Study on a novel thermal management system and heat recovery strategy of range extend electric vehicle

The integrated thermal management system (ITMS) can effectively improve the pure electric range of the vehicle. This work proposes a ITMS based on a super bottle. In this work, the power battery temperature is subdivided into five stages and a control strategy for heating the battery and cabin with dual heat sources in a low-temperature environment is developed. Then a numerical integrated simulation model of the ITMS is developed and experimentally verified in an environmental chamber. The experimental and simulation conditions used throughout the study are set to an ambient temperature of 0°C. At the same time, due to the better sampling of data under 40 km/h, a constant speed of 40 km/h is used. At 0 °C, through 660 s of 40 km/h conditions, the results show that the ITMS can heat the battery to 15 °C in about 20 minutes at a low temperature of 0°C, and heat the cabin to 22 °C in 10 min. The ITMS also improves battery warm-up efficiency by 16.7% and reduces energy consumption by 5.5% compared to the original system. The ITMS is 17% more expensive than the original system. In addition, the low-temperature electric range has been increased by 3.3 km, and the cost of increasing the range by integrating the thermal management components is approximately 28 ¥/km.