Simplified Approach to Model a HEV/PHEV/ Battery Vehicle Cooling System in 1D and Validating using DFSS Methodology

Improving fuel economy and to satisfy more stringent emission legislations the Vehicle electrification becomes more important one. Compared to the combustion engine an electric vehicle will use energy from the grid to recharge their HV battery and this is converted with much higher efficiency and less CO2 emission. This makes a significant role in the present transition from conventional to electric vehicles. The addition of new components, such as power electronics, electric machine and HV battery, increases the torque availability, energy but also the weight. In addition, although they have really high efficiency, they produce a significant amount of heat that has to be removed. Another thermal management issue in PHEV and BEV is cabin heating, since the engine heat is not available. To guarantee system efficiency and reliability, a completely new thermal management layout has to be designed. The time and cost spent on a real time model of new cooling system affect the vehicle development time. So a simplified 1D Modelling approach is defined and followed in this paper by using 1D CFD tool FloMASTER to develop the internal coolant loop and simulate for all critical thermal conditions. DFSS methodology is used to validate the design. This paper focusses on modelling, validating the design more ahead of the product development phase.