A heat exchanger analogy of automotive paint ovens

Abstract

Computational prediction of vehicle temperatures in an automotive paint oven is essential to predict paint quality and manufacturability. The complex geometry of vehicles, varying scales in the flow, transient nature of the process, and the tightly coupled conjugate heat transfer render the numerical models computationally very expensive. Here, a novel, simplified model of the oven is developed using an analogy to a three-stream cross flow heat exchanger that transfers heat from air to a series of moving bodies and supporting carriers. The analogous heat exchanger equations are developed and solved numerically. Steady state Computational Fluid Dynamics (CFD) simulations are carried out to model the flow field and to extract the heat transfer coefficients around the body and carriers. The air temperature distribution from the CFD models is used as a boundary condition in the analogous model. Correction coefficients are used in the analogy to take care of various assumptions. These are determined from existing test data. The same corrections are used to predict air temperatures for a modified configuration of the oven and a different vehicle. The method can be used to conduct control volume analysis of ovens to determine energy efficiency, and to study new vehicle or oven designs.