integrated vehicle thermal management – combining fluid ... · •march 2013 to march 2014 –...
TRANSCRIPT
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NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
U.S .Department of Energy Annual Merit Review P.I.: John P. Rugh Presenter: Daniel Leighton National Renewable Energy Laboratory June 17, 2014
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
Integrated Vehicle Thermal Management – Combining Fluid Loops in Electric Drive Vehicles
Project ID: VSS046 1
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Overview
Project Start Date: FY11 Project End Date: FY14 Percent Complete: 80%
• Complexity: integrated multi-valve system for multiple thermal loads
• Low temperature operation: cabin heating at very low temperatures
• Front-end heat exchanger frosting: heat pumping below 0°
C ambient
Total Project Funding (to date): $ 1,575 K * Funding for FY13: $ 575 K * Funding for FY14: $ 250 K Partner In-Kind Cost Share: $ 375 K **
Timeline
Budget
Barriers
• Interactions/collaborations: o Delphi o Halla Visteon Climate Control
• Project Lead: NREL
Partners
* Shared funding between VTO programs: VSST, APEEM, ESS ** Not included in total
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Relevance: Project Objectives • Combine electric drive vehicle (EDV) fluid loops to
reduce weight, cost, and energy consumption • Integrated thermal solution to increase EDV range
at national level
• Recent focus: bench testing ESS = energy storage system PEEM = power electronics and electric motors
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Relevance: Support Broad VTO Efforts
• DOE VTO Multi-Year Program Plan o “… development of advanced vehicles and
components to maximize vehicle efficiency …”
• EV Everywhere Grand Challenge o A goal of EV Everywhere is to have automobile
manufacturers produce a car with sufficient range that meets consumers’ daily transportation needs
• Combined Fluid Loop (CFL) Project o Develop CFL system to maximize vehicle
efficiency and range by reducing auxiliary loads and improving battery thermal management
VTO = Vehicle Technologies Office
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Relevance: VTO Integration
Vehicle Systems
Lee Slezak David Anderson
Energy Storage
Tien Duong Brian Cunningham
Peter Faguy
Power Electronics & Electric Motors
Susan Rogers Steven Boyd
Hybrid Electric Systems Dave Howell – Program
Manager
Vehicle electric powertrain model
Power electronics and electric motor thermal models
Battery thermal and efficiency models
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Approach/Strategy: Overview
• Evaluate with 1-D thermal model • Bench test verification of performance and address
technical barriers • Collaborate with industry on vehicle-level
demonstration
Modeling (FY11 & FY12)
Bench Testing (FY13 & FY14)
Vehicle Testing (Future)
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Approach/Strategy: Challenges
• Investigate performance over wide range of conditions
• Enable heat pump operation and waste heat recovery
• Identify efficiency versus complexity trade-offs to develop solutions for cost reduction and EDV range improvement
*ANL climate chamber dynamometer testing of stock 2012 Nissan Leaf
Impact of Temperature on Range
ANL = Argonne National Laboratory AVTA = Advanced Vehicle Testing Activity
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Milestones
Month/Year Description
Q3 June 2014
Milestone: • Complete modifications of bench test apparatus for cold
weather operation and test the CFL concept in a cold environmental chamber
Q4 Sept. 2014
Milestone: • Submit a summary of the project results in the DOE annual
report format
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Technical Accomplishments and Progress: Overview
• March 2013 to March 2014 – Bench testing o Constructed bench test apparatus o Integrated vehicle, power electronics, electric motor,
battery, and cabin models into LabVIEW data acquisition and control system
o Constructed CFL system using prototype heat exchangers from Delphi and an electric compressor from HVCC
o Completed hot weather steady-state testing o Near completion of hot weather drive-cycle testing
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Outdoor Simulator
Cabin Simulator
Conditioned: T and
Fron
t-end
W
EG-to
-air
HX
Expansion tanks
Refrigerant
Air WEG
AC
PEEM/PTC Simulator
T
T
T,RH
Cab
in
Coo
ler
Cab
in
Hea
ter
Valve System
AC
ESS Simulator
T,RH
T,RH
Con
dens
er
Evap
orat
or
• Designed for hardware-in-the-loop drive cycle testing with vehicle load simulation
HX = heat exchanger PTC = positive temperature coefficient WEG = water/ethylene glycol
Technical Accomplishments and Progress: Test Apparatus
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PEEM
ESS
S
Var.
Var.
S
S
S
Comp
Evaporator
Liquid
Liquid
Condenser
PTC Heater
S
Front-end WEG-to-air
HX Var.
Refrigerant
Air WEG
Vehicle Cabin
Cabin
Heater
Cabin
Cooler
S
S
• Allows multiple configuration strategies, including waste heat recovery and heat pumping
Technical Accomplishments and Progress: CFL System
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• Most important technical accomplishment was successful design, construction, and operation of CFL test bench
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Technical Accomplishments and Progress: Test Apparatus
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• Stable system operation, reasonable energy balances and errors, and performance meeting expectations
Technical Accomplishments and Progress: Steady-State Cooling
COP = coefficient of performance
Condenser
Evaporator
Compressor
COP
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*Preliminary Results
• Cabin pull-down penalty due to experiment thermal mass – real system more compact UDDS = Urban Dynamometer
Driving Schedule
Technical Accomplishments and Progress: Drive Cycle Cooling
Vent Outlet
Cooler WEG Inlet
Cabin Mass
Cabin Air
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*Preliminary Results
• PEEM temperatures within thermal limits, ESS control strategy needs further investigation HWFET = Highway Fuel
Economy Driving Schedule
Technical Accomplishments and Progress: Drive Cycle Cooling
Battery
Power Electronics
Electric Motor
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*Preliminary Results
-11% -0.3% -2.6%
Technical Accomplishments and Progress: Drive Cycle Cooling
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*Preliminary Results
-11% -26% -16% -0.3% -2.6% -0.5%
-5.5% -0.4% -4.2%
Technical Accomplishments and Progress: Drive Cycle Cooling
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*Preliminary Results
• PEEM cooling <1% penalty to range, ESS cooling penalty significant at higher ambient temperatures
-11% -34% -26% -16% -0.3% -2.6% -0.5%
-5.5% -0.4% -4.2% -3.5%
-0.8%
Technical Accomplishments and Progress: Drive Cycle Cooling
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Responses to FY13 AMR Reviewers’ Comments
Comment: Consider defog and defrost
Response: • Without vehicle cabin, direct testing is not possible, but heating capacity matches conventional vehicle
• If vehicle test is pursued, direct evaluation is possible Comment: Collaborate with vehicle OEM
Response: • Bench testing in close collaboration with Delphi • Interest from Delphi and a vehicle OEM to develop technology for
vehicle demonstration Comment: Characterize baseline for “extreme” environments Response: • Bench testing at ambient temperatures from -30°C to 43°C
OEM = original equipment manufacturer
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Collaboration: Delphi
• Delphi provided prototype refrigerant-to-coolant, and coolant-to-air heat exchangers
Flow Meter
Condenser
Sub-cooler
Chiller
Suction
Discharge
Front-end Heat Exchanger
Cooler Core Heater Core
Receiver/Dryer
TEV 6
7
8
9
TEV = thermostatic expansion valve
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Collaboration: Halla Visteon Climate Control
• Halla Visteon Climate Control provided high-voltage DC electric compressor capable of heat pump operation
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Collaboration: Summary
• Industry o Delphi o Halla Visteon Climate Control
• VTO Tasks o Advanced Power Electronics and Electric Motors
– PEEM thermal models
o Vehicle Systems – FASTSim vehicle powertrain model
o Energy Storage Systems – Battery thermal and efficiency (voltage vs. temperature) models
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Remaining Challenges and Barriers
• Complexity o Must define trade-offs between complexity and efficiency
for industry buy-in
• Low temperature operation o Cold weather testing must demonstrate sufficient heat
pump performance when supplemented with waste heat
• Front-end heat exchanger frosting o Testing must measure impact of hot coolant defrost cycling
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Proposed Future Work
• Remainder of FY14 o Complete hot weather drive cycle testing o Conduct cold weather drive cycle testing o Identify best practices for system design and control o Analyze technology impact on EDV range and thermal
management
• FY15 and beyond o Work with industry partners (suppliers
and an OEM) to demonstrate technology at vehicle level
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Summary
• Designed and built test apparatus to validate potential of CFL to reduce cost, weight, and volume of thermal system while increasing vehicle range
• Hot weather testing almost complete, cold weather testing to begin soon
• Looking to work with industry partners on a vehicle-level demonstration to develop the technology and reduce national energy consumption
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Acknowledgments and Contacts
Special thanks to: Vehicle Technologies Office U.S. Department of Energy Lee Slezak David Anderson
Industry collaborations: Delphi Halla Visteon Climate Control
NREL Team: Kevin Bennion Cory Kreutzer Daniel Leighton John P. Rugh Jeff Tomerlin
For more information: Daniel Leighton National Renewable Energy Laboratory [email protected] 303-275-4489 John P. Rugh National Renewable Energy Laboratory [email protected] 303-275-4413
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Photograph Credits 1) Daniel Leighton, NREL 2) John P. Rugh, NREL 3) Daniel Leighton, NREL 4) Mike Simpson, NREL 5) Daniel Leighton, NREL 6) Daniel Leighton, NREL 7) Daniel Leighton, NREL 8) Daniel Leighton, NREL 9) Daniel Leighton, NREL 10) Daniel Leighton, NREL
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Technical Back-Up Slides
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Cooling Mode (Active ESS Cooling)
PEEM
ESS
Comp
Evaporator
Liquid
Liquid
Condenser
Front-end WEG-to-air
HX
Refrigerant
Air WEG
Vehicle Cabin
Cabin
Cooler
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Cooling Mode (Passive ESS Cooling)
PEEM
ESS
Comp
Evaporator
Liquid
Liquid
Condenser
Front-end WEG-to-air
HX
Refrigerant
Air WEG
Vehicle Cabin
Cabin
Cooler
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“Free” Cooling Mode
PEEM Liquid
Var.
Refrigerant
Air WEG
Vehicle Cabin
ESS Front-end
WEG-to-air HX
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Mild Heating Mode (Only Heat Recovery)
PEEM Liquid
Front-end WEG-to-air
HX Var.
Refrigerant
Air WEG
Vehicle Cabin
Var.
Cabin
Heater
ESS
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Heating Mode
PEEM
ESS
Var.
Comp
Evaporator
Liquid
Liquid
Condenser
PTC Heater
Front-end WEG-to-air
HX
Refrigerant
Air WEG
Vehicle Cabin
Cabin
Heater
Cabin
Cooler