Engine Cooling Systems

Engine Cooling Systems

Hassan Ejaz Institute of mechanical and Aerospace engineering, Air University, Islamabad, Pakistan

c)

Remaining heat is lost in friction and carried away by exhaust gases. [6]

There are mainly two types of cooling systems used in internal combustion engines: a) Air Cooled b) Water Cooled

II. Air Cooled System I. Introduction

Heat engines generate mechanical power by extracting energy from heat flows, much as a water wheel extracts mechanical power from a flow of mass falling through a distance [4]. Although internal combustion engines have improved a lot, they are still not very efficient at turning chemical energy into mechanical power. Most of the energy in the fuel (75-80%) is converted into heat, and it is the job of the cooling system to take care of that heat [5]. In fact, the cooling system on a car driving down the freeway dissipates enough heat to heat two averagesized houses. The primary job of the cooling system is to keep the engine from overheating by transferring this heat to the air [5]. Internal combustion engines burn fuel hotter than the melting temperature of engine materials. The burning of the fuel in the engine cylinders may reach 2200C or higher. However, cylinder walls must not get hotter than about 260C . High temperatures damage engine materials and lubricants (cause lubricating oil to break down and lose its lubricating ability) or in worst cases may leads to the seizing of the engine [1]. Engine cooling removes energy fast enough to keep temperatures low to 150-200 C so the engine can survive. In addition, the cooling system provides a source of heat for the passenger compartment heater and air conditioner [1]. It is also to be noted that: a) About 20-25% of the total heat generated is used for producing brake power (useful work). b) Cooling System is designed to remove 30-35% of the total heat. The simplest type of cooling system is the air-cooled, or direct, method in which the heat is drawn off by moving air in direct contact with the engine [3]. In this system fins or extended surfaces are provided on the cylinder walls, cylinder head (Fig.1). Heat generated due to the combustion in the engine cylinder will be conducted to the fins and when the air flow over the fins, heat will be dissipated to air [6]. The cylinders are mounted independently to the crankcase so an adequate volume of air can circulate directly around each cylinder, absorbing heat and maintaining cylinder head temperatures within allowable limits for satisfactory operation In all cases, the cooling action is based on the simple principle that the surrounding air is cooler than the engine The amount of heat dissipated depends on a) The amount of air flowing over the heated surfaces. b) The thermal conductivity of the metal used and the volume of the metal or its size in cross section. c) The area exposed to the cooling medium (Fin surface area) [3]. All stationary air-cooled engines must have a fan or blowers of some type to circulate a large volume of cooling air over and around the cylinders. The fan for the air-cooled engine shown in (Fig.2) is built into the flywheel. Air-cooled engines, such as those used on motorcycles and outboard engines, do not require the use of fans or shrouds because their movement

Engine Cooling Systems

through the air results in sufficient airflow over the engine for adequate cooling [3].

passes through the hot engine it absorbs heat, cooling the engine. After the water leaves the engine, it passes through a heat exchanger, or radiator. This hot water then is cooled in the radiator partially by fan and partially by the flow developed by the forward motion of the vehicle. The cooled water is then recalculated through the water jackets. The cooling system (Fig.3) uses five basics parts to do its job of controlling the engine temperature [1]. a) b) c) d) e) Water Pump Water Jackets Thermostat Valve Radiator Fan

Fig.1 Cylinder with Fins

a) Water Pump Water pumps are impeller pumps (Fig.3). They attach to front of the engine and are driven by the belt from the crankshaft pulley (Fig.4). The pump circulates as much as 7500 gallons (28,390 litters) of water an hour. As the impeller rotates, the curved blades draw water from the bottom of the radiator. They force the water through the pump outlet to the water jackets. The impeller shaft is supported on sealed bearings which never need lubrication. Seals prevent the water from leaking past the bearing. The water pump may also be driven by a single belt that also drives the other components of the engine. On some engines the water pump is gear driven from the engine crankshaft [1].

Fig.2 Cylinder with fan and shroud

III. Water Cooled System

The cooling system on Water-cooled engines circulates liquid through pipes and passageways in the engine (Fig.4) (Fig.5). Water is the commonly liquid used. Additives may be added to water to further improve its properties which then named as coolant. Water jackets are provided around the cylinder, cylinder head, valve seats etc. As water

Fig.3 Impeller Action Water Pump

Engine Cooling Systems

Fig.4 Components of Liquid Cooling System

Fig.5 Liquid Cooling System of 4-Cylinder Engine

Engine Cooling Systems

b) Water Jackets The water jackets are open spaces between the cylinder walls and the outside shell of the cylinder block and head (Fig.3), (Fig.6) [4]. Water jackets are provided around the cylinder, cylinder head, and any other hot part which are to be cooled. Heat generated in the engine cylinder, conducted to the cylinder walls to the jackets. The water from the water pump flows from these water jackets absorbs this heat and get hot. This hot water then flows to the radiator to be cooled [1]. c) Thermostat Valve The thermostat is a heat operated valve that regulates water temperature. It does this by controlling the water flow from the engine to the radiator. The thermostat is in the cooling passage between the cylinder head and the radiator. The valve in thermostat opens and closes as water temperature changes. When the engine is cooled, the thermostat closes. As the engine warms up, thermostats open. This prevents or allows water through the radiator. By closing the passage to the radiator when the engine is cooled, the engine warms up more quickly. Engine heat stays in the engine instead of being carried to the radiator. This shortens warm up time, wastes less fuel, and reduces exhaust emissions. After warm up, the thermostat keeps the engine running at higher temperature within limits than it would without a thermostat [1]. There are several types of automotive thermostats for example wax pallet, bellows type. The wax pellet type thermostat valve is the most commonly used in pressurized cooling systems incorporates the piston and spring principle (Fig.7). The thermostat consists of a valve that is operated by a piston or a steel pin that fits into a small case, containing a copper impregnated wax pellet. A spring holds the piston and valve in a normally closed position. When the thermostat is heated, the pellet expands and pushes the valve open. As the pellet and thermostat cools, spring tension overcomes pellet expansion and the valve closes [1]. Thermostats are designed to open at specific temperatures. This is known as thermostat rating. Normal ratings are between 185F (85C) and 195F

(91C) for automotive applications and between 170F (77C) and 203F (95C) for heavy-duty applications. Thermostats will begin to open at their rated temperature and are fully open about 20F (11C) higher, For example, a thermostat with a rating of 195F (91C) starts to open at that temperature and is fully open at about 215F (102C) d) Radiator The radiator (Fig.8) is a heat exchanger that removes heat from the engine water passing through it. The heat transfers from the hot water to the cooler outside air.

Fig.8 Down Flow tube-and-fin Radiator An automotive radiator has three main parts. These are radiator cores, inlet and outlet tanks (Fig.8). The cores are usually made of aluminum. The tanks may be made of plastics or metal. The core has two set of passages, a set of tubes and set of fins attached to the tubes. The tubes run from the inlet tank to the outlet tank. Water flows through the tubes and air flows

Engine Cooling Systems

Fig.6 Water Jackets

Fig.7 Wax-Pellet type Thermostat valve

Engine Cooling Systems

between the fins. The hot water sends heat through the tubes to the fins.. (Fig.8) shows a down flow radiator of tube and fin construction which is more commonly used. The water flows from the upper tank down through the tubes to the lower tank. Some cars used cross flow radiator (Fig.9) in which the tubes are horizontal so the water flows from the inlet tank horizontally to the outlet tank. The cross flow radiator takes less space from top to bottom [1].

Engines mounted longitudinally in rear- drive vehicles usually have a mechanical fan. The fan is made of sheet metal or molded plastic. It has four to seven blades driven by a belt from the crankshaft [1].

III. Advantages and Disadvantages of Air Cooled Systems

i. a) Advantages

Radiator/pump and other components are absent so the system is light and less expensive. b) Using air cooling eliminates the liquid water engine subsystem and simplifies engine design c) Water and antifreeze solution are not required. d) There is no leakages in the air cooled system as compared to liquid cooled which have a possibility of leakage. e) The system can be used in cold climates, where if water is used it may freeze. f) No freezing or boiling points issues present. g) No salt and mud deposits are formed as in water cooled engines. ii. Fig.9 Cross Flow Type Radiator a) e) Fan The radiator sometimes needs additional air flow through it to prevent the engine from overheating (Fig.3). This usually occurs at idle and slow speeds. At higher vehicle speeds, the air rammed through the radiator by the forward motion of the vehicle provides all cooling that is needed. An engine fan or cooling fan pulls the additional pulls the additional air through the radiator. The fan may be either a mechanical fan driven from the engine itself or an electric fan. Transverse engines in front drive vehicles usually have an electric fan. An electric motor turns the blades. A thermostatic switch turns on the fan only when needed. For example, in one engine the switch turns on the fan when the water reaches 200F (93C) and turns off the fan if the water drops below the temperature. The fan is turned on or off by electronic control module (ECM) in many vehicles with electronic engine control systems. Comparatively less efficient as the specific heat of air is less than water. b) Due to non-uniform cooling, temperature stresses are developed in the engine parts. c) Commonly used in motorcycle and aero planes engines where the engine is exposed to air directly. d) In multi cylinder air cooled engines the cylinders need to be spaced relatively far apart, with enough room between them for large volumes of air to flow. e) The system becomes noisy if fans or blowers are used [2]. Disadvantages

Engine Cooling Systems IV. Advantages and Disadvantages of Liquid Cooled Systems
i. a) Advantages

References
[1]. Automotive Mechanics by William H Crouse Donald L Anglin Tenth edition/ Chapter 25 Automotive Steering System, Page. 315/ McGraw-Hill Publication [2]. Automobile Engineering by KK jain and R B Asthana / Chapter 9 Cooling System of Engines Page. 150/ McGraw-Hill Publication [3]. http://www.waybuilder.net/sweethaven/MechTec h/Automotive01/default.asp?unNum=5&lesNum =1&modNum=1 ( Automotive Air-Cooled System) [4]. http://en.wikipedia.org/wiki/Internal_combustion _engine_cooling (Internal combustion engine cooling) [5]. http://auto.howstuffworks.com/coolingsystem.htm ( Cooling System) [6]. Paper, Unit 5 cooling systems of ic engines ignou (The Indira Gandhi National Open
University)

Uniform cooling of cylinder, cylinder head and valves. b) Specific fuel consumption of engine improves by using liquid cooling c) Engine is less noisy as compared with air cooled engines, as it has water for damping noise d) Comparatively efficient as the specific heat of water is greater than air. ii. Disadvantages

a) It depends upon the supply of water. b) Salt and mud deposits are formed in water cooled engines. c) The water pump which circulates water absorbs considerable power. d) If the water cooling system fails then it will result in severe damage of engine. e) The water cooling system is costlier as it has more number of parts. f) Requires more maintenance and care for its parts [6].

V. Conclusion
During operation, internal combustion engines convert the energy of fuel into mechanical work and heat. Approximately one-third of the fuel energy goes into the mechanical work of the moving vehicle, onethird into exhaust heat, and one-third into heat transferred by the engine cooling system to the ambient air. This means that heat load to the cooling system at rated power is approximately equal to the rated power of the engine. From this we can see that if an engine is modified to increase its horsepower, the load to the cooling system will also increase. In fact, the heat load to the cooling system will increase by about the same percentage as the increase in engine horsepower. So, if we increase the engine horsepower say by 20 percent, we can expect an increase of about 20 percent in the heat load to the cooling system.