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<p>The automotive industry is increasingly seeking sustainable refrigerants to address environmental concerns and alleviate range anxiety in electric vehicles (EVs). This study experimentally investigates an R290 heat pump system, integrated with secondary loop and vapor injection technologies, for EVs operating under extreme temperatures (−20°C to 40°C). Comprehensive vehicle tests have been conducted under four scenarios: maximum cooling, maximum heating, and the China Light-Duty Vehicle Test Cycle-Passenger (CLTC-P) at 30°C and −7°C. Vehicle-level air conditioning performance analysis demonstrates that the system can meet the cooling and heating requirements specified in the Vehicle Technical Specifications (VTS), even under extreme environmental temperatures. The maximum cooling test results demonstrate that the system achieves a cooling capacity of 2910 W to 3160 W, with a coefficient of performance (COP) of 1.20 to 1.38. During the maximum heating performance evaluation, the system achieves satisfactory cabin heating without positive temperature coefficient (PTC) heater assistance, delivering a heat output of 4988 W to 7517 W with a COP of 1.60 to 1.87. The CLTC-P tests demonstrate superior energy efficiency, with compressor energy consumption of 466 W (COP=20.90) in cooling mode and 528 W (COP=3.34) in heating mode during five-cycle evaluations. Thermodynamic cycle analysis reveals maximum total pressure ratios of 5.6 and 11.5 for cooling and heating modes, respectively. These findings validate the R290 heat pump system as a sustainable and high-efficiency solution for EV thermal management so as to offer valuable insights for mass production applications.</p>

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Experimental Study of an R290 Heat Pump System with Secondary Loop and Vapor Injection for Electric Vehicles under Extreme Temperature Conditions

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Mengliang Yao,
  • Xianzhen Ruan,
  • Zhixin Zeng,
  • Liang Zhu,
  • Siwang Li,
  • Ke Hu,
  • Linggui Zhong,
  • Zhaoxian He,
  • Peng Xie,
  • Jialin Liang,
  • Chuanqi Chen,
  • Chaoqian Wang

摘要

The automotive industry is increasingly seeking sustainable refrigerants to address environmental concerns and alleviate range anxiety in electric vehicles (EVs). This study experimentally investigates an R290 heat pump system, integrated with secondary loop and vapor injection technologies, for EVs operating under extreme temperatures (−20°C to 40°C). Comprehensive vehicle tests have been conducted under four scenarios: maximum cooling, maximum heating, and the China Light-Duty Vehicle Test Cycle-Passenger (CLTC-P) at 30°C and −7°C. Vehicle-level air conditioning performance analysis demonstrates that the system can meet the cooling and heating requirements specified in the Vehicle Technical Specifications (VTS), even under extreme environmental temperatures. The maximum cooling test results demonstrate that the system achieves a cooling capacity of 2910 W to 3160 W, with a coefficient of performance (COP) of 1.20 to 1.38. During the maximum heating performance evaluation, the system achieves satisfactory cabin heating without positive temperature coefficient (PTC) heater assistance, delivering a heat output of 4988 W to 7517 W with a COP of 1.60 to 1.87. The CLTC-P tests demonstrate superior energy efficiency, with compressor energy consumption of 466 W (COP=20.90) in cooling mode and 528 W (COP=3.34) in heating mode during five-cycle evaluations. Thermodynamic cycle analysis reveals maximum total pressure ratios of 5.6 and 11.5 for cooling and heating modes, respectively. These findings validate the R290 heat pump system as a sustainable and high-efficiency solution for EV thermal management so as to offer valuable insights for mass production applications.