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Optimization on control strategy for CO2-based dual-cooling thermal management system in electric vehicles

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  • Zhou, Yuankun
  • Liu, Zhixiang
  • Ruan, Yijia
  • Tian, Yafen
  • Li, Kang
  • Zhang, Hua

Abstract

The thermal management of electric vehicles (EVs) faces a critical challenge in simultaneously maintaining cabin comfort and ensuring battery safety. To tackle this issue, an adaptive control strategy for a CO2 transcritical dual-cooling system is proposed, underpinned by a multiphysics battery model validated experimentally. The model integrates electrochemical, thermal, and aging dynamics, predicting voltage and temperature with high accuracy (maximum errors of 4.2 % and 6.5 %, respectively). Systematic optimization identified a coolant flow rate of 25 L/min to minimize battery temperature difference (ΔT ≤ 0.5 °C) and a 15 % expansion valve opening to balance Coefficient of Performance (COP) with cooling capacity. Dynamic vapor quality regulation at the chiller outlet enhanced system COP by 46.5 % (from 1.29 to 1.89) and reduced optimal discharge pressure by 2.1 %. Compared to a fixed-valve strategy, the variable approach shortened battery cooling time by 38.7 % (from 595 s to 429 s) and increased COP by 3.7 %. The dual-cooling mode reduced battery aging by 10 % but raised energy consumption by 46.4 % versus cabin-only cooling, slightly compromising thermal comfort (Predicted Mean Vote (PMV) = 1.15 vs. target 0.5) and prolonging cabin temperature stabilization by 225 s. At 38 °C ambient temperature, dual-cooling cut driving range by 35 %, with cabin thermal load contributing 77.2 % to the total loss. Under high-speed driving, battery cooling dominated efficiency loss (37.4 %). These findings underscore the essential role of adaptive control in balancing battery durability, cabin comfort, and energy efficiency in next-generation EV thermal systems.

Suggested Citation

  • Zhou, Yuankun & Liu, Zhixiang & Ruan, Yijia & Tian, Yafen & Li, Kang & Zhang, Hua, 2026. "Optimization on control strategy for CO2-based dual-cooling thermal management system in electric vehicles," Energy, Elsevier, vol. 343(C).
    • Handle: RePEc:eee:energy:v:343:y:2026:i:c:s0360544225054477
    DOI: 10.1016/j.energy.2025.139804
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    References listed on IDEAS

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    1. Zhang, Xinghui & Li, Zhao & Luo, Lingai & Fan, Yilin & Du, Zhengyu, 2022. "A review on thermal management of lithium-ion batteries for electric vehicles," Energy, Elsevier, vol. 238(PA).
    2. Jiang, Ziqi & Tian, Yafen & Li, Kang & Zhao, Zhaorui & Liu, Ni & Zhang, Hua, 2024. "Research on refrigerant charge determination under different compressor speed and its effects on the performance of transcritical CO2 air-conditioning heat pump system in electric vehicle," Energy, Elsevier, vol. 296(C).
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    4. Wang, Anci & Yin, Xiang & Xin, Zhicheng & Cao, Feng & Wu, Zan & Sundén, Bengt & Xiao, Di, 2023. "Performance optimization of electric vehicle battery thermal management based on the transcritical CO2 system," Energy, Elsevier, vol. 266(C).
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