Abstract
Widespread adoption of electric vehicles is limited by their mileage, which is severely shortened by the positive temperature coefficient (PTC) heater in cold weather. To alleviate this difficulty, an electric vehicle thermal management system (EVTMS) with waste heat recovery from motor and controller unit is presented in this study. Utilizing a simulation model, the performances of EVTMS are investigated from the aspects of energy, exergy, and thermo-economy. In addition, the effects of waste heat amount and condensation temperature on EVTMS performances are exposed and discussed. It is indicated that increasing waste heat amount and decreasing condensation temperature would contribute to EVTMS performance improvement. Results show that the EVTMS with waste heat recovery leads to, in the best case, the coefficient of performance (COP) increase of 13.2%, the exergy destruction reduction of 20.01%, and the driving mileage improvement of 33.64%. With the waste heat varying in 0–2 kW and condensation temperature varying in 30–45 °C, the COP ranges from 2.05 to 4.71 and the system exergy efficiency varies in 28.63%~40.05%. Compared with the PTC heater, EVTMS with waste heat recovery could save the annual operation cost of 162.31–249.44 €. Base on the operation cost savings, the payback period of EVTMS ranges from 4.57 to 6.77 years.
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