XiLS (X in the Loop Simulation) Based Thermal Management Development

The significance of thermal management performance in electric vehicles (EVs) has grown considerably, leading to increased complexity in thermal systems and a rapid rise in safety and quality-related concerns. The present real-vehicle-based development methods encounter several constraints in their approach when dealing with highly complex systems. Huge number of verification and validation work To overcome these limitations and enhance the thermal system development process, a novel virtual development environment established using the XiLS (X in the Loop Simulation) methodology. This XiLS methodology basically based on real-time coupling between physical thermal system hardware and analytical models for the other systems of vehicle. To control vehicle model and thermal system, various options were realized through hardware, software and model for VCU (Vehicle control unit) and TMS (Thermal management system) control unit. With XiLS evaluation environment as the foundation, conventional air conditioning test such as cabin cooling /heating and component cooling performance were evaluated even without real test vehicle. Furthermore, calibration of thermal management system control was performed, which resulted in partial improvement in energy efficiency. EV driving range and energy efficiency for cold ambient condition (-7°C) were evaluated based on homologation drive cycle tests, such as the MCT (Multi-cycle test) according to the US EPA protocol. The comprehensive evaluation work was conducted during the developmental phase of new electric vehicle projects before SOP, which demonstrated the effectiveness of this proposed methodology.