Analysis of the Effect of Motor Waste Heat Recovery on the Temperature and Driving Range of Electric Heavy Truck Batteries

In some scenarios, electric heavy-duty trucks with battery swapping mode (ETBSm) are more cost-effective than battery charging mode. The viability of battery swapping stations is contingent upon the operational requirements and range capabilities of the ETBSm. Low temperatures have the effect of reducing the range of the ETBSm, thereby creating difficulties for battery swapping. This article proposes the use of motor waste heat recovery (MWHR) to heat batteries, which would improve range. A number of subsystem models have been established, including the ETBSm, battery, motor, and thermal management system (TMS). The calibration of battery temperature and motor efficiency is achieved with a model error of less than 5%. Comparison of performance, such as temperature, energy consumption, and range, when using only positive temperature coefficient (PTC) heating and when using both PTC heating and motor waste heat. The results indicate a 15% increase in the rate of rise in battery temperature and a 10.64 kW·h reduction in energy consumption under Chinese heavy-duty vehicle commercial vehicle test cycle (CHTC) conditions. Then, the motor waste heat percentage, energy consumption, and range are analyzed at different ambient temperatures. At an ambient temperature of −20 °C, −10 °C, and 0 °C, the percentage of the motor waste heat is 32.1%, 35%, and 40.5%; when 75% of the state of charge (SOC) is consumed, the range is improved by 6.55%, 4.37%, and 4.49%. Additionally, the effect of the PTC heater on temperature characteristics and power consumption is investigated by changing the target temperature of the coolant at the battery inlet. In accordance with the stipulated conditions of an ambient temperature of −20 °C and a target coolant temperature of 40 °C at the battery inlet, the simulation results indicated a battery temperature rise rate of 0.85 °C/min, accompanied by a PTC power consumption of 15.6 kW·h. This study demonstrates that as the ambient temperature increases, the utilization of motor waste heat becomes more effective in reducing PTC heating power consumption. At the lowest ambient temperature tested, the greatest improvement in driving range is observed. It is important to note that while an increase in the target heating temperature of the PTC helps to raise the battery temperature more rapidly, this is accompanied by a higher energy consumption. This article provides a reference for the ETBSm with MWHR.