Latest Innovations in Heavy Equipment Cooling System to Improve Machine Performance

In the heavy equipment industry, Heavy Equipment Cooling System plays an important role in maintaining machine performance and operational efficiency. Various case studies show how leading companies are addressing these cooling system challenges through innovation and cutting-edge technology. One example is the collaboration between hydraulic component and refrigeration system providers to create customized solutions in the agricultural sector. In this project, a company was tasked with designing an efficient accelerator cooling system, capable of picking up and distributing oil well, thus keeping the engine’s operating temperature stable.

In addition, steady state analysis of a six-cylinder diesel engine cooling system using GT-Suite simulation software showed that one-dimensional simulation can reduce analysis time and test costs, while still maintaining high accuracy of results. This approach enables a more optimized cooling system design, supporting engine performance under various operational conditions. All these case studies illustrate the importance of innovation in the development of heavy equipment cooling systems, which not only meet technical needs, but also contribute to sustainability and cost efficiency.

Machine Cooling System Optimization with ANN Model

A study developed an Artificial Neural Network (ANN) model to predict and optimize the cooling system in the engine room of an excavator, with the aim of improving cooling performance and energy efficiency. A Computational Fluid Dynamics (CFD) analysis was conducted to build a database that took into account the layout and operating rates of the cooling fans. Two ANN models were created: the first model only considers the coordinates and varying operation levels of the fans, while the second model also considers the fixed coordinates of the fans. The second model was able to use secondary information, such as the distance between fans, thus improving the prediction accuracy compared to the first model.

The developed ANN model successfully predicted the performance of various cooling system designs, maximized cooling performance, and optimized energy efficiency. The design focused on cooling performance shows an increase in cooling margin and a reduction in cooling index, while the design optimized for energy efficiency lowers the operating rate of the cooling fan while maintaining the reference temperature of the heat exchanger. CFD analysis results on the proposed designs confirm that the ANN model predictions are accurate, validating this approach for excavator cooling system design.

Analysis of Heavy Equipment Cooling System with GT-Suite 1D Simulation

In another study, they conducted a steady state analysis of a six-cylinder diesel engine cooling system using GT-Suite 1D simulation software.  GT-Suite is a one-dimensional simulation software that plays an important role in reducing the processing time as well as the overall cost.

Simulation results show that the maximum deviation between simulation and test results is about  +/-2%, indicating a high level of accuracy. The accuracy of this method depends on the characteristics of the cooling system components as well as the operational points of the components, such as pumps and fans, which are within the range of the characteristic data. This 1D simulation has advantages over 3D CFD simulations as it reduces analysis time, effort and testing costs, while keeping the accuracy of the results within acceptable limits.

This study is beneficial for speeding up the analysis and lowering the overall cost. The model can also be modified to include additional components, such as condensers and cabin heaters, which may affect the cooling system. In the future, this model can be coupled with an engine model to observe the influence of the cooling system on engine performance parameters, such as brake specific fuel consumption (bsfc), brake mean effective pressure (bmep), and torque, in the duty cycle. This will help in understanding the behavior of the cooling system and engine performance in greater depth, especially under transient conditions.

Development of Heavy Equipment Cooling System in the Agricultural Sector

A company has established strategic collaborations with partners in developing innovative cooling systems, specifically for the agricultural sector, where their hydraulic products are widely used. One example of this collaboration is a hydraulic motor/pump unit with a capacity of 8 cm³ – 17 cm³ designed to meet the specific needs of heavy machinery manufacturers, such as tractors, harvesters and tillage machines. A key request from one of the leading agricultural machinery manufacturers was to design a shaft cooling system with a hydraulic drive capable of taking oil from the shaft and distributing it to the front and rear shafts of the machine.

As a solution, the company designed a customized air cooling unit and hydraulic motor pump unit. They created a hydraulic motor/pump unit with specific technical specifications, while their partner developed an oil/air cooling unit that had a DC pump/power supply. The combination of these two components resulted in an effective cooling system, with the shaft temperature stabilized at 66°C, using 80W90 oil. The required cooling performance is 5.2 kW at a flow of 30 lpm and a temperature difference (ΔT) of 40 °C at a traveling speed of 2000 rpm. By utilizing the latest technology and customized design, the innovative cooling system can improve engine performance and maintain temperature stability under various operating conditions. This not only meets the demands of the agricultural industry, but also contributes to overall machine efficiency and reliability.

Features of TransTRACK Solutions in Machine Cooling System

TransTRACK offers innovative solutions in machine cooling systems that are designed to improve operational efficiency and machine performance. With advanced technology and a customized approach, these cooling systems ensure that the machine can operate within the optimal temperature, thereby minimizing the risk of overheating and extending the life of the machine.

One of the key features of the TransTRACK Cooling System solution is:

• Real-Time Temperature Monitoring: The system is equipped with temperature sensors that monitor the machine’s condition continuously, providing operators with accurate information about the machine’s working temperature.
• Integration with Fleet Management System: The solution connects with the TransTRACK fleet management platform, enabling in-depth data analysis and more efficient management.
• Performance Data and Reports: TransTRACK provides performance reports that allow users to identify usage patterns and perform better maintenance planning.
• Overheating Prevention: With accurate temperature monitoring, operators can take preventive measures to prevent overheating, reducing the risk of damage to the engine.
• Improved Fuel Efficiency: By keeping the engine in optimal condition, these solutions help improve fuel efficiency and reduce emissions, supporting environmentally friendly practices.

Heavy Equipment Cooling System solutions from  TransTRACK offer a range of advanced features designed to improve engine efficiency and performance. With real-time temperature monitoring, operators can get accurate information about the condition of the machine, so they can take immediate preventive action to prevent overheating. Integration with fleet management systems enables in-depth data analysis, assisting companies in more effective maintenance planning. Additionally, the performance reports provided allow the identification of usage patterns that can be utilized to improve fuel efficiency and reduce operational costs. With this approach, TransTRACK not only keeps the machine’s cooling system in optimal condition, but also supports environmentally-friendly practices through reduced emissions.

Improve your machine’s performance and reliability with TransTRACK’s Cooling System solutions. Contact us today for a free consultation and discover how our technology can help you optimize operations and reduce maintenance costs. Don’t wait for the temperature to rise-schedule a demo and experience the benefits today!