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Thermal management of a low cost range extender for electric vehicles

机译：电动汽车低成本增程器的热管理

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Range extenders are a solution to partly overcome the limitations of current battery technology and are gaining popularity despite their complexity, due to the potential for reduced tailpipe emissions and fuel consumption. The range extender or Auxiliary Power Unit (APU) consists of an on board fuel convertor that converts fuel such as gasoline into electrical power while the vehicle is in operation. This enables the traction battery storage capacity to be reduced whilst still maintaining an acceptable driving range. One of the key requirements of an APU is to provide maximum electrical power. In order to do so it is important that the engine as well as the generator are operated at their maximum efficiency in addition to optimising the complete system to reduce any parasitic losses in auxiliary systems. The conflicting requirements of running the engine at a high temperature (~90°C) and the generator to run as cold as possible (~50°C) has consequences on vehicle system integration such as the need to use separate coolant loops, radiators, pumps etc. Employing a common cooling loop can reduce parasitic loads and simplify vehicle integration, but requires operating the engine and/or the generator under sub-optimum thermal conditions. The paper discusses the development of a thermal management system using a single coolant loop for the APU. The APU was tested on a bespoke rig first using two independent cooling loops to characterise the APU performance. The benefits of employing a single coolant loop are then weighed against the compromise in performance observed as a result of operating the engine and/or generator under suboptimum thermal conditions in a single loop. In the single coolant loop, there is a drop in APU power of around 4% and an ESFC penalty of circa 2% at full load across the operating regime. However there is a sizeable saving in parasitic losses, simplified package installation with reduction in overall package cost.
机译：增程器是一种解决方案，可以部分克服当前电池技术的局限性，尽管其复杂性也得到了广泛应用，但由于其可以减少尾气排放和降低燃料消耗，因此得到了普及。增程器或辅助动力装置（APU）由车载燃料转换器组成，该转换器在车辆运行时将汽油等燃料转换为电能。这使得牵引电池的存储容量减小，同时仍保持可接受的行驶范围。 APU的关键要求之一是提供最大的电力。为此，除了优化整个系统以减少辅助系统中的任何寄生损耗外，重要的是发动机和发电机都应以其最大效率运行。在高温（〜90°C）下运转发动机和发电机尽可能冷（〜50°C）下运转的要求相互矛盾，这对车辆系统集成产生了影响，例如需要使用单独的冷却液回路，散热器，使用公共冷却回路可以减少寄生负载并简化车辆集成，但是需要在次佳的热工况下运行发动机和/或发电机。本文讨论了使用用于APU的单个冷却剂回路的热管理系统的开发。首先在定制设备上使用两个独立的冷却回路对APU进行测试，以表征APU的性能。然后，权衡使用单个冷却剂回路的好处与由于在单个回路中在次佳热条件下运行发动机和/或发电机而观察到的性能折衷之间的权衡。在单个冷却剂回路中，在整个运行状态下，满载时APU功率下降约4％，ESFC损失约2％。但是，可以节省大量的寄生损耗，简化了封装的安装，并降低了总体封装成本。

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