Model Characterization of High-Voltage Layer Heater for Electric Vehicles through Electro–Thermo–Fluidic Simulations

Abstract

This paper focuses on the modeling and analysis of a high-voltage layer heater (HVLH) designed for environmentally friendly vehicles, including electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs), through multiphysics simulations that cover electrical, thermal, and fluid dynamics aspects. Due to the significant expenses and extensive time needed for producing and experimentally characterizing HVLHs, simulation and physical modeling methods are favored in the development stage. This research pioneers the separate modeling of thermal boundary conditions for the heating element (TFE) within the electrical domain, enabling the calculation of Joule heating and the analysis of transient conjugate heat transfer. Moreover, this research initiates the application of transfer function modeling for the HVLH component, expanding its use to the broader context of heating, ventilation, and air conditioning (HVAC) systems. The simulation results, which include calculations for Joule heating and temperature fields based on input voltage and flow conditions, closely follow experimental data. The derived transfer function, along with the regression parameters, precisely predicts the dynamic behavior of the system. The simulation-based modeling approach presented in this study significantly advances the design and control of environmentally friendly electric heating systems, providing a sustainable and cost-effective solution.