Thermal Management of PHEV / EV Charging SystemsJun 10, 2010 · National Renewable Energy...

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Thermal Management of PHEV / EV Charging Systems

U.S. Department of EnergyAnnual Merit Review

P.I. Kevin Bennion

poster presented byMichael O’KeefeNational Renewable Energy Laboratory

Thursday June 10, 2010

APE029This poster does not contain any proprietary, confidential, or otherwise restricted information

Overview

National Renewable Energy Laboratory Innovation for Our Energy Future

Timeline

Budget

Barriers

Partners/Collaboration

•Project Start: FY 2010 (New Project)•Project End: FY 2010•Percent Complete: 5%

•Total Funding (FY10-FY10)•DOE: $300K•Contract: $0K

•Annual Funding•FY10: $300K

•Electrical and Electronics Technical Team (EETT)•USCAR Partners•Oak Ridge National Laboratory• Idaho National Laboratory•National Renewable Energy Laboratory Grid Integration Task•National Renewable Energy Laboratory Vehicle Systems Analysis Task

•Cost & Performance•Weight & Volume•Thermal Management

2

Objectives: Relevance (1/5)

National Renewable Energy Laboratory Innovation for Our Energy Future3

• Multiple charging options available for PHEV and EV ranging from:• Off-vehicle high power rapid charge.• In-vehicle chargers as stand-alone and integrated systems.

• High power levels and limited vehicle package space present integration challenges.• How much heat?• Where should it go?

• Other proposed uses for grid electricity beyond charging.

Level Voltage Current Power Power Loss*1 120 V 12 A 1.44 kVA 220 W (85% Efficiency [1])

2240 V 32 A 7.7 kVA 1.2 kW (85% Efficiency [1])240V 20kW [2,3] 2 kW (90% Efficiency [2,3])

3 480 V Varies

1. Lambert, Frank C., “IWC – Record of Consensus.” PHEV WG Meeting, Palo Alto, CA, 2008. Available: http://et.epri.com/documents/12.11.08_IWC_PHEV_presentations/01_IWC_Actions_Lambert.pdf2. AC Propulsion, “AC Propulsion Provides Power for 500 New Electric Vehicles.” Available: http://www.acpropulsion.com/company/press-releases.php.3. Su, Gui-Jia, “Utilizing the Traction Drive Power Electronics System to Provide Plug-in Capability for HEVs.” DOE Vehicle Technologies Program Advanced Power Electronics and Electric

Machines FY09 Kickoff Meeting, Oak Ridge National Laboratory, 2008.

Significant Heat Loads

* Power losses are approximated to illustrate magnitudes.

http://et.epri.com/documents/12.11.08_IWC_PHEV_presentations/01_IWC_Actions_Lambert.pdf�

http://www.acpropulsion.com/company/press-releases.php�



CompressorEvaporator

Condenser

Expansion Valve

Engine Heat to Coolant

Cowl Air

Ambient Air

Radiator

HeaterCabin

EM/Trans. Heat to Oil

Air Out

Air Out

PE Heat to Coolant

ESSHeat Air Out

Radiator

OilCooler

• Example of current HEV thermal management systems.•Where does the charger go?

• >1 kW heat load




Condenser

Expansion Valve


Cowl Air

Ambient Air

Radiator

HeaterCabin


Air Out

Air Out

PE Heat to Coolant

ESSHeat Air Out

Radiator

OilCooler

Vehicle Cabin•How is cooling provided?•Where does heat go?




Condenser

Expansion Valve


Cowl Air

Ambient Air

Radiator

HeaterCabin


Air Out

Air Out

PE Heat to Coolant

ESSHeat Air Out

Radiator

OilCooler

Integrated PEEM system•How is cooling provided?•Where does heat go?

Activation of multiple pumps and fans.• Parasitic power load• Net charge efficiency• Noise



Objective• Characterize and match EV/PHEV

charging configurations to thermal management technologies and vehicle integration applications.• Support technology development

beyond charging to support other applications for electric vehicle support equipment.

Addresses Targets• Results are guided towards reducing

cost, weight, size, and energy losses.

Uniqueness and Impacts• Applies developed power electronics

thermal technologies to support use of grid electricity in EV/PHEV applications.• Interfaces with other Vehicle

Technologies Program areas.

Cabin

ICE & Trans.

Emissions

Charging or Gr id

Inter face

Energy Storage

Electr ic Machine

Power Electr ics

Heat Exchangers

Approach/Strategy (1/4)


1. Understand uses and applications

2. Quantify thermal loading and efficiency impacts

3. Vehicle thermal integration

Cabin

ICE & Trans.

Emissions

Charging or Gr id

Inter face

Energy Storage

Electr ic Machine

Power Electr ics

Heat Exchangers



Energy Storage Systems (ESS)

Thermal Management

Electric Vehicle Grid IntegrationElectric grid interface

Vehicle Systems AnalysisThermal

Preconditioning

Uses/Loading

Efficiency/HeatIntegrated

Charger Thermal System

Charger Technology

Development

APEEM Activity

Potential Thermal Control Technologies

Vehicle Technologies Program

Collaboration Areas



1. Quantify charger heat loads and parasitic power loads.

2. Understand potential applications for electric grid connection beyond charging.

3. Characterize current thermal management technologies applied to current battery charging configurations.

4. Screen potential alternative thermal management technologies and integration concepts.

5. Select promising technologies for prototyping.

Efficiency

Uses

Vehicle Technologies

Program Collaboration

Areas

Integrated PHEV/EV Charger Thermal

Management

Approach/Strategy (4/4) - Milestones

National Renewable Energy Laboratory Innovation for Our Energy Future

FY10 (Scheduled)• Annual milestone report - status update (October)

11

Technical Accomplishments & Progress (1/4)


• Met with researches at other research organizations within DOE and outside of DOE to understand potential uses, configurations, and control of electric vehicle support equipment which includes chargers.

• Developed collaboration with Idaho National Laboratory (INL) to include charging thermal data from light-duty vehicle PHEV test fleet supported by the Vehicle Technologies Program.

• Charger efficiency data provided by ORNL on high power charging concept developed as part of the APEEM activity that is integrated within the existing electric drive system.

• Working with grid integration activity within NREL to obtain charging efficiency and thermal data.



Developing process to evaluate cooling technologies for electric vehicle support equipment.

Application TargetsHeat, Temperature, Size

Thermal PerformanceTargets

Cooling Technology




Application TargetsHeat, Temperature, Size

Thermal PerformanceTargets

Cooling Technology

1Identify Application Technology Targets (Power Density)

Identify Temperature Specifications Targets

System Thermal Resistance Target [Rth,j-a]

2

Tech

nolo

gy T

arge

t to

Ther

mal

Res

ista

nce

Targ

et

Define Component Geometry 3

0.01

0.1

1

10

100

0 5 10 15 20

Targ

et R

th,j-

a[K

/W]

Power Density [kW/L]

Package:A at ∆T=90°C Package:A at ∆T=60°CPackage:B at ∆T=90°C Package:B at ∆T=60°CPackage:C at ∆T=90°C Package:C at ∆T=60°C

Power Density Target

Example



1Identify Application Technology Targets (Power Density)

Identify Temperature Specifications Targets

System Thermal Resistance Target [Rth,j-a]

2

Tech

nolo

gy T

arge

t to

Ther

mal

Res

ista

nce

Targ

et

0.1

1.0

10.0

1 10 100 1,000 10,000

Rth

,j-a

[K/W

]

R"th,h-a [mm2-K/W] Hea

t Exc

hang

er T

echn

olog

y Se

lect

ion

Define Component Geometry 3

1Define Package Geometry

Develop 3D Parametric FEA Model

Heat Exchanger Target Thermal Resistance [R”th,h-a]

2

Characterize Thermal Package Performance 3

Heat Exchanger Target


Example

Collaboration and Coordination

Industry– Electrical & Electronics Tech Team: Partner

• Input on plans and accomplishments.

Other Government Laboratories– Oak Ridge National Laboratory: Partner

• Charger development work within the APEEM activity.• Grid integration.

– Idaho National Laboratory: Partner• In-use charger efficiency data for PHEV fleets.

– National Renewable Energy Laboratory (Outside of APEEM): Partner.• Applications for electric vehicle support equipment.


Proposed Future Work


• The project is scheduled to end in FY2010


Summary

Relevance• Characterize and match EV/PHEV charging

configurations to thermal management technologies and vehicle integration applications.

• Support technology development beyond charging to support other applications for electric vehicle support equipment.

Approach/Strategy• Apply developed power electronics thermal

technologies to support use of grid electricity in EV/PHEV applications.

• Interface with other Vehicle Technologies Program areas.

• Quantify charger heat loads and screen potential alternative thermal management technologies and integration concepts.


Summary

Technical Accomplishments• Established collaborations with other research partners to obtain

thermal data on EV/PHEV charging systems.

• Developing process to link appropriate thermal management technologies to charging applications.

Collaborations• Collaborations established with R&D partners.

– Idaho National Laboratory

– Oak Ridge National Laboratory

Thermal Management of PHEV / EV Charging SystemsJun 10, 2010 · National Renewable Energy...

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