The application of immersion liquid cooling (ILC) technology in electric vehicle (EV) thermal management systems (TMS) achieves improved heat exchange performance, significantly enhancing the temperature consistency and control responsiveness of both the battery and passenger cabin. A new ILC system for EV TMS is proposed to explore its feasibility and energy economics. Firstly, the mathematical model incorporating a direct ILC system is developed using AMESim® software, with key components parameter-matched and partially validated. Then, the set temperatures of the battery are optimized to maximize the driving range, based on the designed startup strategy under the China Light-duty Vehicle Test Cycle (CLTC) conditions. Finally, simulation studies were conducted to investigate the effect of ILC on improving heat transfer performance during the cold start process, resulting in a relative reduction in cold start times and enhanced passenger compartment comfort. The conclusions indicate that the driving range follows an inverse U-shaped relationship with the set temperature of the battery, with an optimal value of 321.61 km at 5°C. Additionally, the passenger compartment can consistently maintain a temperature between 21°C and 23°C relatively quickly under various operating conditions.
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