This document describes the design, fabrication, and analysis of an automobile radiator test rig using MATLAB. The main divisions of the project include estimating costs, designing the cooling system in MATLAB, assembling components to create the test rig, and analyzing rig values for different parameters. The test rig components include a reservoir, pump, rotameter, thermocouples, radiator, fan, and coolant bottle. Experiments are conducted using water and coolant at different dilution levels. Observations of inlet/outlet temperatures and efficiency calculations are made. Results show inlet temperature decreases with increasing outlet temperature. Thermal efficiency increases with greater temperature difference. The project concludes with recommendations for further analysis and simulation of the system.

1. JSS MAHAVIDYAPEETHA
JSS ACADEMY OF TECHNICAL EDUCATION
NOIDA
Department Of Manufacturing Technology
DESIGN, FABRICATION AND ANALYSIS OF AUTOMOBILE
RADIATOR TEST RIG USING MATLAB
Supervised By :
Mr. VISHNU TIWARI
Assistant Prof.
MT Department
Presented By :
Sharang Bhardwaj 1109141043
Aayushi 1109141002
Shishir Tripathi 1109141044
Sanchit Agrawal 1109141040
(8th Sem Students)
Group no.4

2. MAIN DIVISION OF PROJECT
1. Estimation of cost and availability of the
components.
2. Design of the engine cooling system in
MATLAB .
3. Assembling of the different components
to prepare test rig.
4. Analysis of rig values for different
parameters of the system.
5. Simulate the system, compare and
formulate the results.

3. INTRODUCTION
HEAT GENERATED
IN THE VEHICLE
DUE TO
COMBUSTION
STROKE
POWER TO DRIVE
THE VEHICLE AND
ITS ACCESSORIES
HEAT IS CARRIED
OFF INTO THE
ATMOSPHERE
THROUGH
EXHAUST SYSTEM
REMAINING
REMOVED FROM
THE ENGINE BY
COOLING SYSTEM

4. AUTOMOBILE RADIATOR
A radiator is a type of heat exchanger. It is designed to
transfer heat from the hot coolant that flows through it to
the air blown through it by the fan.

5. TESTING SET UP OF AUTOMOBILE
RADIATOR
• Reservoir with heating element
• Pump
• Rotameter
• Thermocouples
• Radiator
• Fan
• Coolant bottle

6. WORKING PRINCIPLE
• The pump sends the fluid into the engine block, where it makes its way
through passages in the engine around the cylinders. Then it returns
through the cylinder head of the engine.
• The thermostat is located where the fluid leaves the engine. The
thermostat sends the fluid back to the pump directly if the thermostat is
closed.
• If it is open, the fluid goes through the radiator first and then back to the
pump.
• There is also a separate circuit for the heating system. This circuit takes
fluid from the cylinder head and passes it through a heater core and then
back to the pump.
• There is normally also a separate circuit for cooling the transmission fluid
built into the radiator. The oil from the transmission is pumped by the
transmission through a second heat exchanger inside the radiator.

7. PROCEDURE
• Fill the reservoir with the coolant upto indicated level.
• Switch on the power supply,and then switch on the heating
element.
• Allow the coolant to get heated up to 60-90 degree celcius.
• Switch on the fan and the pump.
• Note down the electricity consumed by fan and pump by
energy meter.
• Note down the discharge of the coolant from flowmeter.
• Note down the inlet and outlet temperature/ by varying
pump discharge.
• Plot the graph between discharge vs. temperature.
• Plot the graph between inlet and outlet temperature.

8. COMPONENT SPECIFICATIONS
Maruti Alto:
•Size: 300*335*23 mm
•Make: SUZUKI
•Model no. DL-A039
•Material: Copper
Maruti 800
•Downward flow type
•Cu tubes, Cu plates
•37 plates, dia of tubes-10mm
Capacity= 3lit.
Cooling fan
•Rpm: 1200-2400 rpm
•220/240 V
•Single phase AC

9. Water Pump
•Submersible pump
•165-220V/50 Hz
•Power -19W
•Output -1100 L/H
Energy wire
• 1 phase, 2 wire
•AC 240V , 50Hz
•I (max)- 30A
Heating elements
•Power = 2000W, 1500W
Reservior
•Material: Stainless steel
•Capacity: 25-30L

10. ∆t= time taken(s)
Z= energy meter reading(W)
Ƞₒ= overall efficiency (%)
Ƞ= thermal efficiency(%)
h= convective heat transfer coefficient (w/m2 °C)
∆Q= heat loss (W)

11. CALCULATIONS
• Temperature Difference ∆T = T1 – T2
• Thermal ƞ= ∆T/T1
• Overall ƞₒ=( m*Cp* ∆T)/ z
• Q= h*A*∆T
Where,
T1= temp at inlet(°C)
T2= temp at outlet (°C)
M= mass of the coolant
Cp= specific heat at constant pressure
Q= discharge
P= Power of pump
ῥ=density of water (kg/m3)
g= acceleration due to gravity (m2/s)
H= head of the pump(m)
∆T= temp diff (T1-T2)

12. Water meter
•Dia of inlet & outlet- 15 mm
Frame
•Material: Mild steel
•Angle size: 1``
Pipes and fittings
•Diameter – 0.5`` and 1``

13. COST ESTIMATION
•Radiators : Rs.2500-3000
•Cooling fan: Rs.300
•Energy meter: Rs.300
•Water meter: Rs.600
•Container: Rs. 560
•Water pump: Rs.120
•Heating element:Rs.180
•Frame: Rs.1500
•Pipes and joints: Rs.850
•Electrical boards and switches: Rs.500
•TOTAL:Rs.8000

14. RADIATOR SPECIFICATION USED IN THE
MATLAB
• Size: (300*335*23) mm
• Make: SUZUKI
• Model no. DL-A039
• Material: Copper
• Downward flow type
• Cu tubes, Cu plates
• 37 plates, dia of tubes-10mm

15. ENGINE COOLING SYSTEM MODEL

16. ENGINE MODEL

17. OUTPUT

18. FLUID DENSITY IN THE SYSTEM

19. PARTS PURCHASED
• Radiator: Accent Camry Petrol version
• Submersible pump
• Inverter Circuit for efficient running of the radiator fan at
high current.
• Step down Transformer
• Emulsion heating rod
• Alcoholic Thermometer

20. Steps involved in the removal of
radiator from the car
1. Remove the Radiator Filler Cap and Detach the
Radiator Reservoir Hose.

21. 2. Detach the Driver's side Fan and ECT Switch
Connector.

22. 3. Detach the Passenger side Fan Connector.

23. 4. Disconnect the Supply and Return Transmission
Fluid Lines from the Transmission .

24. 5. Remove the four 10mm bolts that secure the two
cooling fan shrouds. Then pull up and out the passenger
side Cooling Fan Shroud to expose the ECT
Temperature Control Wire Harness Strap.

25. 6. Disconnect the ECT Wire Harness Strap from the
Strap Mount. Then disconnect the ETC Wire Plug from
the Water Temperature Sending Unit.

26. 7. Drain the Coolant

27. 8. Disconnect the Upper and Lower Radiator
Hose

28. 9. Unbolt the two Upper Radiator Support Mounts,
remove the mounts and pull the radiator up from its
lower support mount

29. 10. With the old radiator out, remove the a) Lower
Radiator Hose b) Supply and Return Transmission Oil
Lines c) Water Temperature Sending Unit d) Lower
Radiator Support Mounts if detached from their sockets.

30. INVERTER CIRCUIT
1. Step down transformer
A varying current in the
transformer's primary winding
creates a varying magnetic flux in
the core and a varying magnetic
field impinging on the secondary
winding. This varying magnetic
field at the secondary induces a
varying electromotive force (EMF)
or voltage in the secondary
winding.

31. 2. Voltage Regulator
• A voltage regulator is designed to automatically maintain a
constant voltage level. A voltage regulator may be a simple
"feed-forward" design or may include negative feedback
control loops. It may use an electromechanical mechanism, or
electronic components. Depending on the design, it may be
used to regulate one or more AC or DC voltages.

32. Alcoholic Thermometer
• The alcohol thermometer is an
alternative to the mercury-in-
glass thermometer and has
similar functions. Unlike the
mercury-in-glass thermometer,
the contents of an alcohol
thermometer are less toxic and
will evaporate away fairly
quickly. An organic liquid is
contained in a glass bulb which
is connected to a capillay of the
same glass and the end is sealed
with an expansion bulb.

33. Assembly of the Complete Rig

34. S.NO Inlet Temp Ti(°C) Outlet Temp
TO(°C)
Time (sec)
1 70 62 60
2 75 67 120
3 80 68 180
4 85 71 240
5 90 74 300
OBSERVATIONS AND CALCULATIONS
9.1USING WATER AS FLUID
9.1.1OBSERVATION TABLE
S.NO Inlet Temp Ti(°C) Outlet Temp
TO(°C)
Time (sec)
1 70 62 60
2 75 67 120
3 80 68 180
4 85 71 240
5 90 74 300
OBSERVATIONS AND CALCULATIONS
USING WATER AS FLUID
OBSERVATION TABLE

35. S.NO Temp(ΔT)°C ɳt
1 8 11.42
2 8 10.67
3 12 15
4 14 16.47
5 16 17.78
CALCULATION TABLE
(ΔT) = Ti - TO
ɳt = ΔT/ Ti

36. USING COOLANT AT 50% DILUTION
OBSERVATION TABLE
S.NO Inlet Temp Ti(°C) Outlet Temp
TO(°C)
Time (sec)
1 65 54 60
2 70 57 120
3 75 60 180
4 80 61 240
5 85 64 300
6 90 66 360

37. CALCULATION TABLE
S.NO Temp(ΔT)°C ɳt
1 11 16.92
2 13 18.75
3 15 20
4 19 23.75
5 21 24.7
6 24 26.67
(ΔT) = Ti - TO
ɳt = ΔT/ Ti

38. USING COOLANT AT 75% DILUTION
S.NO. Inlet temp Ti(°C) Outlet temp
TO(°C)
Time (sec)
1 65 58 60
2 70 63 120
3 75 66 180
4 80 69 240
5 85 72 300
6 90 76 360
OBSERVATION TABLE:-

39. CALCULATION TABLE
S.NO Temp(ΔT)°C ɳt
1 7 10.72
2 7 10
3 9 14.66
4 11 13.75
5 13 15.29
6 14 15.56
(ΔT) = Ti - TO
ɳt = ΔT/ Ti

40. CONCLUSIONS
USING WATER AS FLUID
Inlet Temperature(x) versus Outlet Temperature(y):

41. Thermal Efficiency versus Change in Temperature

42. Inlet Temperature versus Thermal Efficiency

43. 50% DILUTION LEVEL
• Inlet Temperature versus Outlet Temperature

44. Thermal Efficiency versus Change in Temperature

45. Inlet Temperature versus Thermal Efficiency

46. 75% DILUTIUON LEVEL
• Inlet Temperature versus Outlet Temperature

47. Thermal Efficiency versus Change in Temperature

48. Inlet Temperature versus Thermal Efficiency

49. FURTHER WORK
• Analysis of rig values for different parameters
of the system.
• Simulate the system, compare and formulate
the results.

50. GANTT CHART

51. References
1. J P Yadav and Bharat Raj Singh,”Study on performance
evaluation of automotive radiator “.S-JPSET:ISSN:2229-
7111,Vol.2,issue 2.
2. F. G. Tenkel, “Computer Simulation of Automotive
Cooling Systems,” SAE Paper 740087, 1974 in page no. 19.
3. J.C. Corbel, “An Original Simulation Method for Car
Engine Cooling Systems: A Modular System,” SAE Paper
870713, 1987 in page no. 27.
4. W. Eichlseder, G. Raab, J. Hager and M. Raup, “Quasi-
Steady Calculation of Cooling Systems with Forecast on
Unsteady Calculations,” SAE Paper 954042, 1995 in page
no. 29.

52. THANK YOU