Development and Evaluation of Ice Detection Methods for Automotive Heat Exchangers Using Capacitance Measurement
(2025) MVKM05 20251Department of Energy Sciences
- Abstract
- Battery Electric Vehicles (BEVs) are increasingly adopted as sustainable alternatives to shift fossil fuel reliance. However, because of battery dependence, their heating systems face significant efficiency losses due to frost formation on heat exchangers in cold climates. This study investigates a capacitance-based sensing approach to detect ice buildup on automotive heat exchangers, aiming to optimize thermal management and reduce unnecessary energy consumption.
Capacitive sensors, which detect changes in dielectric properties due to ice formation, are evaluated through simulation and experimental testing. Multiple sensor topologies, configurations, and materials are proposed and analyzed, including parallel plates of different... (More) - Battery Electric Vehicles (BEVs) are increasingly adopted as sustainable alternatives to shift fossil fuel reliance. However, because of battery dependence, their heating systems face significant efficiency losses due to frost formation on heat exchangers in cold climates. This study investigates a capacitance-based sensing approach to detect ice buildup on automotive heat exchangers, aiming to optimize thermal management and reduce unnecessary energy consumption.
Capacitive sensors, which detect changes in dielectric properties due to ice formation, are evaluated through simulation and experimental testing. Multiple sensor topologies, configurations, and materials are proposed and analyzed, including parallel plates of different materials (copper and aluminum) and a rectangular copper mesh sheet. Simulations using COMSOL Multiphysics assessed electric field distributions and capacitance response to dielectric property changes, while icing behavior simulations analyzed the thermal impact of integrating sensors into the radiator structure. The influence of environmental factors such as relative humidity and airflow is also modeled.
Experiments are conducted in a controlled climate chamber by adjusting the relative humidity (80-90%), ambient temperature (1-2 ℃), and coolant flow (15 liters/minute) with a temperature of -15℃ to examine the sensor design’s performance on the heat exchanger. A camera is used to capture the ice formation phenomena, and capacitance reading data is collected to show the capacitance change value during frost formation and defrost. Among the tested configurations, copper mesh sensors demonstrated higher sensitivity and coverage, while parallel plate sensors offered more stable and localized measurements.
The results provide insights into the feasibility of using capacitive sensors to detect ice formation on heat exchangers to be monitored and integrated with thermal management systems. Thus, it enables dynamic defrosting strategies that can potentially improve energy efficiency and extend the driving range in BEVs under cold weather conditions. (Less) - Popular Abstract
- Can a car detect frost or ice before it actually freezes? This project explores how capacitive sensors can be feasible to monitor ice formation on car heat exchangers, potentially preventing against loss of efficiency.
Modern hybrid and electric vehicles rely on compact but effective heat exchangers to manage thermal loads. In cold and humid conditions, frost can silently build up and accumulate on these components, affecting the performance and, in severe cases, totally blocking airflow. Detecting this frost early is crucial, but current solutions are either too slow or too expensive.
In this thesis, we investigated a low-cost and reliable method: using capacitive sensors to detect water and ice formation on heat exchangers. Capacitance... (More) - Can a car detect frost or ice before it actually freezes? This project explores how capacitive sensors can be feasible to monitor ice formation on car heat exchangers, potentially preventing against loss of efficiency.
Modern hybrid and electric vehicles rely on compact but effective heat exchangers to manage thermal loads. In cold and humid conditions, frost can silently build up and accumulate on these components, affecting the performance and, in severe cases, totally blocking airflow. Detecting this frost early is crucial, but current solutions are either too slow or too expensive.
In this thesis, we investigated a low-cost and reliable method: using capacitive sensors to detect water and ice formation on heat exchangers. Capacitance is a property that changes when the surrounding material (like air, water, or ice) also changes. By measuring these changes, the system can identify when frost is beginning to form.
Several sensor forms are designed and tested such as parallel plate capacitors and interdigitated designs, and their response to frost is evaluated in a range of environmental conditions. Simulations are used to understand how electric fields behave in the presence of water or ice, and how sensor geometry and placement affect sensitivity. This thesis also explores how parasitic capacitance and electromagnetic interference caused by long wires and the test setup can reduce signal quality.
The results showed that electrode shape, placement, and insulation materials influence sensor performance. For example, water near the edge of a sensor causes a bigger capacitance change than water at the center, due to stronger electric fields at the edges. In addition, a mesh-type sensor design is also proposed that preserves heat transfer while maintaining good detection capability.
This sensing technology can be integrated into future vehicles, developing smarter climate control systems that react before frost becomes a problem. With better detection, efficiency can be enhanced, and passenger comfort, even on the coldest days, can be ensured. (Less)
Please use this url to cite or link to this publication:
http://lup.lub.lu.se/student-papers/record/9198029
- author
- Hafiezha, Fadhiela Noer LU and Wu, Kunjing LU
- supervisor
-
- Avo Reinap LU
- organization
- course
- MVKM05 20251
- year
- 2025
- type
- H2 - Master's Degree (Two Years)
- subject
- keywords
- Battery Electric Vehicles (BEVs), Heat Exchangers, Frost Detection, Capacitance Sensor
- report number
- ISRN LUTMDN/TMHP-25/5617-SE
- ISSN
- 0282-1990
- language
- English
- id
- 9198029
- date added to LUP
- 2025-06-16 14:11:30
- date last changed
- 2025-06-16 14:11:30
@misc{9198029,
abstract = {{Battery Electric Vehicles (BEVs) are increasingly adopted as sustainable alternatives to shift fossil fuel reliance. However, because of battery dependence, their heating systems face significant efficiency losses due to frost formation on heat exchangers in cold climates. This study investigates a capacitance-based sensing approach to detect ice buildup on automotive heat exchangers, aiming to optimize thermal management and reduce unnecessary energy consumption.
Capacitive sensors, which detect changes in dielectric properties due to ice formation, are evaluated through simulation and experimental testing. Multiple sensor topologies, configurations, and materials are proposed and analyzed, including parallel plates of different materials (copper and aluminum) and a rectangular copper mesh sheet. Simulations using COMSOL Multiphysics assessed electric field distributions and capacitance response to dielectric property changes, while icing behavior simulations analyzed the thermal impact of integrating sensors into the radiator structure. The influence of environmental factors such as relative humidity and airflow is also modeled.
Experiments are conducted in a controlled climate chamber by adjusting the relative humidity (80-90%), ambient temperature (1-2 ℃), and coolant flow (15 liters/minute) with a temperature of -15℃ to examine the sensor design’s performance on the heat exchanger. A camera is used to capture the ice formation phenomena, and capacitance reading data is collected to show the capacitance change value during frost formation and defrost. Among the tested configurations, copper mesh sensors demonstrated higher sensitivity and coverage, while parallel plate sensors offered more stable and localized measurements.
The results provide insights into the feasibility of using capacitive sensors to detect ice formation on heat exchangers to be monitored and integrated with thermal management systems. Thus, it enables dynamic defrosting strategies that can potentially improve energy efficiency and extend the driving range in BEVs under cold weather conditions.}},
author = {{Hafiezha, Fadhiela Noer and Wu, Kunjing}},
issn = {{0282-1990}},
language = {{eng}},
note = {{Student Paper}},
title = {{Development and Evaluation of Ice Detection Methods for Automotive Heat Exchangers Using Capacitance Measurement}},
year = {{2025}},
}