Design optimization of finned multi-tube PCM heat exchanger for enhancing EV energy performance

This study presents an optimized design of a finned multi-tube phase change material-based thermal energy storage system for electric vehicle thermal management, addressing the challenge of low battery efficiency in cold climates. While finned multi-tube designs are recognized for their thermal advantages, their application in electric vehicles has been underexplored. Previous research often overlooks the full operational cycle of electric vehicles, including charging (melting), discharging (solidification), and driving conditions. This work bridges the gap by optimizing the thermal energy storage design using a multi-objective genetic algorithm to enhance both thermal efficiency and energy density. The optimized design reduces melting and solidification times by 68.6% and 60.3%, respectively, and increases energy density by 4.9% compared to the initial design. The study further integrates the optimized thermal energy storage system into an electric vehicle thermal management strategy, analyzing its performance under real-life driving cycles in various ambient temperatures. This integration reduces total energy consumption by 20.6% compared to a baseline system. These findings offer a novel approach to improving the driving range of electric vehicles in cold climates by minimizing power demand on electric batteries for cabin heating.