Combining Fluid Loops in Electric Drive Vehicles - Department of ...
Combining Fluid Loops in Electric Drive Vehicles - Department of ...
Combining Fluid Loops in Electric Drive Vehicles - Department of ...
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Integrated Vehicle Thermal Management –<br />
<strong>Comb<strong>in</strong><strong>in</strong>g</strong> <strong>Fluid</strong> <strong>Loops</strong> <strong>in</strong> <strong>Electric</strong> <strong>Drive</strong> <strong>Vehicles</strong><br />
John P. Rugh<br />
National Renewable Energy Laboratory<br />
May 15, 2013<br />
Project ID: APE052<br />
This presentation does not conta<strong>in</strong> any proprietary, confidential, or otherwise restricted <strong>in</strong>formation.<br />
NREL is a national laboratory <strong>of</strong> the U.S. <strong>Department</strong> <strong>of</strong> Energy, Office <strong>of</strong> Energy Efficiency and Renewable Energy, operated by the Alliance for Susta<strong>in</strong>able Energy, LLC.
Overview<br />
Timel<strong>in</strong>e<br />
Project Start Date: FY11<br />
Project End Date: FY14<br />
Percent Complete: 50%<br />
Budget<br />
Total Project Fund<strong>in</strong>g (to date): $ 1225 K *<br />
Fund<strong>in</strong>g received prior to FY13: $ 750 K *<br />
Fund<strong>in</strong>g for FY13: $ 475 K *<br />
Partner In-K<strong>in</strong>d Cost Share: $ 300 K **<br />
* Shared fund<strong>in</strong>g between VTO programs: VSST, APEEM, ESS<br />
** Not <strong>in</strong>cluded <strong>in</strong> total<br />
Barriers (to EDVs)<br />
• Cost – cool<strong>in</strong>g loop components<br />
• Life – thermal effects on energy<br />
storage system (ESS) and advanced<br />
power electronics and electric<br />
motors (APEEM)<br />
• Weight – additional cool<strong>in</strong>g loops <strong>in</strong><br />
electric drive vehicles (EDVs)<br />
Partners<br />
• Interactions/ collaborations<br />
– Delphi<br />
– Halla Visteon Climate Control<br />
– Magna Powertra<strong>in</strong> - Eng<strong>in</strong>eer<strong>in</strong>g<br />
Center Steyr<br />
– Ford<br />
• Project Lead<br />
– National Renewable Energy<br />
Laboratory<br />
2
Relevance - The PHEV/EV Thermal Challenge<br />
1<br />
• Plug-<strong>in</strong> hybrid electric vehicles (PHEVs) and<br />
electric vehicles (EVs) have <strong>in</strong>creased vehicle<br />
thermal management complexity<br />
o Separate coolant loop for advanced power electronics<br />
and electric motors (APEEM)<br />
o Thermal requirements for energy storage systems<br />
(ESS)<br />
• Additional thermal components result <strong>in</strong> higher<br />
costs<br />
• Multiple cool<strong>in</strong>g loops lead to reduced range<br />
due to<br />
o Increased weight<br />
o Energy required to meet thermal<br />
requirements<br />
2<br />
3
Relevance<br />
• Support broad VTO efforts<br />
o<br />
o<br />
DOE VTO MYPP<br />
– “…..development <strong>of</strong> advanced vehicles and components to maximize vehicle<br />
efficiency …..”<br />
– This projects seeks to maximize vehicle efficiency by develop<strong>in</strong>g comb<strong>in</strong>ed<br />
cool<strong>in</strong>g loop solutions to reduce parasitic power, improved battery<br />
temperature, and <strong>in</strong>crease range.<br />
President’s EV-Everywhere Grand Challenge<br />
– A goal <strong>of</strong> EV Everywhere is to have automobile manufacturers produce a car<br />
with sufficient range that meets consumer’s daily transportation needs.<br />
– This project is research<strong>in</strong>g techniques to reduce vehicle thermal management<br />
power and improve range.<br />
• Task Objective<br />
o<br />
o<br />
Collaborate with <strong>in</strong>dustry partners to research the synergistic benefits<br />
<strong>of</strong> comb<strong>in</strong><strong>in</strong>g thermal management systems <strong>in</strong> vehicles with electric<br />
powertra<strong>in</strong>s<br />
Solve vehicle-level heat transfer problems, which will enable<br />
acceptance <strong>of</strong> electric drive vehicles<br />
4
Approach/Strategy<br />
• Research benefits <strong>of</strong> comb<strong>in</strong><strong>in</strong>g EV<br />
thermal management systems<br />
• Develop solutions to comb<strong>in</strong>e<br />
vehicle-level cool<strong>in</strong>g systems<br />
• Improve vehicle performance (fuel<br />
use or EV range) and reduce cost<br />
• Reduce APEEM coolant loop<br />
temperature (to less than 105°C)<br />
without requir<strong>in</strong>g a dedicated<br />
system<br />
3<br />
4<br />
5<br />
5
Overall Approach<br />
• Build a 1-D thermal model<br />
(us<strong>in</strong>g KULI s<strong>of</strong>tware)<br />
• Conduct bench tests to verify<br />
performance and identify<br />
viable hardware solutions<br />
• Collaborate with automotive<br />
manufacturers and suppliers<br />
on a vehicle-level project<br />
6<br />
6
Approach/Strategy - Integration Between Vehicle<br />
Technology Programs<br />
Hybrid <strong>Electric</strong> Systems<br />
Dave Howell – Team Lead<br />
Vehicle Systems<br />
Lee Slezak<br />
David Anderson<br />
Energy Storage<br />
Tien Duong<br />
Brian Cunn<strong>in</strong>gham<br />
Peter Faguy<br />
Power Electronics<br />
& <strong>Electric</strong> Motors<br />
Susan Rogers<br />
Steven Boyd<br />
7<br />
<strong>Electric</strong> range and fuel consumption<br />
Battery temperature and life<br />
APEEM temperatures<br />
7
Approach - Milestones<br />
Month<br />
/ Year<br />
Sept/12<br />
Sept/13<br />
Description<br />
Milestone<br />
• Identified advantages <strong>of</strong> comb<strong>in</strong><strong>in</strong>g fluid loops and strategies for<br />
bench test<strong>in</strong>g<br />
Go/No-Go<br />
• Based on the successful outcome <strong>of</strong> analysis <strong>of</strong> the thermal<br />
management system concepts, build a bench test facility to<br />
evaluate comb<strong>in</strong>ed cool<strong>in</strong>g loop strategies<br />
Milestone<br />
• Evaluate comb<strong>in</strong>ed cool<strong>in</strong>g loop system performance dur<strong>in</strong>g<br />
cool<strong>in</strong>g mode us<strong>in</strong>g bench test<strong>in</strong>g<br />
Go/No-Go<br />
• Based on bench test results, design a vehicle-level test that can<br />
demonstrate vehicle system level performance us<strong>in</strong>g a comb<strong>in</strong>ed<br />
cool<strong>in</strong>g loop system<br />
8
Accomplishments<br />
Improvements to Basel<strong>in</strong>e Models (March/12 – March/13)<br />
• Improved air condition<strong>in</strong>g (A/C) compressor control<br />
– Blower speed<br />
– Compressor rpm<br />
– The control state is determ<strong>in</strong>ed by the ambient environment, target<br />
temperatures, and the component temperatures.<br />
– Developed control logic with anti-w<strong>in</strong>dup<br />
• Added <strong>in</strong>verter model (based on feedback from <strong>Electric</strong>al<br />
and Electronics Technical Team)<br />
• Updated battery thermal model based on review with the NREL ESS<br />
group (battery properties and thermal performance)<br />
• Added ability to heat battery coolant to improve warmup<br />
• Created component models for cab<strong>in</strong> heater core and electrical fluid<br />
heater for cab<strong>in</strong> heat<strong>in</strong>g<br />
• Built a cab<strong>in</strong> heat<strong>in</strong>g loop<br />
• Added controls for battery temperature<br />
– Pump speed<br />
– Valve position<br />
– Developed control logic with anti-w<strong>in</strong>dup proportional <strong>in</strong>tegrator controllers<br />
9
EV Basel<strong>in</strong>e Thermal Management System<br />
Air<br />
Air<br />
<strong>Electric</strong><br />
Heater<br />
Air<br />
Comp<br />
Air<br />
ESS Heat Exchanger<br />
Condenser<br />
PEEM Heat Exchanger<br />
Heater Core<br />
Evaporator<br />
Vehicle Cab<strong>in</strong><br />
Heat Exchanger<br />
Liquid to Refrigerant<br />
• Multiple operat<strong>in</strong>g modes<br />
Bypass<br />
Battery Case<br />
Power<br />
Electronics<br />
and Motor<br />
Heater<br />
Cells<br />
10
EV Basel<strong>in</strong>e Thermal Management System<br />
• Hot Cooldown<br />
Air<br />
Air<br />
<strong>Electric</strong><br />
Heater<br />
Comp<br />
Air<br />
ESS Heat Exchanger<br />
Condenser<br />
PEEM Heat Exchanger<br />
Heater Core<br />
Evaporator<br />
Vehicle Cab<strong>in</strong><br />
Heat Exchanger<br />
Liquid to Refrigerant<br />
• Battery or ESS cooled with<br />
chiller<br />
Bypass<br />
Battery Case<br />
Power<br />
Electronics<br />
and Motor<br />
• Cab<strong>in</strong> cool<strong>in</strong>g provided with<br />
conventional A/C system<br />
Heater<br />
Cells<br />
11
EV Basel<strong>in</strong>e Thermal Management System<br />
• Mild Cooldown<br />
Air<br />
Air<br />
<strong>Electric</strong><br />
Heater<br />
Comp<br />
Air<br />
ESS Heat Exchanger<br />
Condenser<br />
PEEM Heat Exchanger<br />
Heater Core<br />
Evaporator<br />
Vehicle Cab<strong>in</strong><br />
Heat Exchanger<br />
Liquid to Refrigerant<br />
• Battery or ESS cooled with<br />
radiator<br />
Bypass<br />
Battery Case<br />
Power<br />
Electronics<br />
and Motor<br />
Heater<br />
Cells<br />
12
EV Basel<strong>in</strong>e Thermal Management System<br />
• Cold Warmup<br />
Air<br />
Air<br />
<strong>Electric</strong><br />
Heater<br />
Air<br />
Comp<br />
Air<br />
ESS Heat Exchanger<br />
Condenser<br />
PEEM Heat Exchanger<br />
Heater Core<br />
Evaporator<br />
Vehicle Cab<strong>in</strong><br />
Heat Exchanger<br />
Liquid to Refrigerant<br />
• <strong>Electric</strong> heater for cab<strong>in</strong> heat<strong>in</strong>g<br />
(5-7 kW for small vehicle)<br />
Bypass<br />
Battery Case<br />
Power<br />
Electronics<br />
and Motor<br />
• <strong>Electric</strong> heater for battery or<br />
ESS heat<strong>in</strong>g (1 kW)<br />
Heater<br />
Cells<br />
13
Basel<strong>in</strong>e EV Thermal Management System<br />
EV Test Case at Four Ambient Temperatures<br />
• 24-kWh EV<br />
• Environment<br />
– 43 o C, 35 o C, 30 o C, 25 o C<br />
– 25% relative humidity<br />
– 850 W/m 2<br />
• 0% recirculation<br />
• US06 drive cycle<br />
• Cooldown simulation<br />
from a hot soak<br />
• ESS – cool<strong>in</strong>g loop<br />
with chiller and low<br />
temperature radiator<br />
• Waste heat load from<br />
FASTSim simulations<br />
8<br />
14
Basel<strong>in</strong>e System<br />
Total Vehicle Thermal Management Power Includ<strong>in</strong>g Compressor, Fans, Blowers, Pumps<br />
Hotter ambient temperatures<br />
require more power<br />
Power drops <strong>of</strong>f when battery cell<br />
temperature reaches control level<br />
A/C evaporator antifreeze control<br />
limits A/C compressor power<br />
Less power required with radiator cool<strong>in</strong>g <strong>of</strong> the battery<br />
15
Comb<strong>in</strong>ed System<br />
<strong>Comb<strong>in</strong><strong>in</strong>g</strong> APEEM and ESS Cool<strong>in</strong>g <strong>Loops</strong><br />
Radiator<br />
WEG Coolant Loop Distribution System<br />
Liquid<br />
Condenser<br />
Refrigerant<br />
Refrigerant<br />
Liquid<br />
Comp<br />
Evaporator<br />
<strong>Electric</strong> <strong>Drive</strong> WEG<br />
Cool<strong>in</strong>g System<br />
Power<br />
Electronics and<br />
Motor<br />
Battery<br />
Vehicle Cab<strong>in</strong><br />
Cab<strong>in</strong><br />
Cooler<br />
Cab<strong>in</strong><br />
Heater<br />
Air<br />
Air<br />
Cells<br />
<strong>Electric</strong> Heater<br />
WEG = Water/Ethylene Glycol<br />
16
Comb<strong>in</strong>ed System – Configuration 1<br />
<strong>Comb<strong>in</strong><strong>in</strong>g</strong> APEEM and ESS Cool<strong>in</strong>g <strong>Loops</strong><br />
Radiator<br />
WEG Coolant Loop Distribution System<br />
Liquid<br />
Condenser<br />
Refrigerant<br />
Refrigerant<br />
Liquid<br />
Comp<br />
Evaporator<br />
<strong>Electric</strong> <strong>Drive</strong> WEG<br />
Cool<strong>in</strong>g System<br />
Power<br />
Electronics and<br />
Motor<br />
Battery<br />
• Enables use <strong>of</strong> APEEM<br />
waste heat for ESS<br />
heat<strong>in</strong>g<br />
Vehicle Cab<strong>in</strong><br />
Cab<strong>in</strong><br />
Cooler<br />
Cab<strong>in</strong><br />
Heater<br />
Air<br />
Air<br />
Cells<br />
<strong>Electric</strong> Heater<br />
WEG = Water/Ethylene Glycol<br />
17
Comb<strong>in</strong>ed System – Configuration 2<br />
<strong>Comb<strong>in</strong><strong>in</strong>g</strong> APEEM and Cab<strong>in</strong> Heat<strong>in</strong>g <strong>Loops</strong><br />
Radiator<br />
WEG Coolant Loop Distribution System<br />
Liquid<br />
Condenser<br />
Refrigerant<br />
Refrigerant<br />
Liquid<br />
Comp<br />
Evaporator<br />
<strong>Electric</strong> <strong>Drive</strong> WEG<br />
Cool<strong>in</strong>g System<br />
Power<br />
Electronics and<br />
Motor<br />
Battery<br />
• Enables use <strong>of</strong> APEEM<br />
waste heat for ESS<br />
heat<strong>in</strong>g or cab<strong>in</strong> heat<strong>in</strong>g<br />
Vehicle Cab<strong>in</strong><br />
Cab<strong>in</strong><br />
Cooler<br />
Cab<strong>in</strong><br />
Heater<br />
Air<br />
Air<br />
Cells<br />
<strong>Electric</strong> Heater<br />
WEG = Water/Ethylene Glycol<br />
18
Warmup: Auxiliary Load Power<br />
VTM Power Reduced by Us<strong>in</strong>g APEEM Waste Heat<br />
Configuration 1 (APEEM and ESS)<br />
Basel<strong>in</strong>e:<br />
• 7-kW cab<strong>in</strong> heater<br />
• 1-kW ESS auxiliary electric heater<br />
APEEM and ESS:<br />
• 7-kW cab<strong>in</strong> heater<br />
• 1-kW ESS auxiliary electric heater <strong>of</strong>f<br />
• ESS warmup supplemented by APEEM waste heat<br />
19
Warmup: Auxiliary Load Power<br />
VTM Power Reduced by Us<strong>in</strong>g APEEM Waste Heat<br />
Configuration 1 (APEEM and ESS) and Configuration 2 (APEEM and Cab<strong>in</strong> Heat<strong>in</strong>g)<br />
Basel<strong>in</strong>e:<br />
• 7-kW cab<strong>in</strong> heater<br />
• 1-kW ESS auxiliary electric heater<br />
APEEM and ESS:<br />
• 7-kW cab<strong>in</strong> heater<br />
• 1-kW ESS auxiliary electric heater <strong>of</strong>f<br />
• ESS warmup supplemented by APEEM waste heat<br />
APEEM and Cab<strong>in</strong>:<br />
• 5.8-kW cab<strong>in</strong> heater<br />
• 1-kW ESS auxiliary electric heater<br />
• Cab<strong>in</strong> warmup supplemented by APEEM waste heat<br />
20
Warmup: Cab<strong>in</strong> Heater <strong>Fluid</strong> Temperature<br />
Cab<strong>in</strong> Heater <strong>Fluid</strong> Temperatures Are Very Similar<br />
Configuration 1 (APEEM and ESS) and Configuration 2 (APEEM and Cab<strong>in</strong> Heat<strong>in</strong>g)<br />
21
Warmup: Average Cab<strong>in</strong> Air Temperature<br />
Cab<strong>in</strong> Air Temperatures Are the Same While Us<strong>in</strong>g Less <strong>Electric</strong>al Power<br />
Configuration 1 (APEEM and ESS) and Configuration 2 (APEEM and Cab<strong>in</strong> Heat<strong>in</strong>g)<br />
Passenger comfort was not degraded<br />
22
Warmup: Battery Temperature<br />
Battery Is Warmer with APEEM Waste Heat<br />
Configuration 1 (APEEM and ESS) and Configuration 2 (APEEM and Cab<strong>in</strong> Heat<strong>in</strong>g)<br />
Better battery performance<br />
23
Warmup: APEEM Coolant Temperature<br />
APEEM Coolant Temperature Is Under The Limit (
Comb<strong>in</strong>ed System – Configuration 3<br />
Liquid Cooled Condenser<br />
Radiator<br />
WEG Coolant Loop Distribution System<br />
Liquid<br />
Condenser<br />
Refrigerant<br />
Refrigerant<br />
Liquid<br />
Comp<br />
Evaporator<br />
<strong>Electric</strong> <strong>Drive</strong> WEG<br />
Cool<strong>in</strong>g System<br />
Power<br />
Electronics and<br />
Motor<br />
Battery<br />
• Enables use <strong>of</strong> APEEM<br />
waste heat for ESS<br />
heat<strong>in</strong>g or cab<strong>in</strong> heat<strong>in</strong>g<br />
• Reduces front heat<br />
exchangers from 3 to 1<br />
us<strong>in</strong>g shared lowtemperature<br />
radiator<br />
Vehicle Cab<strong>in</strong><br />
Cab<strong>in</strong><br />
Cooler<br />
Cab<strong>in</strong><br />
Heater<br />
Air<br />
Air<br />
Cells<br />
<strong>Electric</strong> Heater<br />
WEG = Water/Ethylene Glycol<br />
25
Comb<strong>in</strong>ed System – Configuration 4<br />
Refrigerant to Liquid Evaporator (Secondary Loop)<br />
Radiator<br />
WEG Coolant Loop Distribution System<br />
Vehicle Cab<strong>in</strong><br />
Cab<strong>in</strong><br />
Cooler<br />
Cab<strong>in</strong><br />
Heater<br />
Liquid<br />
Condenser<br />
Refrigerant<br />
Refrigerant<br />
Liquid<br />
Air<br />
Air<br />
Comp<br />
Evaporator<br />
<strong>Electric</strong> <strong>Drive</strong> WEG<br />
Cool<strong>in</strong>g System<br />
Power<br />
Electronics and<br />
Motor<br />
Battery<br />
Cells<br />
<strong>Electric</strong> Heater<br />
• Enables use <strong>of</strong> APEEM<br />
waste heat for ESS<br />
heat<strong>in</strong>g or cab<strong>in</strong> heat<strong>in</strong>g<br />
• Reduces front heat<br />
exchangers from 3 to 1<br />
us<strong>in</strong>g shared lowtemperature<br />
radiator<br />
• S<strong>in</strong>gle chilled-liquid loop<br />
• Compatible with heat<br />
pump operation<br />
• Compact refrigerant loop<br />
WEG = Water/Ethylene Glycol<br />
26
Cooldown: Cab<strong>in</strong> Air Temperature<br />
Slightly Warmer Cab<strong>in</strong> Air (A/C Performance Not Significantly Impacted)<br />
Configurations 3 & 4 (Liquid-Cooled Condenser and Refrigerant to Liquid Evaporator – Secondary Loop)<br />
27
Cooldown: Battery Temperature<br />
Slightly Warmer Battery (But Still a Reasonable Cooldown)<br />
Configurations 3 & 4 (Liquid-Cooled Condenser and Refrigerant to Liquid Evaporator – Secondary Loop)<br />
A reasonably sized front<br />
heat exchanger can handle<br />
the APEEM, cab<strong>in</strong>, and ESS<br />
heat loads<br />
Battery cool<strong>in</strong>g performance<br />
is adequate with heat<br />
exchanger located<br />
downstream <strong>of</strong> the cab<strong>in</strong><br />
cool<strong>in</strong>g heat exchanger<br />
28
Cooldown: APEEM Coolant Temperature<br />
Lower APEEM Coolant Because Refrigerant to Air Condenser Is Elim<strong>in</strong>ated<br />
Configurations 3 & 4 (Liquid-Cooled Condenser and Refrigerant to Liquid Evaporator – Secondary Loop)<br />
Lower coolant temperature<br />
enables higher electric drive<br />
power<br />
29
Accomplishments – Bench Test<br />
• Developed prelim<strong>in</strong>ary comb<strong>in</strong>ed cool<strong>in</strong>g loop concept for test<strong>in</strong>g<br />
– Maximizes operat<strong>in</strong>g configurations and total system energy efficiency<br />
while m<strong>in</strong>imiz<strong>in</strong>g valves, pumps, and heat exchangers<br />
– Thermally conditions vehicle cab<strong>in</strong>, PE, EM, and ESS<br />
– Recovers PE, EM, and ESS waste heat when advantageous<br />
– Enables heat pump operation to reduce electrical resistance load<br />
• Significance<br />
– Unique vehicle thermal<br />
system configuration that<br />
focuses on maximiz<strong>in</strong>g<br />
vehicle range, occupant<br />
comfort, and component<br />
lifetime<br />
30
Accomplishments – Bench Test<br />
• Inventoried current test<strong>in</strong>g capabilities to determ<strong>in</strong>e what can be achieved<br />
– Maximized use <strong>of</strong> exist<strong>in</strong>g equipment and <strong>in</strong>frastructure<br />
• Designed prelim<strong>in</strong>ary bench test facility<br />
– Simulation <strong>of</strong> vehicle cab<strong>in</strong> response via a mathematical model, which controls<br />
<strong>in</strong>let air conditions to cab<strong>in</strong> heat exchangers<br />
– Replication <strong>of</strong> PE, EM, and ESS responses via mathematical models, which control<br />
component outlet coolant temperatures<br />
• Significance<br />
– Initiated bench-test<strong>in</strong>g phase <strong>of</strong><br />
task while m<strong>in</strong>imiz<strong>in</strong>g test<br />
facility upgrade cost<br />
31
Collaboration and Coord<strong>in</strong>ation with Other Institutions<br />
• Delphi<br />
• Halla Visteon Climate Control<br />
– Data<br />
– Eng<strong>in</strong>eer<strong>in</strong>g support<br />
• Magna Powertra<strong>in</strong> – Eng<strong>in</strong>eer<strong>in</strong>g Center Steyr<br />
– KULI s<strong>of</strong>tware<br />
– Eng<strong>in</strong>eer<strong>in</strong>g support<br />
• Ford<br />
– <strong>Electric</strong> Focus (loaned to NREL for the <strong>Electric</strong> <strong>Drive</strong> Vehicle<br />
Climate Control Load Reduction Task)<br />
• VTO Tasks<br />
– Advanced Power Electronics and <strong>Electric</strong> Motors<br />
– Vehicle Systems<br />
– Energy Storage<br />
32
Proposed Future Work<br />
• Rema<strong>in</strong>der <strong>of</strong> FY13<br />
– F<strong>in</strong>alize comb<strong>in</strong>ed cool<strong>in</strong>g loop design <strong>in</strong> conjunction with <strong>in</strong>dustry<br />
o<br />
Coord<strong>in</strong>ate with Delphi and Visteon on configuration and components<br />
– Construct bench test<strong>in</strong>g facility<br />
– Conduct bench test<strong>in</strong>g to evaluate comb<strong>in</strong>ed cool<strong>in</strong>g loop system<br />
performance dur<strong>in</strong>g cool<strong>in</strong>g mode<br />
– Validate previously built KULI models <strong>of</strong> comb<strong>in</strong>ed cool<strong>in</strong>g loop<br />
• FY14<br />
– Utilize exist<strong>in</strong>g bench test<strong>in</strong>g facility and experimental system to<br />
conduct heat<strong>in</strong>g mode test<strong>in</strong>g<br />
– Work with <strong>in</strong>dustry partners to design a vehicle-level test that can<br />
demonstrate vehicle system level performance when us<strong>in</strong>g a<br />
comb<strong>in</strong>ed cool<strong>in</strong>g loop system<br />
– Install experimental system and measurement equipment <strong>in</strong> a test<br />
EDV<br />
– Experimentally evaluate EDV performance to demonstrate the<br />
effect that the comb<strong>in</strong>ed cool<strong>in</strong>g loop has on electric vehicle<br />
range<br />
33
Summary<br />
• DOE Mission Support<br />
– <strong>Comb<strong>in</strong><strong>in</strong>g</strong> cool<strong>in</strong>g systems <strong>in</strong> EDVs may reduce costs and improve<br />
performance, which would accelerate consumer acceptance,<br />
<strong>in</strong>crease EDV usage, and reduce petroleum consumption.<br />
• Overall Approach<br />
– Build a thermal 1-D model (us<strong>in</strong>g KULI s<strong>of</strong>tware)<br />
o<br />
o<br />
APEEM, energy storage, eng<strong>in</strong>e, transmission, and passenger<br />
compartment thermal management systems<br />
Identify the synergistic benefits from comb<strong>in</strong><strong>in</strong>g the systems<br />
– Select the most promis<strong>in</strong>g comb<strong>in</strong>ed thermal management<br />
system concepts and perform a detailed performance assessment<br />
and bench top tests<br />
– Collaborate with automotive manufacturers and suppliers on a<br />
vehicle-level project<br />
– Solve vehicle-level heat transfer problems, which will enable<br />
acceptance <strong>of</strong> vehicles with electric powertra<strong>in</strong>s<br />
34
Summary (cont.)<br />
• Technical Accomplishments<br />
– Completed basel<strong>in</strong>e EV thermal systems model<br />
– Investigated comb<strong>in</strong>ed cool<strong>in</strong>g loop strategies<br />
– Identified advantages <strong>of</strong> comb<strong>in</strong><strong>in</strong>g fluid loops<br />
– Identified strategies for bench test<strong>in</strong>g<br />
• Collaborations<br />
– Collaborat<strong>in</strong>g closely with Delphi, Halla Visteon Climate Control, Magna<br />
Powertra<strong>in</strong> - Eng<strong>in</strong>eer<strong>in</strong>g Center Steyr, and Ford<br />
– Leverag<strong>in</strong>g previous DOE research<br />
o Battery life/thermal model<br />
o Vehicle cost/performance model<br />
o Lumped parameter motor thermal model<br />
– Co-fund<strong>in</strong>g by three VTO tasks demonstrates cross-cutt<strong>in</strong>g<br />
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Acknowledgments:<br />
David Anderson<br />
Steven Boyd<br />
Brian Cunn<strong>in</strong>gham<br />
David Howell<br />
Susan Rogers<br />
Lee Slezak<br />
Vehicle Technologies Office<br />
U.S. <strong>Department</strong> <strong>of</strong> Energy<br />
Team Members:<br />
Kev<strong>in</strong> Bennion<br />
Daniel Leighton<br />
Jeff Tomerl<strong>in</strong><br />
For more <strong>in</strong>formation, contact:<br />
Pr<strong>in</strong>cipal Investigator<br />
John Rugh<br />
john.rugh@nrel.gov<br />
Phone: (303)-275-4413<br />
APEEM Task Leader:<br />
Sreekant Narumanchi<br />
Sreekant.Narumanchi@nrel.gov<br />
Phone: (303)-275-4062
Photo Credits<br />
1. Matt Jeffers, NREL<br />
2. John Rugh, NREL<br />
3. Matt Jeffers, NREL<br />
4. John Rugh, NREL<br />
5. Michelle Rugh, Amateur Photographer<br />
6. Charlie K<strong>in</strong>g, NREL<br />
7. John Rugh, NREL<br />
8. John Rugh, NREL<br />
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