电动汽车电池冷却器换热性能

doi:10.11949/0438-1157.20201569

摘要/Abstract

摘要：

电动汽车中电池组的热管理对汽车的性能和安全性十分重要。通常使用小型电池冷却器（chiller）与车载空调系统的蒸发器并联，用来冷却电池冷却板中的冷却液。为了对实际电池冷却器的换热性能进行评估和分析，设计搭建了一套完整的试验测试系统，并验证了其测试的稳定性和重复性。在此基础上，对最新设计的小型紧凑电池冷却器进行了不同工况下的性能测试和分析，得到了其换热功率和流阻随冷媒侧和冷却液侧参数改变的变化规律，最高换热功率达到了5.6 kW。

关键词: 电动汽车热管理, 电池冷却器, 试验测试系统, 压缩机, 蒸发, 传热

Abstract:

The thermal management of the battery pack inside an electric vehicle is crucial to its safety and performance. Usually, a small and compact chiller with internal turbulence-generating structure is installed in parallel with the evaporator of the vehicle air-conditioning system, so as to cool down the coolant that circulates in the battery cooling plate. However, the establishment of specific testing facilities for the chiller and its experimental analyses have seldom been seen in the literature. In order to provide a steady and reliable chiller performance testing platform and to evaluate and analyze the heat exchanging capacity of a newly-designed chiller, a complete experimental system was thoroughly designed and established, and its stability and repetitiveness were then validated. Based on such a testing facility, the small chiller for the battery coolant was experimentally tested under different working conditions, and its heat exchanging performance and pressure drops were analyzed against the variations of the parameters of both refrigerant side and coolant side. Results reveal that the evaporating pressure of the refrigerant possesses bigger impact on the heat exchange than the superheated temperature at the outlet, and the pressure drop of the refrigerant always has similar trend with the heat exchanging capacity. On the coolant side, the inlet temperature and flowrate both have positive influence on the heat exchange. Finally, the highest heat exchanging capacity reached 5.6 kW, and the calculated efficiency of the compressor varied between 0.6 and 0.8.

Key words: thermal management of electric vehicles, chiller, experimental testing system, compressor, evaporation, heat transfer

中图分类号:

TK 11.3

马秋鸣, 聂磊, 潘权稳, 山訸, 曹伟亮, 王强, 王如竹. 电动汽车电池冷却器换热性能[J]. 化工学报, 2021, 72(S1): 170-177.

MA Qiuming, NIE Lei, PAN Quanwen, SHAN He, CAO Weiliang, WANG Qiang, WANG Ruzhu. Heat exchange performance of a battery chiller for electric vehicles[J]. CIESC Journal, 2021, 72(S1): 170-177.

图/表 9

参考文献 31

1	Kim S C, Won J P, Park Y S, et al. Performance evaluation of a stack cooling system using CO₂ air conditioner in fuel cell vehicles [J]. International Journal of Refrigeration, 2009, 32(1): 70-77.
2	Al-Alawi B M, Bradley T H. Total cost of ownership, payback, and consumer preference modeling of plug-in hybrid electric vehicles [J]. Applied Energy, 2013, 103: 488-506.
3	Brouwer A S, Kuramochi T, van den Broek M, et al. Fulfilling the electricity demand of electric vehicles in the long term future: an evaluation of centralized and decentralized power supply systems [J]. Applied Energy, 2013, 107: 33-51.
4	Habib S, Khan M M, Abbas F, et al. A comprehensive study of implemented international standards, technical challenges, impacts and prospects for electric vehicles [J]. IEEE Access, 2018, 6: 13866-13890.
5	Opitz A, Badami P, Shen L, et al. Can Li-ion batteries be the panacea for automotive applications? [J]. Renewable and Sustainable Energy Reviews, 2017, 68: 685-692.
6	Hong S H, Jang D S, Park S, et al. Thermal performance of direct two-phase refrigerant cooling for lithium-ion batteries in electric vehicles [J]. Applied Thermal Engineering, 2020, 173: 115213.
7	Santhanagopalan S, Zhang Q, Kumaresan K, et al. Parameter estimation and life modeling of lithium-ion cells [J]. Journal of the Electrochemical Society, 2008, 155(4): A345.
8	Arora S, Kapoor A, Shen W X. A novel thermal management system for improving discharge/charge performance of Li-ion battery packs under abuse [J]. Journal of Power Sources, 2018, 378: 759-775.
9	Doucette R T, McCulloch M D. Modeling the prospects of plug-in hybrid electric vehicles to reduce CO₂ emissions [J]. Applied Energy, 2011, 88(7): 2315-2323.
10	Wang H, Liu Y, Fu H, et al. Estimation of state of charge of batteries for electric vehicles [J]. International Journal of Control and Automation, 2013, 6(2): 185-194.
11	Kim D W, Lee M Y. Theoretical approach on the heating and cooling system design for an effective operation of Li-ion batteries for electric vehicles [J]. Journal of the Korea Academia-Industrial Cooperation Society, 2014, 15(5): 2545-2552.
12	Lee H S, Won J P, Lim T K, et al. Experimental study on performance characteristics of the triple fluids heat exchanger with two kinds of coolants in electric-driven air conditioning system for fuel cell electric vehicles [J]. Energy Procedia, 2017, 113: 209-216.
13	Alaoui C. Solid-state thermal management for lithium-ion EV batteries [J]. IEEE Transactions on Vehicular Technology, 2013, 62(1): 98-107.
14	Wang Q, Jiang B, Li B, et al. A critical review of thermal management models and solutions of lithium-ion batteries for the development of pure electric vehicles [J]. Renewable and Sustainable Energy Reviews, 2016, 64: 106-128.
15	Choi K W, Yao N P. Heat transfer in lead-acid batteries designed for electric-vehicle propulsion application [J]. Journal of the Electrochemical Society, 1979, 126(8): 1321-1328.
16	Kim G H, Pesaran A. Battery thermal management design modeling [J]. World Electric Vehicle Journal, 2007, 1(1): 126-133.
17	黄蔚. 电动汽车电池冷却器仿真研究[D]. 贵阳: 贵州大学, 2019.
	Huang W. Simulations of chiller for electric vehicles [D]. Guiyang: Guizhou University, 2019.
18	Pesaran A A. Battery thermal models for hybrid vehicle simulations [J]. Journal of Power Sources, 2002, 110(2): 377-382.
19	Rao Z H, Wang S F. A review of power battery thermal energy management [J]. Renewable and Sustainable Energy Reviews, 2011, 15(9): 4554-4571.
20	Bandhauer T M, Garimella S, Fuller T F. A critical review of thermal issues in lithium-ion batteries [J]. Journal of the Electrochemical Society, 2011, 158(3): R1.
21	Drummond K P, Back D, Sinanis M D, et al. A hierarchical manifold microchannel heat sink array for high-heat-flux two-phase cooling of electronics [J]. International Journal of Heat and Mass Transfer, 2018, 117: 319-330.
22	张荣荣, 张根祥, Stanke Edwin, 等. 电子膨胀阀在电动汽车空调和电池冷却系统中的应用[J]. 制冷与空调, 2018, 18(5): 77-80, 85.
	Zhang R R, Zhang G X, Stanke E, et al. Electronic expansion valve in the application of the electric car air conditioning cooling system and battery [J]. Refrigeration and Air-Conditioning, 2018, 18(5): 77-80, 85.
23	张春秋, 罗玉林. 电动汽车电池冷却系统对空调系统性能的影响[J]. 制冷与空调, 2020, 20(2): 49-52, 72.
	Zhang C Q, Luo Y L. Effect of battery cooling system on performance of air-conditioning system for electric vehicle [J]. Refrigeration and Air-Conditioning, 2020, 20(2): 49-52, 72.
24	Longo G A. The effect of vapour super-heating on hydrocarbon refrigerant condensation inside a brazed plate heat exchanger [J]. Experimental Thermal and Fluid Science, 2011, 35(6): 978-985.
25	Mancin S, de del Col D, Rossetto L. R32 partial condensation inside a brazed plate heat exchanger [J]. International Journal of Refrigeration, 2013, 36(2): 601-611.
26	Sarraf K, Launay S, Tadrist L. Analysis of enhanced vapor desuperheating during condensation inside a plate heat exchanger [J]. International Journal of Thermal Sciences, 2016, 105: 96-108.
27	Longo G A, Mancin S, Righetti G, et al. HFC404A condensation inside a small brazed plate heat exchanger: comparison with the low GWP substitutes propane and propylene [J]. International Journal of Refrigeration, 2017, 81: 41-49.
28	吴学红, 李灿, 龚毅, 等. 板式换热器相变流动的传热及压降特性[J]. 化工学报, 2017, 68(S1): 133-140.
	Wu X H, Li C, Gong Y, et al. Heat transfer and pressure drop characteristic of phase change flow in plate heat exchanger [J]. CIESC Journal, 2017, 68(S1): 133-140.
29	李明春, 肖刚, 史和春, 等. 人字形波纹板相变流动及换热特性研究[J]. 工程热物理学报, 2016, 37(3): 581-585.
	Li M C, Xiao G, Shi H C, et al. Study on phase change flow and heat transfer characteristics of chevron corrugated plate [J]. Journal of Engineering Thermophysics, 2016, 37(3): 581-585.
30	Ian H. Bell and the CoolProp Team. CoolProp 6.1.0 documentation [EB/OL]. [2020-05-06]. .
31	Clifford A A. Multivariate error analysis: a handbook of error propagation and calculation in many-parameter system [EB/OL]. 1973.

部件	型号	规格	生产厂家
压缩机	EVS50B (低压版) EVS50HLBCAA-8AA	全封闭电动涡旋压缩机，排量50c/rev，转速1500~6000； 8.5kW~6000 r/min,0.2/1.4 MPa[G] SH/SC=10/5K； 6.3kW~6000 r/min T_e/T_c=-20/45℃ SH/SC=10/5 K；接口管径OD 15.5 mm / ID 21.3 mm 高压工作范围400~720 V；低压工作范围9~36 V 通讯协议CAN2.0；波特率500	上海海立新能源技术有限公司
冷凝器	B3-020G-42D-304-4.5	钎焊板式换热器总换热面积：0.8 m² 外形尺寸312 mm×76 mm×64 mm 接口管径：制冷剂侧15.5 mm，水侧19 mm	江苏唯益换热器股份公司
过冷器	B3-020G-10D-304-4.5	钎焊板式换热器总换热面积：0.2 m² 外形尺寸312 mm×76 mm×18 mm 接口管径：制冷剂侧15.5 mm，水侧19 mm	江苏唯益换热器股份公司
电子膨胀阀	EAS-16K001	阀口通径1.6 mm 接口管径OD 11.05/ID 15.5 mm	浙江三花汽车零部件有限公司
气液分离器	RA-207	接口管径ID/OD 19/21 mm 桶身高度218 mm 配备分子筛适用冷量10 kW	天津双昊车用空调有限公司
高压电源	HNX-600V-7200W	输入380 V AC 输出6~600 V DC 12 A	深圳市海纳信科技有限公司

部件	型号	规格	生产厂家
压缩机	EVS50B (低压版) EVS50HLBCAA-8AA	全封闭电动涡旋压缩机，排量50c/rev，转速1500~6000； 8.5kW~6000 r/min,0.2/1.4 MPa[G] SH/SC=10/5K； 6.3kW~6000 r/min T_e/T_c=-20/45℃ SH/SC=10/5 K；接口管径OD 15.5 mm / ID 21.3 mm 高压工作范围400~720 V；低压工作范围9~36 V 通讯协议CAN2.0；波特率500	上海海立新能源技术有限公司
冷凝器	B3-020G-42D-304-4.5	钎焊板式换热器总换热面积：0.8 m² 外形尺寸312 mm×76 mm×64 mm 接口管径：制冷剂侧15.5 mm，水侧19 mm	江苏唯益换热器股份公司
过冷器	B3-020G-10D-304-4.5	钎焊板式换热器总换热面积：0.2 m² 外形尺寸312 mm×76 mm×18 mm 接口管径：制冷剂侧15.5 mm，水侧19 mm	江苏唯益换热器股份公司
电子膨胀阀	EAS-16K001	阀口通径1.6 mm 接口管径OD 11.05/ID 15.5 mm	浙江三花汽车零部件有限公司
气液分离器	RA-207	接口管径ID/OD 19/21 mm 桶身高度218 mm 配备分子筛适用冷量10 kW	天津双昊车用空调有限公司
高压电源	HNX-600V-7200W	输入380 V AC 输出6~600 V DC 12 A	深圳市海纳信科技有限公司

参数	测量仪表	量程	精度	厂商
制冷剂温度T/℃ 制冷剂绝对压力 p/kPa	高温温压传感器	T -30~125 p 184~3518	±1.5%	盾安传感
制冷剂温度T/℃ 制冷剂绝对压力 p/kPa	低温温压传感器	T -30~125 p 101~1025	±1.5%	盾安传感
冷却液温度/℃	水温传感器	-40~200	±0.5℃	三花汽零
冷却液压差/kPa	压差传感器	0~100	±1%	杭州美控
冷却液流量/(L/min)	体积流量传感器	5~25	±1%	长征仪表
输入电流/A	直流电流传感器	0~20 A DC	±0.5%	杭州美控
输入电压/V	直流电压传感器	0~1000 V DC	±0.5%	杭州美控

参数	测量仪表	量程	精度	厂商
制冷剂温度T/℃ 制冷剂绝对压力 p/kPa	高温温压传感器	T -30~125 p 184~3518	±1.5%	盾安传感
制冷剂温度T/℃ 制冷剂绝对压力 p/kPa	低温温压传感器	T -30~125 p 101~1025	±1.5%	盾安传感
冷却液温度/℃	水温传感器	-40~200	±0.5℃	三花汽零
冷却液压差/kPa	压差传感器	0~100	±1%	杭州美控
冷却液流量/(L/min)	体积流量传感器	5~25	±1%	长征仪表
输入电流/A	直流电流传感器	0~20 A DC	±0.5%	杭州美控
输入电压/V	直流电压传感器	0~1000 V DC	±0.5%	杭州美控

工况参数	数值
膨胀阀进口温度T₃/℃	50
膨胀阀进口绝对压力p₃/MPa	1.5
chiller出口过热度SH₃/℃	5
chiller出口绝对压力p₅/MPa	0.3
冷却液侧流量V₃/(L/min)	12
冷却液侧进口温度T₁₁/℃	20