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, 2026, 62(6): 292-301.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

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

http://www.cjmenet.com.cn/EN/Y2026/V62/I6/292

References

[1] ZHANG X，LI Z，LUO L，et al. A review on thermal management of lithium-ion batteries for electric vehicles[J]. Energy，2022，238：121652.1-12.
[2] LAJUNEN A，YANG Y，EMADI A. Review of cabin thermal management for electrified passenger vehicles[J]. IEEE Transactions on Vehicular Technology，2020，69(6)：6025-6040.
[3] HWANG F S，CONFREY T，REIDY C，et al. Review of battery thermal management systems in electric vehicles[J]. Renewable & Sustainable Energy Reviews，2024，192：114171.
[4] 肖宗鑫，胡明辉，石力王，等. 电动汽车内置式永磁同步电机转子温度在线估计[J]. 机械工程学报，2023，59(24)：209-222. XIAO Zongxin，HU Minghui，SHI Liwang，et al. Rotor temperature online estimation of built-in permanent magnet synchronous motor for electric vehicle[J]. Journal of Mechanical Engineering，2023，59(24)：209-222.
[5] WANG X，LI B，GERADA D，et al. A critical review on thermal management technologies for motors in electric cars[J]. Applied Thermal Engineering，2022，201：117758.
[6] VIKRAM S，VASHISHT S，RAKSHIT D，et al. Recent advancements and performance implications of hybrid battery thermal management systems for Electric Vehicles[J]. Journal of Energy Storage，2024，90：111814.
[7] 陈泽宇，熊瑞，孙逢春. 电动汽车电池安全事故分析与研究现状[J]. 机械工程学报，2019，55(24)：93-104，116. CHEN Zeyu，XIONG Rui，SUN Fengchun. Research status and analysis for battery safety accidents in electric vehicles[J]. Journal of Mechanical Engineering，2019，55(24)：93-104，116.
[8] TAN L，YUAN Y. Computational fluid dynamics simulation and performance optimization of an electrical vehicle Air-conditioning system[J]. Alexandria Engineering Journal，2022，61(1)：315-328.
[9] LIANG K，WANG M，GAO C，et al. Advances and challenges of integrated thermal management technologies for pure electric vehicles[J]. Sustainable Energy Technologies and Assessments，2021，46：101319.
[10] LIU Y，ZHANG J. Electric vehicle battery thermal and cabin climate management based on model predictive control[J]. Journal of Mechanical Design，2020，143：1-8.
[11] LIM T K，GARUD K S，SEO J H，et al. Experimental study on heating performances of integrated battery and HVAC system with serial and parallel circuits for electric vehicle[J]. Symmetry，2021，13(1)：93.
[12] GUO J，JIANG F. A novel electric vehicle thermal management system based on cooling and heating of batteries by refrigerant[J]. Energy Conversion and Management，2021，237：114145.
[13] 邹慧明，唐坐航，杨天阳，等. 电动汽车热管理技术研究进展[J]. 制冷学报，2022，43(3)：15-27. ZOU Huiming，TANG Zuohang，YANG Tianyang，et al. Review of research on thermal management technology for electric vehicles[J]. Journal of Refrigeration，2022，43(3)：15-27.
[14] 胡志林，张天强，杨钫. 特斯拉电动汽车热管理技术发展趋势[J]. 汽车文摘，2021(1)：53-57. HU Zhilin，ZHANG Tianqiang，YANG Fang. Development trend of tesla electric vehicle thermal management technology[J]. Automotive Digest，2021(1)：53-57.
[15] YUAN R，PRICE C，KASURKAR R，et al. Numerical investigation of heat retention and warm-up with thermal encapsulation of powertrain[C]// WCX SAE World Congress Experience：April 21-23，2020，Online.:Society of Automotive Engineers，2020：625-632.
[16] MA J，LIU A，ZHANG P，et al. Collaborative thermal management of power battery and passenger cabin for energy efficiency optimization[J]. Energy Conversion and Management，2023，293：117514.
[17] LI W，WANG Y，YANG W，et al. Design and optimization of an integrated liquid cooling thermal management system with a diamond-type channel[J]. Thermal Science and Engineering Progress，2024，47：102325.
[18] ROLANDO L，MILLO F，VINOGRADOV A，et al. A virtual test rig for performance and efficiency assessment of heat pump thermal management system for battery electric vehicles[J]. Applied Thermal Engineering，2024，247：123055.
[19] ZHANG X，GAO C，GAO Q，et al. Experimental study on an integrated thermal management system for electric vehicle with collaborative control[J]. Applied Thermal Engineering，2024，240：122249.
[20] WANG Z，HAN J，ALAJBEGOVIC A，et al. Long term transient cabin heating simulation with multiple fluid node approach[C].//Vehicle Thermal Management Systems Conference Proceedings (VTMS11)：May 15-172013，Coventry，2013：319-333.
[21] TORREGROSA-JAIME B，BJURLING F，CORBERÁN J M，et al. Transient thermal model of a vehicle’s cabin validated under variable ambient conditions[J]. Applied Thermal Engineering，2015，75：45-53.
[22] FAYAZBAKHSH M A，BAHRAMI M. Comprehensive modeling of vehicle air conditioning loads using heat balance method[C]// SAE 2013 world congress and Exhibition：April 16-18，2013，Detroit，Michigan，USA.:Society of Automotive Engineers，2013:12561-12573.