Multi-physics simulation modeling and energy flow characterization of thermal management system for a sport utility vehicle under high-temperature conditions

Driving range and overall performance of electric sport utility vehicles (ESUVs) are closely linked to their thermal management system (TMS). To accurately analyze energy flow characteristics of TMS for an ESUV, a multi-physics simulation model was developed and calibrated using World Light Vehicle Test Cycle (WLTC) test data at 35 °C. On this basis, the impacts of various driving conditions and cycles on energy flow of TMS under steady and transient states were investigated. The results indicate that compressor is the primary energy consumer under high-temperature conditions, accounting for 87% of total energy consumption. The real-time cooling efficiency of air conditioning system exhibits four distinct troughs corresponding to compressor efficiency curve, with reduced cooling efficiency observed at high compressor power levels. When interior and exterior environments of ESUV reach a relative equilibrium state, energy consumption of TMS per cycle is approximately 0.51 kW·h for China Light-duty Vehicle Test Cycle (CLTC) and WLTC, and 0.35 kW·h for New European Driving Cycle (NEDC). The proportion of battery discharge energy utilized by TMS under the WLTC, NEDC and CLTC is 13.5%, 18.2% and 20.1%, respectively. These findings provide valuable insights and data support for performance evaluation and optimization of TMS in ESUVs.