MAC Solutions for Hybrid-and Electric Vehicles

1. MAC Solutions for Hybrid- and Electric Vehicles
MAC Solutions for Hybrid- and Electric Vehicles
4th of June 2010
汽车空调新技术国际研讨会
中国 南京2010.6.3-2010.6.4
1
G-P, Dr. Wesenberg, July 2009
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2. MAC Solutions for Hybrid- and Electric Vehicles
Importance of Efficiency for Hybrid- and Electric Vehicles
混和动力和电动车的功效的重要性
Vehicle with Combustion Electric Vehicle or E-mode of
Engine带发动机的车 Hybrid Vehicle
电动车或电动模式的混和动力
50 l fuel tank -> 460 kWh Energy storage 120 l Li-Ion Battery -> 20 kWh
50 l燃油箱-> 460 kWh 蓄能 (future)
2 kW for heating or AC for
1 hour -> 2 kWh -> 0,4 l fuel 2 kW for heating or AC for
(50% efficiency 1 hour -> 2 kWh
2 kW 用于加热或制冷 Consequence
1 hour -> 2 kWh -> 0,4 l fuel 结果
(50% efficiency 效率 Reduction of driving range:
65 km (at 2,5 kW needed power for
Reduction of driving range: driving, at average speed 18,3km/h)
5 km (at 8l/100km)在百公里油 Compensation
耗8l时减少驾驶距离5公里 补偿 80% bigger battery, Very expensive
0,8% bigger tank 相当于油箱
要大0.8%
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G-P, Dr. Wesenberg, July 2009
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Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

3. MAC Solutions for Hybrid- and Electric Vehicles
Fuel efficient cabin cooling: ECO-AC
Reduced mechanical Efficient refrigerant circuit
power consumption 高效的制冷管路
 High performance heat exchanger
减少机械能消耗  Internal Heat exhanger + TXV-adaption
 高效能换热器 circuit balancing
Refrigerant
内置换热器＋TXV－相应接口
制冷管路平衡
Reduced electrical Efficient blower
power consumption 高效的鼓风机
 Silent Blower
减少电能消耗 • Brushless - blower motor
• PWM Controller
静音鼓风机
无刷鼓风机
PWM功率模块
Cooling as much Efficient control
as necessary 高效的控制
• Gliding evaporator temperature control Plus
必要制冷量 • Adapted OSA/REC control
平顺的蒸发器控制
合适的内外循环
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G-P, Dr. Wesenberg, July 2009
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4. MAC Solutions for Hybrid- and Electric Vehicles
Heating in Electric Vehicles
Adapted OSA/ REC Control
合适的 新风/回风 控制
Avoidance of heat losses  Reduction of ventilation losses
减少风道损失
避免热量损失  Humidity sensor to prevent windscreen
fogging
 湿度传感器防止风挡 结雾
High Voltage PTC
高电压PTC
 Much better efficiency than PTC
比PTC更好的效率
Heat Pump  Less restrictions for driving range than
热泵 with PTC
 对驾驶行程较少的限制
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G-P, Dr. Wesenberg, July 2009
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Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

5. MAC Solutions for Hybrid- and Electric Vehicles
Heating for cars with electric propulsion电动车的加热
High Voltage PTC-heater for Full-Hybrids & E-Cars高电压PTC－用于混和动力和电动车
Motivation: Internal conbustion engine is not available as heat source for the cabin
原因：内燃机不能提供整车的热源
Solution : High Voltage Airside PTC-heater (based 3rd Generation PTC)
方案：高电压空气侧PTC（第三代PTC）
 Electric Power :5 KW @ 300V, 300kg/h und -20°C air intake PTC-heater
 电能 ： 5 KW @ 300V, 300kg/h 在进风为-20°C 空气
 Package :46 mm (compatible w/ todays package)
 外围尺寸 ：46mm(和目前产品兼容）
 Weight :1000 g w/o cable
 重量 ：1000g 不带线束
 Efficiency : best in class heat exchanger matrix
 效率 ：换热器高效
 接触片
 陶瓷
 密封胶
 绝热材料
 绝热片
• 翅片
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G-P, Dr. Wesenberg, July 2009
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Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

6. MAC Solutions for Hybrid- and Electric Vehicles
Operating limits Heat pump热泵操作的局限
Based on first test bench result基于第一轮试验
 Basis for a A/B class car (heat up performance as today Diesel car + PTC)基于A/B 级别车（加热
效果如柴油车加PTC)
 Tamb > -7°C heat pump only seems possible (if 6000 rpm is o.K. regarding
NVH )*仅有热泵
 -7°C >Tamb > -12 °C heat pump + additional PTC 热泵＋PTC
 Tamb < -12°C PTC only because of oil (operation limit can be changed with
由于回油仅有热 different compressor oil)
 For deicing outside heat exchanger 除冰换热器
• Shut off heat pump切断热泵
• Switch on A/C mode开关在空调模式
• PTC only for cabin heating PTC仅用于车内制热
*) @ -7°C 3.3 kW heating power is required
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Abteilung Name August 2007 Dok-Nr.ppt
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7. MAC Solutions for Hybrid- and Electric Vehicles
Interfaces Battery Cooling – Automotive Cooling Systems
电池冷却－自动冷却系统
Cooled air冷却空气
Li-Ion battery锂电池
Tmax = <40°C Refrigerant制冷剂 Refrigerant
∆Tin cell = 5-10K circuit
制冷剂回路
∆Tbetw. cells = 5K
Second. Loop第二个回路
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G-P, Dr. Wesenberg, July 2009
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Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

8. MAC Solutions for Hybrid- and Electric Vehicles
Products Battery Cooling电池冷却产品
Cooled air冷却空气
Li-Ion battery锂电池
Tmax = <40°C
∆Tin cell = 5-10K
Refrigerant
Refrigerant
∆Tbetween cells = 5K
制冷剂 circuit
制冷剂回路
Second. Loop Chiller电池冷却器
第二个回路
Inside Battery
Outside Battery电池外部
 cooling plates冷却板  Evaporator蒸发器
 cooling frame冷却框架  Chiller冷却器
 low temperature cooler低温冷却器
 Valves阀
 Pumps泵
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G-P, Dr. Wesenberg, July 2009
The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

9. MAC Solutions for Hybrid- and Electric Vehicles
Virtual Path: SimulationTechnology虚拟方法：模拟技术
BISS Battery Component Simulation
Electric and Thermal Model电及热力模型
电池元件模拟系统
from
cell core
up to
cooling system从
电池单元到冷却系统
BISS Battery System Simulation电池 FEM / CFD Simulation
冷却系统模拟 FEM/CFD模拟
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G-P, Dr. Wesenberg, July 2009
The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

10. MAC Solutions for Hybrid- and Electric Vehicles
Experimental Path: Hardware Technology试验设施：硬件技术
Cell & Battery thermal Dummy
Battery Cell Evaluation电池组评估
电池单元热力学模拟
from
cell core
up to
cooling system
从电池单元到冷却系统
Validation Battery Cooling Components
Battery System Test Bench电池系统测试台
电持冷却元件研证
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G-P, Dr. Wesenberg, July 2009
The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.