COOLING SYSTEM

Submitted by, K. Chendil velan A2326211009 M.Tech Automobile Engineering

INTRODUCTION
This heat is created when the gasoline and air mixture is ignited in the combustion chamber. This explosion causes the piston to be forced down inside the engine, levering the connecting rods, and

turning the crankshaft, creating power.

Metal temperatures around the combustion chamber can exceed 1000 F.

 Approximately 1/3 of the heat in combustion is converted into power to drive the vehicle and its accessories. Another 1/3 of the heat is carried off into the atmosphere through the exhaust system. The remaining 1/3 of the heat is conducted by the Cylinder walls which will lead to preignition. So a suitable cooling system has to be provides to remove the heat from the cylinder walls.

TYPES OF COOLING SYSTEMS

AIR COOLING SYSTEM LIQUID COOLING SYSTEM

AIR COOLING SYSTEM

Air cooled system is generally used in small engines say up to 15-20 kW and in aero plane engines. Important component of air cooling system are the FINS. Fins or extended surfaces are provided on the cylinder walls, cylinder head, etc. Heat generated due to combustion in the engine cylinder will be conducted to the fins and when the air flows over the fins, heat will be dissipated to air.

 The amount of heat dissipated to air depends upon :

a. Amount of air flowing through the fins. b. Fin surface area.

c. Thermal conductivity of metal used for fins. d. Temperature difference between the heated surface and air.

DIAGRAM OF AIR COOLING SYSTEM

LIQUID COOLING SYSTEM(WATER)

In this method, cooling water jackets are provided around the cylinder, cylinder head, valve seats etc. The water when circulated through the jackets, it absorbs heat of combustion. This hot water will then be cooling in the radiator partially by a fan and partially by the flow developed by the forward motion of the vehicle. The cooled water is again recirculated through the water jackets.

TYPES OF WATER COOLING SYSTEM

THERMOSYPHON SYSTEM PUMP CIRCULATION SYSTEM

THERMOSYPHON SYSTEM
This system was used in early automobiles upto 1940. In this the circulation of water is obtained from the difference in densities of the hot and cold regions of cooling water. The heat absorbed by the circulating water is dissipated into the atmosphere through the radiator by conduction and convection.

 The rate at which the water circulates is proportional to the heat output or the load on the engine. Some of them contained Fans mounted behind the radiator. The fan is driven by belt and pulleys from the crankshaft.

PUMP CIRCULATION SYSTEM

This is similar to the thermosyphon system. The only difference is that a pump is used for the circulation of coolant. Thermostat is also employed to control the flow of coolant. The pump and fan are driven by means of belt from the engine crankshaft.

ADVANTAGES OF PUMP CIRCULATION SYSTEM OVER THERMOSYPHON SYSTEM

Circulation of coolant is proportional to both load and speed. Smaller water jackets can be used and hence can be employed in compact or small engines. The header tank is not necessary to be placed above the engine level. Radiator can be placed on the sides.

COMPONENTS
Water cooling system mainly consists of :
(a) Radiator,

(b) Thermostat valve,

(c) Water pump, (d) Fan, (e) Water Jackets, and (f) Antifreeze mixtures.

RADIATOR
A radiator is a type of heat exchanger. It is designed to transfer heat from the hot flows through it to the air blown through it by the fan. Most modern cars use aluminum radiators. These radiators are made by brazing thin aluminum fins to flattened aluminum tubes. The fins conduct the heat from the tubes and transfer it to the

air flowing through the radiator.

RADIATOR-CONSTRUCTION
It mainly consists of an upper tank and lower tank and between them is a core. The upper tank is connected to the water outlets from the engines jackets by a hose pipe and the lover tank is connect to the jacket inlet through water pump by means of hose pipes. There are 2-types of cores :
Tubular Cellular

 In tubular type the coolant flows through the tubes and air passes around them. In the cellular type air passes through the tubes and coolant flows in the spaces between them. The thickness of tubes are made from 0.1 to 0.3 mm sheet. Fins are made with thickness 0.1 mm. Core tubes and fins are made of thin copper and brass material.

CONSIDERATIONS FOR RADIATOR CONSTRUCTION

CORROSION RESISTANT HIGH THERMAL CONDUCTIVITY SIZE WEIGHT COST

THERMOSTAT VALVE
It is a valve which prevents flow of water from the engine to radiator, so that engine readily reaches to its maximum efficient operating temperature. After attaining maximum efficient operating temperature, it automatically begins functioning. Generally, it prevents the water from flowing below 70C.

THERMOSTAT VALVE IN OPEN AND CLOSED CONDITION

TYPES OF THERMOSTAT BELLOW TYPE THERMOSTAT WAX THERMOSTAT

BELLOW TYPE THERMOSTAT CONSTRUCTION AND WORKING

It contains a bronze bellow containing liquid alcohol. Bellow is connected to the butterfly valve disc through the link. When the temperature of water increases, the liquid alcohol evaporates. The bellow expands and in turn opens the butterfly valve. Hence allows the hot water to the radiator, where it is cooled.

WAX THERMOSTAT CONSTRUCTION AND WORKING

There is a small cylinder located on the engine-side of the device. This cylinder is filled with a wax that begins to melt at around 180 F. A rod connected to the valve presses into this wax. When the wax melts, it expands

significantly, pushing the rod out of

the cylinder and opening the valve.

COOLANT PUMP
It is used to pump the circulating water. Impeller type pump will be mounted at the front end. Pump consists of an impeller mounted on a shaft and enclosed in the pump casing. The pump casing has inlet and outlet openings. The pump is driven by means of engine output shaft only through belts. When it is driven water will be pumped.

FAN
It is driven by the engine output shaft through same belt that drives the pump. It is provided behind the radiator and it blows air over the radiator for cooling purpose.

 For economic and efficient running it is required that the fan must give adequate air flow at all condition of vehicle speed and load. At low speeds only minimum amount of air flow is necessary and during high speeds more air flow is necessary. Unnecessary running of fan will consume nearly 5% of engine horse power and more noise.

METHODS FOR EFFICIENT RUNNING

FAN blades of variable pitch type.
Speed sensitive type Temperature sensitive

FAN driven by fluid coupling which has two rotors.

One rotor at coupling run by the engine One rotor attached to FAN.

FAN driven by separate electric motor.

AIR COOLING SYSTEM

LIQUID COOLING SYSTEM

The design of this system is simple and The design of this system is less costly complicated and more costly
The mass of cooling system is very less. The mass of cooling system is much more The fuel consumption is more Its installation and maintenance is very easy and less costly There is no danger of leakage or freezing of the coolant It works smoothly and continuously. Moreover it does not depend on any coolant. The fuel consumption is less Its installation and maintenance is difficult and more costly There is a danger of leakage or freezing of the coolant If the system fails, it may cause serious damage to the engine within a short time.