A new simulation capability is presented to enable the performance of a hardware-based temperature control system to be assessed in thermally-managing heat-generating automotive vehicle powertrain parts. Temperature control is assumed to involve spray evaporative cooling of powertrain parts exposed to vibration. Two hypotheses are proposed to enable construction of a practical simulation that is both accurate and computationally efficient. The first is that a dynamic correlation model for single-nozzle spray evaporative cooling of a flat test-piece exposed to vibration, can be used as a reasonable model for multiple-nozzle spray evaporative cooling of component parts with curved cooling surfaces of non-horizontal orientation. The second is that the transient heat diffusion properties of a particular 3-dimensional component can be replaced by a 1-dimensional (1D) equivalence. To test this hypothesis, Finite Element models for two representative parts have been constructed and used to demonstrate the quality of the 1D heat diffusion equivalence, for which a fast Finite Difference solution can be exploited. To test the accuracy of test-piece surface temperature control simulation, an experimental test facility has been built in hardware, in which the temperature of two instrumented test-pieces exposed to vibration (from a shaker) are controlled by spray evaporative cooling. Each test piece is electrically-heated and the hardware control system is configured using PID control, for which appropriate gains are selected. Detailed comparisons of temperature control by hardware and simulation are given for the two test-pieces under static and dynamic conditions. Good agreement is generally obtained between simulated surface temperatures compared with measurements taken from both test-pieces. The paper shows that temperature control of a hardware-based control system using spray evaporative cooling of powertrain parts can be confidently simulated.

提出了一种新的仿真功能，可以在热管理发热的汽车动力总成零件中评估基于硬件的温度控制系统的性能。假定温度控制涉及动力总成零件的喷雾蒸发冷却，该零件要承受振动。提出了两个假设，以便能够构建既精确又计算高效的实际仿真。首先是可以对暴露于振动的扁平试件进行单喷嘴喷雾蒸发冷却的动态相关模型，作为具有非水平弯曲曲面的零件的多喷嘴喷雾蒸发冷却的合理模型。方向。第二个问题是，特定3维组件的瞬态热扩散特性可以用1维（1D）等价物代替。为了检验该假设，已构建了两个代表性零件的有限元模型，并用于证明一维热扩散当量的质量，为此可以利用快速的有限差分解决方案。为了测试试件表面温度控制仿真的准确性，已在硬件中建立了一个实验测试设施，其中两个暴露于振动（来自振动器）的仪器化测试件的温度通过喷雾蒸发冷却来控制。每个试件都经过电加热，并且硬件控制系统使用PID控制进行配置，为此选择了适当的增益。给出了在静态和动态条件下这两个测试件通过硬件和仿真进行的温度控制的详细比较。与从两个试件获得的测量值相比，通常在模拟的表面温度之间获得了很好的一致性。本文表明，可以可靠地模拟基于动力总成零件的喷雾蒸发冷却的基于硬件的控制系统的温度控制。