Analysis and Optimization of Coupled Thermal Management Systems Used in Vehicles

About 2/3 of the combustion energy of internal combustion engine (ICE) is lost through the exhaust and cooling systems during its operation. Besides, automobile accessories like the air conditioning system and the radiator fan will bring additional power consumption. To improve the ICE efficiency, this paper designs some coupled thermal management systems with different structures which include the air conditioning subsystem, the waste heat recovery subsystem, engine and coolant subsystem. CO2 is chosen as the working fluid for both the air conditioning subsystem and the waste heat recovery subsystem. After conducting experimental studies and a performance analysis for the subsystems, the coupled thermal management system is evaluated at different environmental temperatures and engine working conditions to choose the best structure. The optimal pump speed increases with the increase of environmental temperature and the decrease of engine load. The optimal coolant utilization rate decreases with the increase of engine load and environmental temperature, and the value is between 38% and 52%. While considering the effect of environmental temperature and road conditions of real driving and the energy consumption of all accessories of the thermal management system, the optimal thermal management system provides a net power of 4.2 kW, improving the ICE fuel economy by 1.2%.