Modeling and Control of a Multiple-Heat-Exchanger Thermal Management System for Conventional and Hybrid Electric Vehicles

Abstract

The powertrain in combustion engine and electric vehicles requires a thermal management system to regulate the operating temperature of the under-hood components. The introduction of computer-controlled cooling system actuators (e.g., variable speed fans, pump, and valves) enables power savings over drive cycles. The radiator is typically sized for maximum heat rejection per environmental and vehicle thermal loading conditions. This paper explores the use of multiple radiators to adapt the cooling system operations to driving demands. A nonlinear multiple-input (i.e., fan array speed, pump, and outlet valve positions) thermal model is presented to predict system behavior. A stateflow controller has been designed and implemented to maintain the component temperature within a desired range (~80 °C). A series of experimental tests have been conducted to compare the proposed architecture’s performance against a single radiator design. A standard driving cycle featuring low (20 kW) and high (40 kW) heat loads was implemented in the laboratory for a vehicle starting from rest. The coolant temperature tracking, fan speeds, and fan power draw were studied over the representative operating cycle. The test results show a much faster warmup time (~10 min) and temperature tracking for the twin radiator experimental test as compared to the single radiator (~13 min). The net fan energy consumption was reduced by 4.6% with the twin radiator as opposed to the single-radiator configuration. Considering that engines usually operate at idle to medium loads, these findings can improve the powertrain’s overall performance.