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Institut für Verbrennungsmotoren und Kraftfahrwesen
1 20.10.2014 Markus Auer
Simulation of a Battery Electric Vehicle
M. Auer, T. Kuthada, N. Widdecke, J. Wiedemann
IVK/FKFS University of Stuttgart
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2 20.10.2014 Markus Auer
Agenda
Motivation
Thermal Management for BEV
Simulation Model
Baseline Range
Optimizations of Thermal Management System
Preconditioning of Cabin
Summary
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Institut für Verbrennungsmotoren und Kraftfahrwesen
3 20.10.2014 Markus Auer
Motivation
Emission-free traveling
Limited range
Uncertain lifespan of battery
Smaller waste heat
HVAC of cabin
Smart thermal management
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Institut für Verbrennungsmotoren und Kraftfahrwesen
4
Components
Electric motor
Inverter
Cabin
Battery
Requirements
Limit max. temperature of
motor and inverter
Satisfy need for cabin
comfort
Condition battery to
operating range
20.10.2014 Markus Auer
Thermal Management for BEV
[3]
[1] [2]
[4]
[1] fotos.autozeitung.de
[2] eal.jku.at
[3] gwv-fachverlage.de
[4] autogenau.de
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5 20.10.2014 Markus Auer
Simulation Model - TheFaMoS
Matlab / Simulink
Heat flow
Speed of coolant pumps
AC compressor speed
Fan and blower speed
Vehicle velocity
Ambient conditions
GT-SUITE
Temperatures
Pump power
Compressor power
Blower power
Fan power
For reliable
prediction a
simulation tool
was developed
Co-Simulation
Matlab / Simulink
and GT-SUITE
Usage of test
bench results for
calibration
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6 20.10.2014 Markus Auer
Thermal Management System
AC HP AC LP Batt. Motor
C
o
n
d
E
v
a
p
HX
P
T
C
Chiller PTC
Batt
Charger Motor
H
T
/
L
T
C
H
X
Cond
p
p
p
Inverter
Bypass HT-LT
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Institut für Verbrennungsmotoren und Kraftfahrwesen
7 20.10.2014 Markus Auer
GT-SUITE Model
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8
dummyR
an
ge
/ k
m
25
35
45
55
65
75
85
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NEDC NYCC
20.10.2014 Markus Auer
Baseline Range
Range is determined with drive
until the battery is empty
NEDC and CADC similar
ranges
Range in FKFS cycle is slightly
lower
In very slow NYCC (Vave=11,4
km/h) the range is low due to
HVAC consumption
Trends of the range depending
on temperature are similar for
all cycles
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9
DR
an
ge
/ %
0
2
4
6
8
10
12
14
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NYCC NEDC
dummy
20.10.2014 Markus Auer
Circulating Air Quota (50%)
Speed control of the blower is
not changed
Usage of a mixer which is set
to approximately 50%
recirculating air
At -18°C and 35°C, the
benefits of recirculating air are
clearly visible
At 10°C and 25°C, the effect is
negligible
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Institut für Verbrennungsmotoren und Kraftfahrwesen
10
DR
an
ge
/ %
-10
-8
-6
-4
-2
0
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NYCC NEDC
dummy
20.10.2014 Markus Auer
Usage of Waste Heat to Heat the Cabin
The baseline uses a cabin
heat exchanger to use waste
heat from the motor circuit
If this usage is suppressed
and the heat deficit
compensated by the PTC and
the heat pump, the range
drops significantly
If a synchronous motor is
used, the effect is smaller
since the efficiency is higher
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Institut für Verbrennungsmotoren und Kraftfahrwesen
11
DR
an
ge
/ %
-7
-6
-5
-4
-3
-2
-1
0
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NYCC NEDC
dummy
20.10.2014 Markus Auer
Heat Pump
The baseline uses a heat
pump for the heating of the
cabin
If the heat pump is turned off
and the heat deficit is
compensated by the cabin heat
exchanger and the PTC, the
range decreases
The elimination of the heat
pump is more drastic than the
elimination of the cabin heat
exchanger
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Institut für Verbrennungsmotoren und Kraftfahrwesen
12
DR
an
ge
/ %
1.0
1.5
2.0
2.5
3.0
3.5
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NYCC NEDC
dummy
20.10.2014 Markus Auer
Waste Heat Usage for Heating of Battery
In the baseline the PTC is
below 10°C used to keep the
battery at operating
temperature
If waste heat is used instead,
the range is increased
Range is on average
increased by about 2.5%
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Institut für Verbrennungsmotoren und Kraftfahrwesen
13
DR
an
ge
/ %
-6
-5
-4
-3
-2
-1
0
1
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NYCC NEDC
dummy
The battery loses / gets a lot of heat from the environment, if
it is not insulated
If α is increased from 0 W/m²K to 10 W/m²K, the range
decreases
NEFZ
a / W
/m2K
0
5
10
15
20
25
30
35
40
45
50
Tamb / °C
-20 -10 0 10 20 30 40
1.8090.0410.6451.752
2
1.75
1.7
1.5
1.25
1
0.75
0.5
0.25
NEDC |QBatt=>Amb/QBatt|
20.10.2014 Markus Auer
Insulation of Battery
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Institut für Verbrennungsmotoren und Kraftfahrwesen
14
dummy
DR
ang
e / %
0
5
10
15
20
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NEDC NYCC
20.10.2014 Markus Auer
Combination of Single Optimizations
Relative to baseline
Recirculating air 50%
Lightened motor
Adapted cabin mean
temperature with
compensation of heat deficit
Usage of waste heat to heat
the battery
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Institut für Verbrennungsmotoren und Kraftfahrwesen
15
dummy
DR
ang
e / %
0
5
10
15
20
25
30
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NEDC NYCC
dummy
Ra
nge
/ k
m
30
40
50
60
70
80
90
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NEDC NYCC
20.10.2014 Markus Auer
Combination of Single Optimizations
As before, only with respect to baseline without cabin heat
exchanger and heat pump
Significant advantages can be seen at low temperatures
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Institut für Verbrennungsmotoren und Kraftfahrwesen
16
NEDC
Co
nsu
mp
tio
n / k
Wh
4.0
4.5
5.0
5.5
6.0
6.5
TCabin,start / °C
-20 -10 0 10 20 30
with consumption for preconditioning w/o consumption for preconditioning
dummy
dummy
DC
on
sum
ptio
n / %
-15
-10
-5
0
5
Tamb / °C
-20 -10 0 10 20 30 40
CADC FKFS NYCC NEDC
20.10.2014 Markus Auer
Preconditioning of Cabin
Total energy consumption increases with preconditioning
With preconditioning at low temperatures, the consumption
can be significantly reduced
-18°C
ambient
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Institut für Verbrennungsmotoren und Kraftfahrwesen
17 20.10.2014 Markus Auer
Summary
Simulation model of a battery electric vehicle
Thermal management system with AC and heat pump
Baseline range
Potential for single optimizations
Potential of combination of single optimizations
Effect of preconditioning of cabin on consumption
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Institut für Verbrennungsmotoren und Kraftfahrwesen
18 20.10.2014 Markus Auer
Acknowledgement
The authors would like to thank
Forschungsvereinigung
Verbrennungskraftmaschinen e. V.
Gamma Technologies
Members of the working group
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Institut für Verbrennungsmotoren und Kraftfahrwesen
19 20.10.2014 Markus Auer
Thank you for your kind
attention!
Questions?
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20 20.10.2014 Markus Auer
Backup
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21 Time [s]
0 500 1000 1500 2000 2500 3000 3500 4000
Gra
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[%]
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Sp
ee
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km
/h]
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140FKFS
20.10.2014 Markus Auer
FKFS Lap (Stuttgart, Germany)
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22 Time [s]
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20.10.2014 Markus Auer
NYCC
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23 Time [s]
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20.10.2014 Markus Auer
NEDC
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24 Time [s]
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[%]
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140CADC
20.10.2014 Markus Auer
CADC
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