Simulative development of thermal management for warm-up

Since the invention of the internal combustion engine thermal management is an important feature. In the beginning cooling of performance engines had priority. Today the defining topics are rigorous emission targets, consumption targets and comfort. Using engine in cars a regularity of heating-up and cooling process occurs. For NEDC the warm-up can amount to an extra fuel consumption of 8-15 % (depending on the motor size).There are varieties of measures to support a better distribution of heat. The difficulty by decreasing development times and increasing costs is the selection of the best measures. So the simulative development is an important tool.The used coupled simulation area is divided into a thermal net of fluids and structures, a friction model and a consumption model. Calibration and verification of the model is supported by heat balancing, friction measuring and cooling curves by varying engine configuration. For a second loop of verification different thermal management concepts were integrated in the simulation. The finally calibrated model can be used to compare consumption potentials of varying measures for future engine generations with costs, package and effort. In this way the measures can consider at an early stage by the design department.