In order to reduce the impact of the vehicle's air conditioning system on the cruising range, Kia's Soul pure electric vehicle uses a series of designs, including the addition of a heat pump.
Whether it is cabin heating in winter or air conditioning in summer, it will bring a huge burden to the valuable battery resources of electric vehicles, which will seriously affect the mileage of the vehicle, sometimes even as high as 50-60%, which greatly increases pure electric vehicles. The difficulty of car cost reduction.
In order to solve this problem, many R&D vehicles have adopted many advanced and innovative systems, but this will greatly increase the complexity of the vehicle and increase the cost. Recently, two speakers at the SAE WCX 2018 conference introduced some more cost-effective and less complex alternative solutions to the audience.
The first method is to improve the thermal storage capacity to ensure that the vehicle's mileage will not be affected by the heating needs of the people on the car; the second method is to reduce the vehicle's air conditioning load in warm and cold weather conditions-this You can reach a comfortable temperature faster with a smaller battery, or extend the mileage with the existing battery.
The Kia Soul pure electric vehicle has been improved, adding an electric heater core, a built-in heater core for the plug-in pre-preparation phase, and a circuit system that can recover waste heat when the heat generated in the pre-preparation phase is exhausted. The LTR low temperature radiator can assist the cooling of the motor/electronic system in hot weather.
Strengthen the heat storage system
If cost and vehicle size are not considered, increasing the battery capacity is indeed a way to ensure mileage without sacrificing cabin comfort. Another method is to install a heat pump system. Currently, Toyota Prius Prime plug-in hybrid electric vehicles have adopted a complex heat pump system. Equipped with a set of liquid-gas separation circuit, the operating temperature of Toyota heat pump can reach as low as -10°C (14°F), while the lowest operating temperature of ordinary automobile heat pump is only about 0°C (32°F). This is because As the ambient temperature drops, the mass flow rate of the refrigerant also drops. Prime will serve as a technical test platform for this heat pump solution. Even if the battery pack is exhausted, the Prius gasoline engine can provide energy for heating the cabin.
Currently, Hanon Systems is working with Hyundai-Kia American Technology Center and the National Renewable Energy Laboratory (NREL) of the U.S. Department of Energy to carry out cooperation projects. Among them, the 2015 Kia Soul pure electric vehicle was selected as the research object. Briefly, Soul is a pure electric car used for daily commuting and driving in the city. Under normal circumstances, the cruising range is between 75 and 100 miles (120 to 160 kilometers), but it will be in the hot summer and cold winter. Significantly shortened.
This bar graph shows the energy consumption of the HVAC system during short-distance driving in three cold weather conditions. Although the overall energy consumption of "HP (heat pump) + TS (thermal storage)" is the lowest, when necessary, the effect of "TS (thermal storage) + PTC" is better than that of using "HP (heat pump)" alone.
In a speech at the WCX – SAE 2018 Global Automotive Conference, Dr. John J. Meyer, a technical researcher at Hanon, pointed out that in order to maximize the cruising range, in addition to the use of traditional PTC heaters, Soul pure electric vehicles seem to have "everything" "Extremely", specific measures include the use of original heat pumps, climate control seats, heated steering wheels, cabin pretreatment (heating or cooling), partial recirculation A/C, dual-zone and single-zone HVAC, Eco electric driving mode and air cooling Type battery pack, etc. In this case, Dr. Meyer's research will focus on increasing the heat storage capacity. Meyer pointed out that the heat pump design used in Soul electric vehicles can restore 30-40% of the lost mileage caused by heating, but the vehicle can still only achieve 60% of the cruising range. For an electric car with a total cruising range of only 100 kilometers, this means that the actual cruising range of the vehicle is only 60 miles. However, because the heat pump circuit will increase the cost of the vehicle, increase the complexity and packaging difficulty, and increase the amount of refrigerant used, it may not be the best solution. At present, a small number of vehicles equipped with heat pumps in the US market use R-134a refrigerant, obviously because of the low price of this refrigerant, which is less than 10% of R-1234yf refrigerant.
If heat pump loops are added and equipped with matching heat exchangers, complex flow paths and piping, the final refrigerant demand may nearly double. Compared with vehicles without a heat pump system (19 ounces, or 550 grams), Soul electric vehicles use 33 ounces (900 grams) of refrigerant. To make the situation even more serious, according to the plan of the US Environmental Protection Agency (EPA), the United States will completely ban the application of R-134a refrigerant in new cars by 2021, which will inevitably further increase the cost of heat pump solutions.
If the increased cost and the additional demand for refrigerant are not considered, the heat pump system has the best effect on optimizing the cruising range of pure electric vehicles. However, a collaborative study by Hanon, Kia Hyundai, and NREL shows that this "traditional wisdom" does not necessarily apply to the mileage requirements of typical driving scenarios such as commuting or urban driving.
Hanon has added two glycol coolant circuits with connectable valves to the Soul electric vehicle. Each circuit is equipped with a heat exchanger with a total fluid capacity of 2L (0.5 gallon). A heat exchanger system includes a 1500 watt electric heater, which can also generate heat for the pretreatment heater core in the car. When the vehicle is running, the power transmission will be turned off, the heating system will use the stored heat, and additionally collect waste heat from the motor and electronic circuits-when the stored heat is consumed, this heat source can continue to function.
Dr. Meyer said that a typical short-distance pure electric vehicle has a cruising range of 40 minutes, which is about 50 kilometers (30 miles). The Soul electric vehicle has also undergone a three-wheel wind tunnel test of the EPA UDDS (Urban Cycle) cycle. The vehicle will be pre-processed during the battery charging process before the test, and the HVAC is set to 22°C (72°F). The temperature settings for the wind tunnel test are 5°C (41°F), -5°C (23°F) and -18°C (0°F). In all three rounds of tests, "using a heat pump alone" consumes more energy than "using a PTC heater with heat storage system". The test results show that only when combined with a heat storage system, the heat pump can show its own advantages. For short-range pure electric vehicles that are very price sensitive, the thermal storage system with PTC heater seems to be the best combination of efficiency and cost-effectiveness. For electric vehicles with longer cruising range, although the data is not yet complete, pure heat pump solutions are likely to have more advantages.
Hyundai Sonata's plug-in electric vehicles use a series of functions to reduce the vehicle's thermal load.
Reduce heat load
Researcher Jason Lustbader explained that NREL's "Climate Control System Heat Load Reduction Project" aims to increase the range of electric drives by an average of 20% during the high temperature in summer and severe cold in winter. The goal of this project is broader, not only includes the "Soul Pure Electric Vehicle Research Project" trying to solve the problem of the loss of cruising range of short-distance pure electric vehicles (75 to 100 miles).
The NREL project selected two identical plug-in hybrid electric vehicles (PHEV) as test objects. The first phase of the project (completed) mainly models related technologies and records their apparent data; the second phase mainly applies these technologies to Hyundai Sonata plug-in hybrid electric vehicles, and targets EPA cities/highways Driving cycle, real working condition test.
The NREL project used two Sonata plug-in hybrid vehicles: one without any improvement, the other with a special heat treatment system, including electric heating windshield and solar reflective glass provided by Pittsburgh Plate Glass And solar reflective coatings, and Gentherm’s heating surface materials around the driver’s seat, door glass defrosters and temperature-controlled seats. Tests have proved that special seats, glass and paint will affect the heating and cooling effect of the vehicle.
The NREL project has been tested in Fairbanks, Alaska in winter at the end of February 2017, with a high ambient temperature of -7°C (20°F). The summer test was conducted in Mojave, California, and the ambient temperature was between 38-50°C (99-122°F).
Sonata's windshield uses an electric defroster, which consumes less power than traditional defrosters.
During the winter test in Alaska, NREL conducted objective data measurements on the windshield of the vehicle. The test results show that the electric heating device can complete the deicing in 6 minutes, and the power consumption is 0.1 degrees. In contrast, a traditional defroster takes 19 minutes and consumes 2.6 degrees of electricity.
Comfort measurement is more subjective and mainly reflects the feeling reports provided by passengers. The researchers pointed out that because the comfort level can be achieved with lower energy input, both the driver and passengers can lower the settings of heating and air conditioning. In cold weather tests, the improved Sonata reached a comfortable level within 15 minutes, while the original Sonata required 29 minutes.
NREL cycle test results show that Hyundai Sonata's improved air conditioning system can reduce the load and reach a comfortable temperature faster.
In addition, the two Sonatas have also completed pure electric driving tests at the Hyundai American Technology Center in Mohave, California. Compared with the original version, the improved Sonata's cruising range has increased by 11.4%, and the air conditioning energy consumption has been reduced by 23.7%.
In addition, the improved Sonata has also shown greater advantages in a series of other test projects (including climate chamber tests), such as reaching the comfort level faster; NREL will use the simulation and regional climate accumulated in its early tests and research The data predicts the level of performance improvement the system can achieve in different regions of the United States. NREL believes that, like the project carried out by Hanon Systems, this project also proves that we can use some more cost-effective climate control strategies to greatly reduce the burden of air conditioning systems on electric vehicle batteries, thereby helping some small pure electric vehicles To better meet the daily driving needs of consumers.
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