Design and Performance Testing of Integrated Modular Thermal Management System for Electric Vehicles

doi:10.3901/JME.260193

Abstract

Abstract: The integrated modular thermal management system significantly reduces system volume and energy consumption, becoming a major development focus in electric vehicle (EV) thermal management technologies. Traditional EV systems use compact layouts with short piping, which do not effectively reduce volume and result in high flow resistance. This paper presents an integrated modular thermal management system incorporating a refrigerant and a coolant module, and examines their thermal management principles. Simulation of flow resistance and heat transfer under various operating conditions show that the maximum flow resistance of the refrigerant module is 75 kPa, while for the coolant module the motor circuit has a maximum resistance of 16.6 kPa, and the battery circuit has a maximum resistance of 17.3 kPa, validating the rationality of the system design. Then, a prototype of the integrated modular thermal management system was built, and a testing platform was established to evaluate its performance. Experimental results indicate that the coefficient of performance of the system is above 2.5 under different operating conditions, reaching 3.5 under thermal equilibrium in cooling mode, validating its energy efficiency and promising application potential.

Key words: electric vehicle, vehicle system, thermal management, integrated module, flow resistance, heat transfer

CLC Number:

TK11

LI Qingming, HU Guanyang, XU Zhengzheng, ZHOU Haonan, MEI Deqing, WANG Yancheng. Design and Performance Testing of Integrated Modular Thermal Management System for Electric Vehicles[J]. Journal of Mechanical Engineering, 2025, 62(6): 292-301.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260193

http://www.cjmenet.com.cn/EN/Y2025/V62/I6/292

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