Virtual calibration of thermal management system using 1D simulations

Examensarbete för masterexamen
Master's Thesis
Mobility engineering (MPMOB), MSc
Munimahadeva, Harshith
Selvan Anuradha, Vishnu Simba
The integration of electrical components in Battery Electric Vehicles (BEVs) has resulted in a significant increase in the complexity of thermal management systems. Unlike Internal Combustion Engine (ICE) vehicles, BEVs require meticulous control of temperature to ensure optimal performance and mitigate the adverse effects of heat accumulation. Efficient thermal management plays a crucial role in BEV development as it directly impacts the system’s overall efficiency and, consequently, the vehicle’s range. Achieving precise temperature control throughout the system presents challenges that necessitate the implementation of circuits and valves specifically designed for effective thermal regulation. The optimization of thermal management in BEVs is of paramount importance, while simultaneously maintaining performance and climate control capabilities. Calibration plays a pivotal role in achieving optimal performance in the system, ultimately enhancing the overall efficiency and range of the vehicle. Currently, the calibration process entails the availability of a physical vehicle and a dedicated test chamber. The vehicle undergoes a series of meticulously designed test cases conducted at varying temperatures. The data collected from these tests is then utilized to generate a calibrated map, building upon a base map. This iterative process may involve repeating the calibration cycle multiple times, typically around 7-8 iterations, to ensure a comprehensive and finely-tuned calibrated map encompassing a wide range of pump requests. By diligently fine-tuning the calibration, it is possible unlock the full potential of the vehicle’s performance and optimize its overall efficiency. The thesis proposal aims to accomplish calibration using 1D simulations within a virtual environment, eliminating the requirement for a physical vehicle and dedicated test chamber. This innovative approach not only expedites the calibration process but also enables automation, enhancing efficiency while reducing the likelihood of errors. One of the key advantages of utilizing virtual models is their availability years in advance, even before the physical vehicle is accessible. This advantageous time frame allows for the acquisition of calibrated values well ahead of the vehicle’s actual availability, offering a significant advantage in terms of planning, optimization, and early validation. By leveraging 1D simulations, the proposed methodology revolutionizes the calibration process, facilitating faster and more efficient development.
Thermal system , calibration , virtual calibration , 1D simulations , calibration , BEV , efficiency , thermal management
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