Method for Using Modeling Fidelity in Battery-Electric Vehicle Thermal System Simulations to Optimize Real-World Component Design Targets
The optimal performance of a battery electric vehicle (BEV) is highly dependent on the thermal environment in which the electric components operate. If the maximum temperature levels for crucial elements are exceeded, there are impacts to the life and reliability of the component. While the standard industry practice is to protect for the worst-case steady-state thermal load condition, this may result in the over-specification of the cooling system. It�s been established that BEVs are impacted by temperature, they are also sensitive to the mass of the cooling system, therefore components must not be over-designed to target extreme operating points. In order to meet these demands, a system level simulation has been developed to analyze the performance of several key electrical components. Detailed component models of the BorgWarner electric motor and inverter are included so that the temperature within these components can be monitored. This presentation will give results from this combined cooling system, detailed component, and vehicle simulation. The model will be exercised over a fuel economy drive cycle, 0-100 kph acceleration, and hillclimb at several different ambient conditions.