Co simulation of refrigerant circuits on the HiL-ThermoLab testbed as part of a holistic development methodology for thermal management systems

Abstract

The transformation towards sustainable mobility in the individual and transport sector requires the parallel development of various propulsion technologies. In addition to the development of efficient and sustainable powertrain systems themselves, research focuses on optimizing the development process to meet the increased system complexity and the desire for minimizing engineering efforts. As the electrification of powertrain systems in Hybrid Electric Vehicles (HEVs), Battery Electric Vehicles (BEVs), and Fuel Cell Electric Vehicles (FCEVs) continues to increase, the importance of thermal management as an essential part of the vehicle’s energy management is growing significantly. In order to take into account, the high thermal sensitivity of electric powertrain components within tight operating limits, it is essential to consider all thermally relevant subsystems and their interactions during the development process. Particular attention must be paid to the interaction between the HVAC system and the thermal management system of the powertrain components, as can be found in state-of-the-art heat pump systems for electrified vehicles. In order to be able to develop operating strategies at an early stage, taking these interactions into account, an integrated approach is used that links simulation and testing on the HiL-ThermoLab testbed. For testing and developing efficient operating strategies, the refrigerant circuit and the interconnection to the thermal circuit system is installed on the testbed. Hardware components that are not yet available are substituted on the ThermoLab using an innovative approach for emulation. Therefore, an interconnection of co simulation and dynamic thermo-hydraulic modules enables the transfer of boundary conditions on the ThermoLab. The co simulation platform enables the testing of operation strategies in an early phase of the vehicle development. This study shows the newest results of running a heat pump system using an innovative approach on the HiL-ThermoLab testbed.