Heat exchange performance of a battery chiller for electric vehicles

doi:10.11949/0438-1157.20201569

Abstract

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

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

CLC Number:

TK 11.3

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.

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.

Figures/Tables 9

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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