Optimization design of integrated module for thermal management system in electric vehicle

Abstract

The temperature control of vehicle is achieved through thermal management system, the design of which is critical to regulating vehicle temperature and reducing energy consumption. In this study, an integrated coolant circulation module was developed. The internal flow dynamics of the module were simulated using the computational fluid dynamics K-ε turbulence model. The research objective was to investigate the correlation between pressure drop and coolant flow in different operational modes. The results reveal a nonlinear positive correlation between pressure loss and coolant volumetric flow rate. Through structural optimization in regions of high pressure difference within the flow field, the average pressure loss within the module was reduced by 37 %. The accuracy of the simulation was confirmed by rapid prototype testing on a test bench, followed by in-vehicle verification of the prototype. These validations demonstrate that the module meets design standards and effectively controls vehicle temperature. The implementation of the integrated module reduced the number of coolant pipelines in the thermal management system from 23 to 10, significantly decreasing the number of pipes and interfaces and thereby lowering the risk of coolant leakage. Additionally, it resulted in a 15.64 % reduction in material costs and a 354-s reduction in installation labor time. These improvements can significantly lower the production cost of the thermal management system of electric vehicle.