significantly …”

F. Groh, R. Apfelbeck, W. v. Gilst, A. Karl Innovative shear panel in plastic for vehicles with shortened battery modules S. 519-532

„… compound. By placing the thin crossply directly on the pressing compound, cooling of the laminate below the …”

E. Spini, R. Galeazzi Reinforced polyamides with low environmental impact: post-consumer materials S. 627-644

„… direct contact with engine cooling liquids. This partially recycled post-industrial PA66-based material …”

Polycarbonatbasierte Karosseriebauteile mit Funktionsintegration Polycarbonate-based body components with functional integration S. 553-584

„… after cooling, which have a negative effect on dimensional accuracy and on the stress balance. In order …”

doi.org/10.51202/9783181024188

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VDI Wissensforum GmbH (ed.)

Dritev 2023

Series: VDI-Berichte

Volume 2420 2023

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Y. Jin Smart eDrive – Autonomous cooling eDrive for small BEVs and P4 AWD S. 21-36

„… Smart eDrive Autonomous cooling eDrive for small BEVs and P4 AWD Yejin Jin, Valeo, Shanghai …” „… solution with its autonomous cooling design, the Smart eDrive, especially developed for this small BEVs …” „… Characteristics Fig. 3: Smart eDrive concept The concept of the Smart eDrive is to remove all the water cooling …”

A. Paone, J. Larbig, A. Rohm, T. Höche ZF TherMaS: Holistic Thermal Management for BEV S. 45-60

„… cooling-power Pcool_total > 25 kW - refrigerant fill: 192g R-290 / propane - weight: mprototype = 21.2 kg …” „… with a smart cooling system enables higher power-density and allows to exceed current power limits of …” „… inevitably always do have losses, so, for avoiding temperature issues measures for cooling or …”

J. Bonifacio, V. Warth, S. Scharr Optimizing sustainable high-performance e-drives S. 349-358

„… demonstrated. A significant torque/weight ratio has been reached through a holistic system and cooling …” „… , 2023 351Direct Conductor Cooling. The ability to manage the thermal behavior of the high currents and …” „… situations the decision was made to design a Direct Conductor Cooling approach. Therefore, the gearbox oil is …”

H. Sandquist, E. Barrientos, S. Klacar Systemized Modular Approach for Electric Drive Unit Family Development S. 89-106

„… coaxial layshaft design, the EDU family includes common torque transfer-, cooling and lubrication …” „… internal components such as torque transfer and cooling and lubrication systems are common for all variants …” „… ., cooling, battery, lubrication etc. The calculated limitations and criteria are later used to create the …”

L. Bayoux, K.-L. Kimmig, D. Reitz Has the potential in terms of weight, installation space, and function already been exhausted for hybrid transmissions? S. 205-220

„… of cooling and lubricating oil. Suitable simulation and validation methods are an important …” „… responsible for cooling and lubrication as well as for operating the clutch and the parking lock. Since a …” „… transmission enables a gradual cooling concept (fig. 6), in which the low-temperature circuit of the vehicle …”

L. Roslaniec, T. Hackl Next generation Electric Drive Units with multi-level GaN inverter for highest HV EV performance and efficiency – Comparison of 2-level and 3-level inverter topologies S. 107-114

„… improvement translates into less cooling demand, increased performance, and an extended driving range …” „… industry, since this results in less cooling demand and increased performance as well as driving range. The …” „… reduces the cooling system requirements and the size of the electronic car's inverter; thus, EV Cars can …”

B. Cebulski, S. Mühlbauer, D. Sailer, L. Schmieden, R. Wunderlich, O. Seidler, A. Stiegelmeyr About the benefits of permanent rotor temperature measurement S. 143-152

„… operation. In general, during operation - losses and cooling needs to be known quite accurately to predict …” „… of design, material (pairings) and cooling concept. It is done with a reduction of the machine model …” „… losses (heating), cooling also has a major influence on the temperature curve of the magnets. The biggest …”

T. Schneider, K. Völkel, K. Stahl Failure Characteristics of Wet-Clutches in Limited Slip Differentials S. 307-324

„… in transient slip with five slip phases and a subsequent cooling phase is shown in Figure 3. The …” „… remains stationary for a duration of t2 = 1 s between each slip phase. To ensure complete cooling of all …” „… plates, the clutch is run at a defined speed for t3 = 20 s during the cooling phase. A total of 200 times …”

R. Plavullathil, M. Rihn, C. Bridier Marelli’s eAxle family strategy – Agile answer to a moving EV market S. 281-294

„… at the customer's request: parking system, cooling or forced lubrication with an electric pump, or …” „… motors, the development of stator and rotor oil cooling is a priority. For inverters, the aim is to use …” „… , like EESM, rotor and oil cooling, advanced software functions or park lock and 2-speed systems …”

M. Gukelberger Magna’s Dedicated Hybrid Drive DHD Duo – a Platformbased two e-Machine System S. 197-204

„… cooled by an oil spray cooling. The inverter is a double inverter, which is connected to the …” „… low-temperature cooling circuit of the vehicle. Communication with the vehicle is carried out via CAN FD. The …”

Titelei/Inhaltsverzeichnis S. I-XIV

„… Management 13S. Kaimer, Magna Powertrain GmbH & Co. KG, Lannach, AustriaSmart eDrive – Autonomous cooling …”

M. Magnusson, O. Nicklasson, H. Jacobsson Electric Cross Differential, eXD S. 235-252

„… larger total oil volume. This is beneficial both from a cooling and durability point of view.The force …” „… both from a cooling and durability point of view.The force from the piston is transferred to the clutch …”

A. Kappes, S. Frei, P. Noone, Stephan Rinderknecht Development and Design of a Range Extended four-speed Two-Drive-Powertrain S. 253-280

„… design through integration in a common housing and cooling. Considering the overall system, advantages …” „… cooling regarding the super overload during shifting. As Fig. 8 shows, the smaller module can further …” „… , which is characterized by the interconnection of the various cooling circuits. This allows heat sources …”

D. Schweigert, B. Morhard, F. Oberneder, L. Pointner-Gabriel, M. Otto, K. Stahl Speed4E: Simulative and Experimental Results on the Vibration Behavior of a High-Speed Planetary Gearbox S. 441-458

„… management based on a water-containing gear fluid. The water-containing gear fluid is used for cooling the …”

doi.org/10.51202/9783181024201

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