Two Paths Towards Real-Time HIL Simulation of EV Thermal Management Systems

Effective thermal management is crucial for ensuring the operational efficiency, safety of electric vehicle (EV) components, and the comfort of its passengers. Comprehensive testing and validation of control algorithms for EV thermal management systems requires physical models that capture the intricate interactions among various thermal-fluid components while also satisfying the requirements for real-time simulation for hardware-in-the-loop (HIL) testing. Notably, the complex dynamics within the refrigeration subsystem often pose considerable challenges in achieving real-time performance. This talk explores two methodologies to overcome these challenges, demonstrated through case studies utilizing a model of an EV thermal management system available from Simscape Fluids™. The first approach involves a detailed analysis and optimization of the model's numerical performance, with a focus on the refrigeration subsystem, preparing the model for real-time simulation using a fixed-step, fixed-cost solver. The second approach introduces the creation of a data-driven, reduced-order model for the refrigeration subsystem. This model integrates with the rest of the physical model and captures the effect of the refrigeration on other working fluids and feedback to controllers. Through this discussion, the session aims to equip engineers with the knowledge and tools necessary to efficiently navigate the complexities of real-time simulation in EV thermal management systems. Attendees will gain insights into selecting appropriate strategies and applying them effectively to achieve their engineering objectives.