Engineering topics

Rugh, John

Publications and source records attributed to Rugh, John.

6 records

DOE OSTI2018

Total Thermal Management of Battery Electric Vehicles (BEVs)

The key hurdles to achieving wide consumer acceptance of battery electric vehicles (BEVs) are weather-dependent drive range, higher cost, and limited battery life. These translate into a strong need to reduce a significant energy drain and resulting drive range loss due to auxiliary electrical loads the predominant of which is the cabin thermal management load. Studies have shown that thermal subsystem loads can reduce the drive range by as much as 45% under ambient temperatures below -10°C. Often, cabin heating relies purely on positive temperature coefficient (PTC) resistive heating, contributing to a significant range loss. Reducing this range loss may improve consumer acceptance of BEVs. The authors present a unified thermal management system (UTEMPRA) that satisfies diverse thermal and design needs of the auxiliary loads in BEVs. Demonstrated on a 2015 Fiat 500e BEV, this system integrates a semi-hermetic refrigeration loop with a coolant network and serves three functions: (1) heating and/or cooling vehicle traction components (battery, power electronics, and motor) (2) heating and cooling of the cabin, and (3) waste energy harvesting and re-use. The modes of operation allow a heat pump and air conditioning system to function without reversing the refrigeration cycle to improve thermal efficiency. The refrigeration loop consists of an electric compressor, a thermal expansion valve, a coolant-cooled condenser, and a chiller, the latter two exchanging heat with hot and cold coolant streams that may be directed to various components of the thermal system. The coolant-based heat distribution is adaptable and saves significant amounts of refrigerant per vehicle. Also, a coolant-based system reduces refrigerant emissions by requiring fewer refrigerant pipe joints. The authors present bench-level test data and simulation analysis and describe a preliminary control scheme for this system.

Chowdhury, Sourav↗

DOE OSTI2017

Advanced Climate System for EV Extended Range

The Kia Soul Battery Electric Vehicle (BEV) is available with either a Positive Temperature Coefficient (PTC) heater or an air-source R134a heat pump with PTC heater combination. Hanon Systems, Hyundai America Technical Center, Inc. (HATCI) and the National Renewable Energy Laboratory (NREL) are jointly, with financial support from the U.S. Department of Energy (DOE), developed and proved-out technologies that extend the driving range of the vehicle while maintaining thermal comfort in cold climates. Improved system configuration concepts that use thermal storage and waste heat recovery more effectively were developed and evaluated. This report reviews the three-year effort, including test data of the baseline and modified vehicles, resulting range extension, and recommendations for future actions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Thermal Load Reduction System Development in a Hyundai Sonata PHEV

Increased market penetration of electric drive vehicles (EDVs) requires overcoming a number of hurdles, including limited vehicle range and the elevated cost in comparison to conventional vehicles. Climate control loads have a significant impact on range, cutting it by over 50% in both cooling and heating conditions. To minimize the impact of climate control on EDV range, the National Renewable Energy Laboratory has partnered with Hyundai America and key industry partners to quantify the performance of thermal load reduction technologies on a Hyundai Sonata plug-in hybrid electric vehicle. Technologies that impact vehicle cabin heating in cold weather conditions and cabin cooling in warm weather conditions were evaluated. Tests included thermal transient and steady-state periods for all technologies, including the development of a new test methodology to evaluate the performance of occupant thermal conditioning. Heated surfaces demonstrated significant reductions in energy use from steady-state heating, including a 29%-59% reduction from heated surfaces. Solar control glass packages demonstrated significant reductions in energy use for both transient and steady-state cooling, with up to a 42% reduction in transient and 12.8% reduction in steady-state energy use for the packages evaluated. Technologies that demonstrated significant climate control load reduction were selected for incorporation into a complete thermal load reduction package. The complete package is set to be evaluated in the second phase of the ongoing project.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2016

Increasing EDV Range through Intelligent Cabin Air Handling Strategies: Annual Progress Report

Computational fluid dynamics (CFD) simulations of a Ford Focus Electric demonstrated that a split flow heating, ventilating and air conditioning (HVAC) system with rear recirculation ducts can reduce cabin heating loads by up to 57.4% relative to full fresh air usage under some conditions (steady state, four passengers, ambient temperature of -5 deg C). Simulations also showed that implementing a continuous recirculation fraction control system into the original equipment manufacturer (OEM) HVAC system can reduce cabin heating loads by up to 50.0% relative to full fresh air usage under some conditions (steady state, four passengers, ambient temperature of -5 deg C). Identified that continuous fractional recirculation control of the OEM system can provide significant energy savings for EVs at minimal additional cost, while a split flow HVAC system with rear recirculation ducts only provides minimal additional improvement at significant additional cost.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2016

Climate Control Load Reduction Strategies for Electric Drive Vehicles in Cold Weather

When operated, the climate control system is the largest auxiliary load on a vehicle. This load has significant impact on fuel economy for conventional and hybrid vehicles, and it drastically reduces the driving range of all electric vehicles (EVs). Heating is even more detrimental to EV range than cooling because no engine waste heat is available. Reducing the thermal loads on the heating, ventilating, and air conditioning system will extend driving range and increase the market penetration of EVs. Researchers at the National Renewable Energy Laboratory have evaluated strategies for vehicle climate control load reduction with special attention toward grid connected electric vehicles. Outdoor vehicle thermal testing and computational modeling were used to assess potential strategies for improved thermal management and to evaluate the effectiveness of thermal load reduction technologies. A human physiology model was also used to evaluate the impact on occupant thermal comfort. Experimental evaluations of zonal heating strategies demonstrated a 5.5% to 28.5% reduction in cabin heating energy over a 20-minute warm-up. Vehicle simulations over various drive cycles show a 6.9% to 18.7% improvement in EV range over baseline heating using the most promising zonal heating strategy investigated. A national-level analysis was conducted to determine the overall national impact. If all vehicles used the best zonal strategy, the range would be improved by 7.1% over the baseline heating range. This is a 33% reduction in the range penalty for heating.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS2006

Phase II Testing of Liquid Cooling Garments Using a Sweating Manikin, Controlled by a Human Physiological Model

An Advanced Automotive Manikin (ADAM) developed at the National Renewable Energy Laboratory (NREL) is used to evaluate NASA's liquid cooling garments (LCGs) used in advanced space suits for extravehicular applications. The manikin has 120 separate heated/sweating zones and is controlled by a finite element physiological model of the human thermoregulatory system. Previous testing showed the thermal sensation and comfort followed the expected trends as the LCG inlet fluid temperature was changed. The Phase II test data demonstrates the repeatability of ADAM by retesting the baseline LCG. Skin and core temperature predictions using ADAM in an LCG/Arctic suit combination are compared to NASA physiological data to validate the manikin/model. Additional LCG configurations are assessed using the manikin and compared to the baseline LCG. Results can extend to other personal protective clothing, including HAZMAT suits, nuclear/biological/chemical protective suits, and fire protection suits.

Paul, Heather↗