Design and Implementation of a Thermal Load Reduction System for a Hyundai Sonata PHEV for Improved Range 2018-01-1186

Increased adoption of electric-drive vehicles requires overcoming hurdles including limited vehicle range. Vehicle cabin heating and cooling demand for occupant climate control requires energy from the main battery and has been shown to significantly degrade vehicle range. During peak cooling and heating conditions, climate control can require as much as or more energy than propulsion. As part of an ongoing project, the National Renewable Energy Laboratory and project partners Hyundai America Technical Center, Inc., Gentherm, Pittsburgh Glass Works, PPG Industries, Sekisui, 3 M, and Hanon Systems developed a thermal load reduction system to reduce the range penalty associated with electric vehicle climate control. Solar reflective paint, solar control glass, heated and cooled/ventilated seats, heated surfaces, and a heated windshield with door demisters were integrated into a Hyundai Sonata plug-in hybrid electric vehicle. Cold weather field-testing was conducted in Fairbanks, Alaska, and warm weather testing was conducted in Death Valley, California, to assess the system performance in comparison to the baseline production vehicle. In addition, environmental chamber testing at peak heating and cooling conditions was performed to assess the performance of the system in standardized conditions compared to the baseline. Experimental results are presented in this paper, providing quantitative data to automobile manufacturers on the impact of climate control thermal load reduction technologies to increase the advanced thermal technology adoption and market penetration of electric drive vehicles.