Measurement techniques and models for integrated thermal management and control in electric vehicle design

The persistent rise in global pollution, primarily due to conventional gasoline vehicles, necessitates a shift to sustainable transportation options. Electric vehicles (EVs) offer a clean solution but face challenges, including limited driving range. A crucial aspect affecting EV performance is their thermal management system (TMS), vital for passenger comfort and subsystem operation. This study focuses on the Electric Thermal Management (e.TM) system in EVs, aiming to enhance efficiency by integrating various thermal regulation systems. It explores the impact of cabin air recirculation on HVAC energy consumption and CO2 levels, utilizing real-time measurements from a crane cabin. The e.TM system adapts thermal regulation to meet cabin, battery, and electronic control unit needs, improving vehicle performance in diverse environments. Simulations using the Simscape platform evaluate two secondary loop layouts, emphasizing optimal waste heat recovery, particularly in colder conditions. An Intelligent Valve system and a variable PI controller for the heat pumps's compressor ensure precise temperature control across vehicle subsystems. A Hardware-in-the-Loop (HIL) system combines real heat pump testing with simulation models to evaluate TMS control logic. Despite hardware limitations, the HIL system shows promise for accurate testing, aiding the development of EV thermal management systems.