As an example listed here:

Engine heat exchange

The thermal management takes in fuel consumption and emissions of combustion engines a significant role. Cold engine operating conditions are causes of increased fuel consumption (CO2), which is accompanied by increased formation of HC, CO and soot particles. In the project "engine heat exchange" to the heat flows are calculated in the warm-up phase of an internal combustion engine by means of a thermal network. The goal was to create a simulation model for validatable the engine warm-up. The goal is a consideration of the potential to reduce internal engine friction, and CO2 emissions.

Measuring point: A total of 71 sensors were installed.
Temperature sensors:
All component temperatures in a range of 0 - 600 ° C were measured with jacket and flat-film resistance temperature sensors (Pt-100). The measuring points were placed in the area of ​​3rd and 4th cylinder. Thus, the heat flow can be viewed along a cylinder unit.
Next sensors are located in the area of ​​camshaft, crankshaft, cylinder blocks, cylinder head and also various media temperatures (oil, water, air) were recognized.

Flow sensors:
Use of flow sensors for determining the cooling water media streams (heating, main water heat exchanger and EGR cooling).

Pressure sensors:
Cylinder pressures were recorded in the reference cylinders 3 and 4 to the piezoelectric miniature probes. These sensors were screwed an adapter sleeve instead of the glow plugs. In the cylinders 1 and 2, the original built piezoresistive sensors are used.

1D simulation:
The modeling is done with the help of the simulation program MS Imagine.LabAMESim ®.
The simulation model includes 20 point masses, and a capacity for media cooling water and oil. The difference resulting from the combustion heat input was taken into account by maps in the simulation model and derived from actual cylinder pressure curves. The combustion behavior can be reproduced by the cylinder pressures. In the warm-up phase, the friction has a special meaning. Low temperatures in the lubricant, leading to increased friction due to increased viscosity. This friction causes heat transfer to the medium oil and the components involved. Friction mean effective pressures are a characteristic size for mechanical losses. For the calculation of the total friction mean pressure, the model of Black Meier is used. A breakdown of the total friction mean pressure in individual units is determined by the engine, temperature-dependent friction characteristic fields. With the current simulation model it is possible to calculate the heating behavior of the individual point masses with an accuracy of 1-3K.

More project examples externally linked: