Full-stack energy efficiency collaborative optimization: Design and validation of vehicle energy consumption optimization

The innovation of energy-saving technologies for new energy vehicles is not only a breakthrough solution to the challenges of fossil fuel dependency and environmental pollution, but also a core driving force for modern transportation systems to transition toward low-carbon and sustainable development. Since the impact of vehicle energy efficiency spans the entire chain from underlying hardware architecture to top-level control logic, and there currently lacks an integrated approach to reveal the energy-saving mechanism, the potential for energy savings in vehicles remains largely untapped. Therefore, this paper constructs a full-stack energy efficiency collaborative optimization theoretical framework comprising “vehicle level-component level-strategy level”. It establishes systematic optimization methods oriented toward the vehicle power domain, targeting physical architecture, powertrain coupling, and control strategies, effectively expanding the efficiency boundary. Building upon this foundation, an energy consumption optimization design is conducted using a P1+P3 plug-in hybrid electric vehicle as a case study. Simulation calculations and real vehicle validation results demonstrate that this integrated optimization approach achieves a 10.89% fuel savings rate, delivering significant improvements in vehicle fuel economy, effectively verifying both the superior energy-saving potential and the real-time application capability of the proposed framework. This research provides an effective systematic methodology for enhancing the energy efficiency of hybrid powertrain systems, offering a practical engineering reference for the development of new energy vehicles with high energy efficiency.