Optimizing Inlet Geometries for Integrated Coolant Pumps : An experimental workflow to minimize pressure drop

Sammanfattning

The increasing electrification of heavy vehicles demands highly efficient thermal management systems, where optimized coolant flow is crucial to maintain battery and component temperatures. This thesis investigates the optimization of inlet geometries for integrated coolant pumps to minimize pressure drop while considering packaging constraints and manufacturing cost. A systematic design methodology was developed combining parametric CAD modeling, Computational Fluid Dynamics (CFD) simulations, and physical testing on a closed-loop flow rig. The design space was explored using a full factorial Design of Experiments (DoE), generating 196 theoretical configurations, from which five representative prototypes were selected for 3D printing and evaluation. The results points towards that a larger bend radius can reduce pressure drop but only when replacing straight pipe sections, highlighting a tradeoff between space efficiency and hydraulic performance. Measurement uncertainties were carefully analyzed to assess the significance of observed trends. The study concludes with design guidelines prioritizing packaging constraints, recommending that designers first minimize inlet path length within available space, and only refine geometry when space allows. The proposed method was validated through both experimental and numerical results, offering a repeatable approach for future integrated coolant pump designs.