BỘ GIÁO DỤC VÀ ĐÀO TẠO

TRƯỜNG ĐẠI HỌC CÔNG NGHỆ TP. HỒ CHÍ MINH

Topic: Cooling system of internal combustion engine

Lecturer: Nguyễn Văn Bản

Nhóm: 5
Number Name Id student Evaluate signature
1 Nguyễn Phú Sĩ 2282506615 100%
2 Trần Thanh Phát 100%
3 Huỳnh Nguyễn Hoàng 100%
Thái

Ho Chi Minh City, October 25, 2024

 CONTENTS
INTRODUCTION................................................................................................2
Chapter 1: OVERVIEW OF ENGINE COOLING SYSTEM.....................................3
1.1: Purpose and requirements of the cooling system.................................3
1.1.1: Purpose of the cooling system........................................................3
1.1.2: Cooling system requirements..........................................................3
Chapter 2: DUTIES OF THE COOLING SYSTEM.................................................4
2.1: Cooling and warming the engine...........................................................4
2.2: Cool the lubricating oil...........................................................................5
Chapter 3: WATER COOLING SYSTEM..............................................................6
3.1: Evaporative cooling system...................................................................6
3.2: Cooling by natural convection...............................................................8
3.3: Cooling by forced circulation.................................................................9
3.3.1: Closed-loop forced circulation cooling system..............................10
3.3.2: Two-circuit forced cooling system.................................................11
3.3.3: Single open loop cooling system...................................................12
3.4: Detailed structure of the cooling system.............................................13
3.4.1: Cooling tank..................................................................................13
3.4.2: Water pump...................................................................................14
3.4.3: Thermostat valve..........................................................................16
3.4.3.1: Thermostatic valve is composed of the following main
components:........................................................................................16
3.4.3.2: Operating principle of thermostatic valve...............................17
3.4.3.3: Coolant Solvent.......................................................................18
3.4.3.4: Important technical parameters of thermostatic valves in
automobile cooling systems.................................................................18
3.4.3.5: Type of Thermostat.................................................................19
Chapter 4: AIR COOLING SYSTEM (WIND)......................................................20
4.1: Air-cooled structure.............................................................................20
4.2: Working Principle of Air Cooling System..............................................21
Chapter 5: COMPARE AIR COOLING SYSTEM AND WATER COOLING SYSTEM.22
REFERENCES:.................................................................................................24

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INTRODUCTION
The cooling system in a car is a crucial component that helps maintain the optimal
operating temperature of the engine. When the engine is running, the fuel combustion
process generates a significant amount of heat. If not controlled, excessive heat can
damage engine components, reducing their lifespan and overall performance. The cooling
system functions to dissipate heat and keep the temperature within a safe range, ensuring
stable operation, improved efficiency, and protection of engine parts.

The cooling system operates based on the circulation of coolant, usually a mix of water
and antifreeze to enhance heat transfer capabilities and prevent freezing in cold weather.
Key components include the water pump, radiator, cooling fan, thermostat, and coolant
hoses. The water pump pushes coolant from the engine through parts like the radiator,
where heat is quickly dissipated into the surrounding environment. During this process,
the thermostat automatically adjusts the coolant flow to maintain the engine temperature
within a safe limit.

Modern cooling systems also incorporate temperature sensors and electronic control
units. When the engine temperature reaches a certain level, the temperature sensor sends
a signal to the central control unit (ECU), activating the cooling fan to enhance heat
dissipation. This system operates effectively under harsh conditions, such as long drives,
uphill climbs, or extremely hot weather. Some high-end vehicles even use oil-based
cooling systems instead of water, achieving higher engine performance and fuel
efficiency.

Moreover, regular maintenance of the cooling system is essential. Frequently replacing

the coolant, inspecting and cleaning the radiator, and checking components such as the
cooling fan, water pump, and thermostat will help keep the system operating steadily.
This not only protects the engine but also extends the vehicle’s lifespan and improves
overall performance.

In summary, the cooling system plays an essential role in maintaining a stable engine
temperature, significantly impacting vehicle efficiency, durability, and fuel consumption.
It is one of the critical factors that ensure a vehicle operates effectively and reliably over
time.
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Chapter 1: OVERVIEW OF ENGINE COOLING SYSTEM
1.1: Purpose and requirements of the cooling system
1.1.1: Purpose of the cooling system
The purpose of the engine cooling system is to regulate the high temperature generated
during engine operation, especially in components that come into contact with
combustion gases, such as pistons, piston rings, valves, cylinder heads, and cylinder
walls. These components absorb around 25-35% of the total heat produced by fuel
combustion. As a result, they are intensely heated, and high temperatures can lead to
negative outcomes, including reduced strength and durability of engine parts, lowered
viscosity of lubricating oil, and increased friction losses. Therefore, engine cooling is
essential.

The engine cooling system's function is to transfer heat from the combustion gases
through the combustion chamber walls and into the cooling medium, ensuring that
component temperatures remain neither too high nor too low. Excessive heat in the
engine leads to the issues mentioned above, while an overly cooled engine means
excessive heat loss to the coolant, reducing the heat available for power generation and
thus lowering engine thermal efficiency. Additionally, if the engine is too cool, the
viscosity of the lubricating oil increases, making it less fluid and more difficult to
circulate, resulting in higher mechanical and friction losses. This affects the engine’s
economic performance and power output significantly.

1.1.2: Cooling system requirements

For the cooling system to operate effectively, it must meet the following requirements:

 Maintaining a Stable Temperature: The cooling system must keep the engine
temperature within an optimal range, enabling the engine to perform efficiently
without overheating or overcooling. This ensures optimal fuel combustion
efficiency and the longevity of internal engine components.
 Rapid Cooling Capability: When the engine operates under heavy load or in hot
weather conditions, the cooling system should be able to dissipate heat quickly to
meet the engine’s demands and prevent overheating.
 Reliable and Continuous Operation: The cooling system should be designed for
stable operation throughout the engine’s running time. Components such as the
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 water pump, radiator, cooling fan, and thermostat need to be durable, with high
reliability and minimal risk of failure.
 Capability to Operate Under Harsh Conditions: The cooling system must
withstand extreme weather conditions (hot and cold) and complex driving
conditions (such as uphill, heavy load, or long-distance driving) without reducing
cooling efficiency.
 Compatibility with Engine Design: The cooling system should be compatible with
the engine structure and should not occupy excessive space in the engine
compartment, contributing to an optimized overall vehicle design.

Chapter 2: DUTIES OF THE COOLING SYSTEM

The primary function of a car engine’s cooling system is to dissipate heat and
maintain a stable temperature (Cool when the engine is at high temperature and
warm the engine when necessary) for the engine throughout its operation. This
process not only prevents overheating but also protects engine components from
damage due to high temperatures, maintains the appropriate viscosity of
lubricating oil, and thereby reduces wear and friction losses. The cooling system
keeps the engine at an optimal temperature for efficient fuel combustion,
promoting fuel savings and minimizing emissions.

Additionally, the cooling system in many vehicles also supplies heat to the cabin
heating system. Hot coolant from the engine can be directed to the heating system,
enhancing comfort for the driver and passengers, especially during cold seasons.

2.1: Cooling and warming the engine

cooling and warming the engine are two important functions that help maintain
performance and protect the engine.

 Cooling the Engine: This is the primary function of the cooling system.
When the engine operates, fuel combustion in the combustion chamber
generates a large amount of heat. Without cooling, the engine temperature
would rise, leading to overheating and potential damage to components,
particularly pistons, cylinders, and bearings. The cooling system uses water
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 or coolant to absorb heat from the engine and directs it through the radiator
to dissipate heat into the environment, maintaining a stable temperature and
preventing the engine from overheating.
 Warming the Engine: The engine needs to reach a certain temperature to
operate optimally. When the engine is cold, especially during a morning start
or in cold weather conditions, the cooling system helps warm the engine to
its ideal operating temperature. The thermostat remains closed to keep
coolant within the engine, allowing the temperature to rise quickly to the
optimal level. Once the engine reaches the ideal temperature, the thermostat
opens to begin the cooling process. This helps improve fuel combustion
efficiency, reduce emissions, and increase fuel economy.

2.2: Cool the lubricating oil

Cooling lubricating oil is an important part of protecting and maintaining the
performance of your car engine. Lubricating oil is responsible for lubricating the engine's
moving parts, reducing friction and wear. However, during operation, lubricating oil also
absorbs some heat from machine parts, causing the temperature of the oil to increase. If
the oil is too hot, its viscosity will decrease, reducing its ability to lubricate and
increasing friction between parts. This can lead to engine damage and reduced life of
machine parts.

To solve this problem, the lube oil cooling system is often integrated into the engine's
cooling system or a separate oil cooler may be used.

 Oil radiator: Some vehicles are equipped with an oil radiator, a device located on
the outside of the engine, with oil pipes passing through the radiator fins to
disperse heat to the surrounding air. An oil cooler works similarly to a water
cooler, helping to reduce the temperature of the oil before it returns to the engine.
 Water cooling: On some engines, the lubricating oil may be cooled by the engine
coolant system. The oil will be guided through heat exchange tubes, where the
coolant will absorb heat from the oil, helping to lower the temperature of the
lubricating oil.

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  Oil temperature control valve: Some oil cooling systems are equipped with a
temperature control valve, which helps control the flow of oil through the radiator
depending on the oil temperature. When the oil is too hot, the valve will open to
let the oil pass through the radiator, and when the oil is cold, the valve will close to
keep the oil temperature at an ideal level.

Chapter 3: WATER COOLING SYSTEM

The water cooling system in a car is a system that uses water or coolant to control and
maintain the engine's temperature within an ideal level, preventing the engine from
overheating during operation.

Mechanism of operation of water cooling system: Water or coolant is circulated through

channels in the engine to absorb heat from hot parts, then transferred to the radiator for
cooling through air circulation or cooling fans. This system usually includes a water
pump, radiator, thermostatic valve, cooling fan, and temperature sensor to control the
flow and temperature of the coolant, ensuring the engine temperature is always at a stable
level. determined.

3.1: Evaporative cooling system

Evaporative water cooling systems are the simplest type. This system does not require
pumps or fans.

The water storage part has two parts: The water chamber surrounding the cylinder wall
(8), the cylinder cover chamber (5) and the evaporation water tank (2) above.

operating principle diagram:

When the engine is working, the water surrounding the combustion chamber will boil.
Boiling water has a lower density so it floats on the open surface of the container to
evaporate into the air. Cool water in a container with high density will sink to the bottom
to make room for hot water to rise, thus creating natural convection. Based on the heat of
the engine and the arrangement of the engine standing or lying down to design this type
of evaporation system.

6
With evaporative cooling, the amount of water in the tank will decrease rapidly, so it is
necessary to add water regularly and promptly. Therefore, this type of cooling is not
suitable for engines used in transport vehicles.

Evaporative water cooling system due to its simple structure and fluidity

convection motion mentioned above, so this system is used for internal combustion
engines

Horizontal cylinder type, especially engines on small agricultural machines.

The disadvantage of this cooling system is high water loss and uneven cylinder wear.

Image 1: Evaporative water cooling system

1 Fuel tank 7 Piston

2 The water tank evaporates 8 Cylinder

3,4 Хuрар 9 Transmission bar

5 Cylinder cover 10 Crankshaft

6 Machine body 11 The crankcase contains oil

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3.2: Cooling by natural convection
In a natural convection cooling system, water circulates thanks to the pressure difference
between the hot and cold water columns without a pump. Hot water column in the engine
and cold water column in the tank or water tank.

Water receives heat from the cylinder in the machine body, causing the density of water
to decrease so the water floats to the top. In the cavity of the cylinder cover, the water
continues to receive heat from the details surrounding the combustion chamber: cylinder
cover, valve... the temperature of the water continues to increase and the density of water
continues to decrease, so the water floats to the top. path to the upper compartment of the
cooling tank (5). The blower (6) is driven by a pulley from the engine crankshaft and
draws air through the tank. Therefore, the water in the tank is cooled, causing the water
density to increase, the water will sink to the lower compartment of the tank and from
here enter the machine body, performing a circulation cycle.

The pressure difference depends on the temperature difference of the two water columns,
so the cooling intensity can automatically adjust according to the load. When starting up,
due to the temperature difference between the hot and cold water columns, the pressure
difference between the two water columns is small. Therefore, water flows slowly, the
engine quickly reaches temperature in working mode. Then the load increases, the
temperature difference of the two water columns also increases, and the water flow speed
also increases. The pressure difference also depends on the difference in average height
of the two water columns, so always ensure that the water level of the tank is higher than
the engine's output water.

However, the system has the disadvantage that the water in the system has movement the
baby's speed is about V = 0.12 - 0.19 m/s. That leads to water temperature differences the
inlet and outlet water are large, so the cylinder walls are cooled unevenly. Want to
engrave To overcome this drawback, it is necessary to increase the water circulation area
in the engine, leading to a heavy and cumbersome cooling system. Therefore, this type of
cooling system is not suitable for tractor engines, but is often used on current engines.

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Image 2: Cooling by natural convection

1 Water line 5 Water tank

2 Cylinder 6 Wind fan

3 Water pipe into the cooling tank 7 Engine cooling water line

4 Water tank cover 8 Fire chamber

3.3: Cooling by forced circulation

The forced circulation cooling system overcomes the disadvantages of the convection
cooling system. In this system, water flows due to the water column thrust of the water
pump. Depending on the number of cycles and type of circulation, we have types of
forced circulation such as:

- Closed-loop forced circulation cooling system.

- Open-loop forced circulation cooling system.
- Two-cycle forced circulation cooling system.

Each type of cooling has different working principles, advantages and disadvantages, and
scope of use.

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3.3.1: Closed-loop forced circulation cooling system

Image 3: Closed-loop forced circulation cooling system

1 Machine body 6 Thermostat valve

2 Water line exiting the engine 7 Cooling tank

3 Water pump 8 Fan

4 The water pipe is connected to the pump 9 Water pipe to the pump

5 Thermometer 10 Lubricating oil cooler

In figure (3.3) is the forced circulation cooling system of a single-cylinder tractor engine.
Here, water is circulated through the centrifugal pump (3), through the water distribution
pipe into the storage compartments of the cylinders. To distribute coolant evenly to each
cylinder, water after being pumped into the engine body (1) flows through the
prefabricated distribution pipe in the engine body. After cooling the cylinder, the water
cools the engine cover and then follows the pipe (2) out of the engine at high temperature
and then to the thermostat valve (6). When valve Thermostat (6) is open, part of the water
flows through pipe (4) to the suction pipe of the water pump (3), a large part of water
passes through the thermostat valve (6) into the upper compartment of the water tank.

Next, water from the upper compartment of the tank passes through thin tubes with
radiator fins. Here, the water is cooled by the air flow through the tank created by the fan
(8). The fan is driven by belt or gear from the engine's crankshaft. In the lower
compartment, water with a lower temperature is pushed into the engine by the water
pump (3) to perform a circulating cooling cycle.

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The advantage of a closed-loop forced cooling system is that the water after passing
through the cooling tank returns to the engine. Therefore, there is less need to add water,
taking advantage of the water return to continue cooling the engine. So this system is
very favorable for long-distance vehicles, especially in areas lacking water sources.

3.3.2: Two-circuit forced cooling system

In this system, the water cooled in the water tank is not by the air flow created by the fan
but by water flow with lower temperature, such as river or sea water. The first loop cools
the engine as in a single-circuit forced cooling system, also known as closed-loop water.
The second loop with river or sea water is pumped to the cooling tank to cool the closed
loop water, then discharged into the river or sea, so it is called open loop. Two-loop
cooling systems are commonly used in marine engines.

Image 4: Two-circuit forced cooling system

1 Distribution water lines 6 The water line to the loop is open

2 Machine body 7 Open loop water pump

3 Cylinder cover 8 Water inlet to open loop water pump

4 Thermostatic valve 9 The water line is turned off to the closed loop pump

5 Cooling tank 10 Closed loop water pump

Fresh water cools the engine in a closed cycle, water pump (10) to the engine cools the
body and cylinder head to the fresh water cooling tank (5). Fresh water in the closed
system is cooled by water from outside the pumped environment by the pump (7) through

11
the filter screen, through the oil coolers, through the cooling tank (5) to cool the fresh
water and then through the pipeline (6). items out into the environment.

When the engine first starts, the water temperature in the closed circulation system is still
low, the thermostat valve (4) closes the water line passing through the fresh water cooler.
Therefore, the cooling water in the outer cooling loop is sucked from the pump (7)
through the cooling tank (5) through pipe (6) to the outside. The thermostatic valve (4)
can be placed on the fresh water circuit so that when the coolant fresh water temperature
is low, it will close the pipe going into the cooling tank (5). At this time, the fresh water
has a low temperature after cooling the engine through the thermostat valve (4) and then
follows the pipe into the fresh water pump (10) to pump it back to the engine.

3.3.3: Single open loop cooling system

This type of cooling system is essentially not much different from a closed-loop forced
cooling system.

Image 4: Single open loop cooling system

1 Distribution water lines 5 The water line to the loop is open

2 Machine body 6 The water line to the pump is broken

3 Machine cover 7 The water line is turned off to the pump

4 Thermostat valve 8 Water pump

In this system, the cooling water is river and sea water, which is sucked into the engine
by pump (8) to cool the engine, then follows the water line (5) to the river and sea. This
system has the advantage of simplicity. However, in some engine models coolant is
achieved at 100°C or higher. When water is at high temperature, it will evaporate. Steam

12
may form the cooling water jacket (internal evaporation type) or the steam is generated in
a separate device (external evaporation type). Therefore, it is necessary to have a separate
cooling system for the engine.

Comparing the two open and closed cooling systems of marine engines, the open system
has a simpler structure, but its disadvantage is that the temperature of the cooling water
must be kept in the range of 500 + 60°C to reduce heat loss. deposits of salts on the
cylinder walls, but at this temperature due to uneven cooling, the thermal stress of the
parts will increase. Also due to the water jacket wall being clogged with salt residue, the
heat transfer is from Coolant input to the cylinder is also poor. In addition, due to the
influence of water temperature changes outside the ship, the water temperature in the
open system also fluctuates greatly. This is not beneficial for cooling mode

3.4: Detailed structure of the cooling system

3.4.1: Cooling tank
The cooling tank has the effect of storing hot water from the engine, lowering the water
temperature and providing cold water into the engine when the engine is working.
Therefore, the water tank is required to absorb and release heat quickly. To ensure that
requirement, the radiator part of the water tank is often made of brass because this
material has a high heat dissipation coefficient.

The cooling tank consists of three main parts: The upper compartment contains hot water
from the engine for cooling, the lower compartment contains cold water after dissipating
heat to the environment to cool the engine and the connecting heat transfer pipe. upper
compartment with lower compartment.

To evaluate the quality of the cooling tank, the heat transfer coefficient of the radiator is
large and the power consumed is low to drive the water pump and fan. Both of those
indicators depend on the following 3 factors:

- The ability of heat pipes and fins to conduct heat from water to air.

- Flow rate of water and cooling air.

- Structure of the safe.

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To solve the first problem, people use materials to make heatsink tubes and fins with high
thermal conductivity such as copper.

The second problem is done by increasing the capacity of the water pump and the
capacity of the fan to increase their convection heat transfer coefficient.

However, increasing the speed of water movement requires increasing the power
consumed by driving water pumps and fans.

The third issue includes choosing the shape and size of the tubes and fins, and how to
arrange the tubes on the tank.

Structure of water tank

Water tanks are usually made up of:

- Pipes: Hot coolant from the engine is directed through these pipes, which are thin and
long, usually made of a metal that conducts heat well such as aluminum or copper.

- Heatsink fins: Attached to pipes to increase surface area, helping to enhance heat
dissipation. These leaves are thin and close together, helping the coolant dissipate heat
quickly as air passes through.

- Cooling fan: Placed behind the radiator to push air through the radiator when the
vehicle is running slowly or standing still. This fan usually turns on/off automatically
based on the cooling system's temperature sensor.

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3.4.2: Water pump
The water pump has the effect of creating pressure to increase the circulation speed of
cooling water. The pump is responsible for providing water to the cooling system with a
certain flow and pressure. The circulating coolant flow in different types of engines
varies in the range of 68-245[1/Kwh] (50-180[1/ml.h]) and with a circulation frequency
of about (7-12) times/minute.

Types of pumps used in engine cooling systems include: Centrifugal pumps, piston
pumps, gear pumps, paddle pumps...

* Centrifugal pump structure:

Centrifugal pumps are commonly used in cooling systems for tractor engines, stationary
engines and ships. Because this type of pump has many advantages:

- Compact structure, sturdy, reliable work.

- The pump's efficiency is relatively high compared to other pump types.

-Price is relatively cheap.

- The pump creates a relatively large pressure head compared to a suction pump.

The working principle is to take advantage of the centrifugal force of water between the
blades to push water from the inside out and then cool.

15
Image 5: Pump structure

1 Puly 7 Impeller

2 Then half moon 8 Nut

3 Pump shaft 9,10 Bearings

4 Fat breasts 11 Pump body

5 Blocking ring 12 Bolt

6 Spring

The pump cover and pump body are made of cast iron, the impeller (7) is usually made of
copper or plastic. To ensure pump performance, the radial clearance between the impeller
(7) and pump body (11) must not be greater than 1mm and the axial clearance must not
be greater than 0.2mm. To reduce pump size, the transmission ratio between the water
pump shaft (3) and the crankshaft is usually chosen to be close to 1 (for high-speed
engines) and 1.6 (for low-speed engines). The total pressure head created by the pump is
about 0.05 ÷ 0.15 MPa and the water speed on the pipe leading to the pump does not
exceed 2.5 ÷ 3 m/s. The power consumed to drive the pump accounts for about 0.5-1.0%
of the useful power of the engine, which is (0.005 - 0.01) Ne. The pump shaft is placed
on two ball bearings (9,10), to seal the grease in the bearings using seals and sealed with
a sealing ring (5).

3.4.3: Thermostat valve

An important part of the car engine's cooling system, helping to control the flow of
coolant between the engine and the radiator (radiator) to maintain the ideal temperature
for the engine.

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Image 5: Thermostat valve

3.4.3.1: Thermostatic valve is composed of the following main components:

1. Body:

Made from metal (usually aluminum or copper) to withstand heat well and be durable
against the effects of high temperature and pressure.

The valve body has two ports to connect to the cooling system, including one connection
to the engine and one connection to the radiator.

2. Thermal Pellet:

This is the most important component of the thermostatic valve, containing a special wax
with high heat sensitivity.

As the temperature increases, the wax expands and pushes the piston to open the valve,
allowing the flow of coolant through the radiator.

When the temperature drops, the wax contracts, the piston returns to its original position
and the valve closes.

3. Piston:

Located above the wax capsule, the piston is affected by the expansion and contraction of
the wax to push or pull the valve, adjusting the valve opening.

The piston moves to open or close the coolant passage, helping to control the amount of
coolant circulating through the engine and radiator.

4. Spring:

The spring helps keep the valve closed when the engine temperature is low.

As the wax expands and pushes the piston, the spring is compressed, allowing the valve
to open. When the wax cools and contracts, the spring will push the piston back to its
original closed position.

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5. Seal or Gasket:

The gasket helps ensure a tight connection between valve parts, preventing coolant
leakage.

Sealing gasket made of heat-resistant material to avoid damage due to high temperature
effects during operation.

3.4.3.2: Operating principle of thermostatic valve

When the engine reaches operating temperature, the wax in the capsule expands, pushing
the piston and opening the valve, allowing coolant to circulate through the radiator to
dissipate heat. On the contrary, when the temperature decreases, the wax contracts, the
spring pushes the piston back to its original position and closes the valve.

3.4.3.3: Coolant Solvent

liquid used in a vehicle's cooling system to absorb and transfer heat away from the
engine, helping to maintain optimal operating temperature. Common coolants are
typically a mixture of water and various additives to enhance heat resistance and prevent
corrosion.

1. Water: High thermal conductivity and is low-cost, so it is often the main component of
coolant. However, pure water easily freezes at low temperatures and boils at high
temperatures, increasing the risk of overheating or freezing in the engine.

2. Glycol Solutions (Ethylene Glycol or Propylene Glycol): Primary component in

automotive coolant solutions. When mixed with water, glycol helps to lower the freezing
point and raise the boiling point of the coolant, ensuring cooling capability even in
extreme temperatures. Ethylene glycol has good efficiency but is toxic, while propylene
glycol is safer and less toxic, though slightly less efficient.

3. Anti-Corrosion and Anti-Rust Additives: Included in coolant to prevent corrosion in

the cooling system, protecting components like pipes, the radiator, and metal parts of the
engine. These additives also prevent scale buildup and protect the cooling system from
oxidation.

4. Premixed Coolant Solutions (Coolant Concentrates): These coolant solutions are pre-
blended, containing glycol, water, and additives in balanced ratios to ensure optimal

18
performance. They are often available in a 50/50 water-to-glycol ratio, ready for use
without further mixing.

3.4.3.4: Important technical parameters of thermostatic valves in automobile

cooling systems
1. Opening Temperature: This is the most important parameter of the thermostatic valve,
determining the temperature at which the valve begins to open to allow coolant to
circulate through the water tank. Typically valve opening temperatures range from 80-
90°C (176-194°F), depending on engine design and operating conditions.

2. Full Open Lift Height: This is the maximum distance the valve can open when the
temperature reaches its peak (usually above 95°C). The maximum opening is usually
from 7 to 10 mm, ensuring that the coolant can circulate at the highest flow rate through
the water tank.

3. Hysteresis: This is the temperature difference between the point where the valve begins
to open and when the valve completely closes. The difference is usually 5-10°C, ensuring
the valve opens/closes accurately and promptly, helping to maintain a stable temperature.

4. Maximum Pressure Tolerance: Thermostat valves must withstand high pressure in the
cooling system without leaking or deforming. Typically, valves can withstand pressures
ranging from 1.5 to 2.5 bar (22-36 psi), depending on the valve type and cooling system.

3.4.3.5: Type of Thermostat

1. Ingle thermostatic valve: Consists of a capsule containing thermal wax, piston and
return spring. When the engine temperature reaches the set threshold (usually about 80-
90°C), the wax expands, pushes the piston and opens the valve to allow coolant to
circulate through the radiator, helping to reduce engine temperature. The single
thermostat valve is suitable for engines that do not require complex temperature control,
especially vehicles with basic cooling needs.

2. Dual thermostatic valve: Has a more complex structure, with two capsules or two
independent cooling circuits. Dual valves can adjust the flow of coolant in two levels,
helping to regulate engine temperature more accurately. This is essential for large or
high-performance motors, as the two stages help the motor reach ideal operating
temperature faster and maintain temperature stability under heavy load conditions.

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3. Electronic thermostat valve: Thermostat valve with this structure helps the cooling
system operate effectively, ensuring the engine remains at the ideal temperature, avoiding
overheating or overcooling.

For modern cars, especially high-end cars, electronic thermostats are the top choice. This
type of valve has an additional electronic controller, connected to the ECU (engine
control unit) and thermal sensor. Through signals from the ECU, the electronic valve
adjusts the valve opening level based on engine temperature and operating conditions.
This helps increase engine performance and optimize fuel economy, especially in
frequently changing driving conditions.

Chapter 4: AIR COOLING SYSTEM (WIND)

The air cooling system is one of the popular methods of cooling car engines, especially
on small cars or sports cars. This system operates on the principle of using air to absorb
and dissipate heat from the engine, to maintain the temperature at a safe and optimal
level.

4.1: Air-cooled structure

This system is designed with three key components: cooling fins, a cooling fan, and an
air guide plate each playing a critical role in maintaining engine temperature stability
under different operating conditions.
1. Cooling Fins: Cooling fins are carefully shaped metal extensions that cover the engine
block and cylinder head. The purpose of these fins is to increase the surface area of the
engine, allowing more heat to dissipate into the surrounding air. The effectiveness of
cooling fins depends on factors such as shape, thickness, quantity, and arrangement, all of
which influence how much heat can be transferred. The positioning of the fins also
matters, as proper spacing ensures adequate airflow over the entire engine surface.
However, this structural complexity can make the engine design more challenging and
costly to produce, as each fin must be carefully manufactured to optimize air contact and
thermal conductivity.
2. Cooling Fan: To maintain a steady supply of air over the engine, a high-speed cooling
fan is essential, especially when the vehicle is stationary or moving at low speeds where
natural airflow may be insufficient. The fan directs air toward the cooling fins, ensuring
that even when the engine is idle, it still receives enough airflow to regulate its
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temperature. In some systems, fan speed is automatically adjusted based on engine
temperature, optimizing airflow while minimizing energy usage and reducing noise. This
forced air approach makes the fan a crucial component for sustaining continuous,
effective cooling across varying driving conditions.
3. Air Guide Plate: The air guide plate serves as a directed pathway for airflow, ensuring
that cool air reaches all critical engine components. Positioned strategically around the
engine block, the plate is designed to channel air effectively, directing it towards specific
areas that may require more cooling due to higher thermal loads. Constructed from steel
with a typical thickness of 0.8 to 1 mm, the guide plate is robust and capable of
withstanding engine vibrations. By distributing air efficiently, it helps to prevent hotspots
on the engine, thus enhancing cooling uniformity and improving overall thermal
efficiency.

Image 6: The air cooling system

4.2: Working Principle of Air Cooling System

The air cooling system in cars operates based on the principle of transferring heat from
the engine to the surrounding air through a closed cycle.
1. Heat Transfer from the Engine: When the engine is running, the combustion process
generates a significant amount of heat. This heat is transferred to various engine
components, such as the cylinders, pistons, and cylinder head. The temperature of these
components can rise rapidly, and if not controlled, it can lead to overheating.
2. Use of Cooling Fins: To enhance heat dissipation, the engine is equipped with cooling
fins. These fins have a specific design that expands the surface area in contact with the
surrounding air. As air flows over the cooling fins, heat from the engine is transferred to
the air, thereby reducing the temperature of the engine components.
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3. Cooling Fan: Under normal operating conditions, when the vehicle is in motion,
natural airflow will circulate through the cooling fins. However, when the vehicle is
stationary or moving slowly, the natural airflow may not be sufficient for effective
cooling. In this case, the cooling fan will activate to create a more powerful airflow,
enhancing cooling efficiency. This fan is usually electrically or mechanically driven and
can automatically adjust its speed based on the engine temperature.
4. Airflow Direction: To ensure that air is evenly distributed and optimized, an air guide
plate is used to direct the cool air flow to the necessary areas of the engine. The air guide
plate helps to increase cooling efficiency by focusing airflow on the hotter components.
5. Temperature Control: The air cooling system must be continuously monitored to
ensure that the engine operates within a safe temperature range. If the temperature
becomes too high, the cooling fan will increase its speed to provide more air. Conversely,
if the engine is too cold, the fan may reduce its speed or stop completely to avoid wasting
energy.

Chapter 5: COMPARE AIR COOLING SYSTEM AND WATER COOLING

SYSTEM

1. Basic Functionality
- Air Cooling System: This system dissipates heat using airflow. As the engine generates
heat from combustion, fins or cooling plates attached to the engine surface help release
that heat into the air. A fan may assist in increasing airflow, especially when the vehicle is
stationary or moving slowly.
- Water Cooling System: This system uses a liquid coolant (usually a mixture of water
and antifreeze) to absorb heat from the engine. The heated coolant is then circulated
through a radiator where it releases the heat to the air outside, effectively cooling the
engine.
2. Effectiveness
- Air Cooling System: While effective for smaller engines or in lower-temperature
conditions, air cooling can struggle to maintain optimal engine temperatures during
heavy use or extreme weather. It may lead to overheating if airflow is insufficient.
- Water Cooling System: Generally provides superior cooling performance. It can handle
higher engine temperatures and maintains stable operating temperatures even under
heavy loads or extreme conditions, making it the preferred choice for most modern
vehicles.

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3. Design and Complexity
- Air Cooling System: Simpler in design, consisting mainly of cooling fins, a fan, and
sometimes an air guide. This simplicity can lead to easier installation and maintenance.
- Water Cooling System: More complex, involving components like a radiator, water
pump, thermostat, and various hoses. This complexity allows for better temperature
control but also requires more maintenance.
4. Weight and Cost
- Air Cooling System: Typically lighter since it does not require heavy components or
liquids, which can be beneficial for performance. It's often cheaper to produce and
maintain due to fewer parts.
- Water Cooling System: Heavier due to the liquid coolant and additional components.
While it may be more expensive to manufacture and maintain, it often results in better
overall engine performance and longevity.
5. Application Suitability
- Air Cooling System: Best suited for smaller engines found in motorcycles, scooters, and
some compact cars. It’s a good choice when weight is a concern and the engine doesn't
produce excessive heat.
- Water Cooling System: Widely used in most modern cars, especially those that require
high performance or operate under heavy loads, like trucks and sports cars.
6. Risk of Leaks
- Air Cooling System: No risk of leaks since it doesn't use liquid coolant, which can make
it more reliable in certain conditions.
- Water Cooling System: There is a potential for leaks, which can lead to coolant loss and
engine overheating. This requires regular checks to ensure the system is functioning
correctly.

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REFERENCES:
1. https://www.britannica.com/technology/automobile/Cooling-system
2. https://vinfastauto.com/vn_vi/van-hang-nhiet-o-to
3. https://hanke.com.vn/van-hang-nhiet-la-gi-cau-tao-cong-dung-dia-chi-mua-ban-
uy-tin-2/#:~:text=Van%20h%E1%BA%B1ng%20nhi%E1%BB%87t%20l
%C3%A0%20m%E1%BB%99t,lanh%20v%C3%A0%20b%C3%ACnh%20l
%C3%A0m%20m%C3%A1t.
4. https://oto.edu.vn/he-thong-lam-mat-o-to/
5. https://otohathanh.com/he-thong-lam-mat-o-to-cau-tao-cong-dung-nguyen-ly-lam-
viec.aspx

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