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A methodology for design and development of commercial vehicle cooling system is derived with an objective to minimize part cost, engineering resources and time to market. This approach is very useful in companies with more variant of engines and vehicles. For this it is identified to have a common cooling system for a set of engines. A systematic approach to develop cooling system based on heat rejection is conceptualised. Engines are classified based on heat loads in to various groups. The cooling package selected for a particular group is independent of type of vehicle (bus or truck), cab (day, sleeper, FES or FBS), Type of drive (LHD or RHD), Emission norm (BSIII or BSIV) and fuel (Diesel or CNG). These packages will cover up the entire range of vehicles and engines. The packaging space available for each group is derived and the cooling package size is finalised. Fan and fan pulley options are listed based on air flow and fuel efficiency requirements.

The objective of the project is to study the re-circulation of hot air into the radiator of the engine cooling system in commercial vehicles; to analyze the effects of the same on the performance of the cooling system and to propose one or more solutions to minimize the re-circulation of hot air. It has been proposed to introduce a cowl arrangement ahead of the radiator to prevent the re-circulation of hot air back to the radiator and to direct the airflow to the core of the radiator more effectively. The 3D model of the cooling system comprising of Radiator, CAC, cowl, fan, engine, front grille and CAB body was constructed. The whole assembly was placed in the virtual wind tunnel domain created in the modeling software. ANSYS ICEM software was used for geometry simplification & meshing and for pre-processing, whereas for solving and post-processing, ANSYS CFX was used. The simulations have been carried out for both the cases, with & without implementing the extra FRONT COWL.