Optimization of injection-port design for multi-level waste heat recovery in an electric vehicle heat pump system

•A novel injection model was established based on flow visualization experiment.•The effect of port design on the multi-level heat pump system was investigated.•The optimal port geometries are derived with integrated thermal management model.•Re-designing of injection port saved power consumptions a...

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Bibliographic Details
Published in:Applied thermal engineering 2023-03, Vol.223, p.119970, Article 119970
Main Authors: Lee, Sangwook, Jeong, Yeonwoo, Hwang, Inchan, Kim, Min Soo
Format: Article
Language:English
Subjects:
EV (electric vehicle)
Flow visualization
Jet impingement
Thermal management system
Vapor injection technique
Waste heat recovery
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Summary:•A novel injection model was established based on flow visualization experiment.•The effect of port design on the multi-level heat pump system was investigated.•The optimal port geometries are derived with integrated thermal management model.•Re-designing of injection port saved power consumptions and advanced cross points. A multi-level waste heat recovery (MWHR) is an effective heat recovery strategy to utilize a limited amount of waste heat in electric vehicles (EVs). Because the MWHR system relies on the vapor injection technique, the port hole design critically affects the system performance. However, none of previous studies presented the optimal design of injection port for MWHR system. In this study, the effect of port design on the MWHR system performance was investigated. A continuous injection model was developed to reflect the dynamic behavior of MWHR system and integrated into a transient heat pump model. Integrated thermal management system (ITMS) model was established by combining the transient heat pump model with electric device model. The effects of injection port location and size were analyzed with the ITMS model under cold-start conditions. The optimal port hole design was suggested as the dual port located at 600° with a radius of 2 mm from the perspective of total energy consumption. Total power consumptions were saved up to 12.0 % and 10.6 % with the optimal port size and angle, respectively. This study can provide reference data and an optimization methodology for designing the MWHR system port hole.
ISSN:1359-4311
DOI:10.1016/j.applthermaleng.2022.119970