In the two previous articles, we worked out how the required heating power of an electric car with an electric high-voltage heater eats up range and that a heat pump system like the one from MAHLE provides up to 20 percent more range under the same conditions. We are now looking at future component integration with a module that combines the refrigerant and coolant side. This saves costs and installation space, facilitates possible repairs and brings further efficiency benefits.
Thermal management has the task of cooling and heating. As the number of components that need to be kept within a certain temperature range increases, so does the complexity of the system: the high-voltage battery, power electronics, electric motor, interior and, in the case of hybrids, the combustion engine, all have different temperature requirements in order to function optimally: for greater efficiency, range and customer acceptance.
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Current heat pump systems have a problem: they consist of many individual components such as actuators, sensors, pumps, valves or pipes, which are usually installed somewhere where space is available in current vehicles. This increases the weight, as each part needs a holder, and the coolant and refrigerant filling quantities are larger due to the long lines.
And of course it takes up space because each component has to be installed and removed, including the space required for hoses and lines. If there is a problem,
troubleshooting and repairs are correspondingly time-consuming.
Based on its in-depth understanding of vehicle temperature management, MAHLE has developed thermal management modules. The first module is soon to go into series production in an electric vehicle from an established, globally positioned vehicle manufacturer. A module integrates individual components such as the electric compressor, heat exchanger, sensors, valves and coolant pumps into a single unit. Thanks to the high level of integration and therefore short distances, the modules work significantly more efficiently than their individual parts - for a greater range and higher charging speed.
In addition, the approach enables smaller installation spaces and drastically reduced assembly work. And although the thermal management module is designed for the service life of the vehicle, MAHLE has thought about service and repair: faults are much easier to locate and, depending on the design, components can be replaced while installed. In addition, the module can be overhauled or repaired in a quality-assured manner in the event of major defects.