Investigating the potential energy savings of MVHR in automotive HVAC systems

Champion, Victoria; Allen, Antony; Wigston, Jonathan · 2023 · Crossref

DOI: 10.1177/09544070221080803

archive: archived pipeline: cataloged verified

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Summary

This study investigates the potential energy savings and range improvements of integrating Mechanical Ventilation with Heat Recovery (MVHR) technology into automotive Heating, Ventilation, and Air Conditioning (HVAC) systems for electric vehicles (EVs). The research is motivated by the significant impact HVAC systems have on EV energy consumption, which can account for 20–40% of total energy use and substantially reduce driving range. While heat pumps are a common solution, they suffer from complexity and inefficiency in cold climates. MVHR, a technology established in building standards like Passivhaus, offers a simpler alternative by transferring heat between extracted cabin air and incoming fresh air, potentially reducing HVAC load while maintaining air quality. The authors developed a MATLAB Simulink model to simulate an automotive MVHR HVAC system, calibrated against baseline data from an industry sponsor. The model incorporates a PID controller for temperature regulation, a recirculation loop to manage cabin pressurization, and a bypass mechanism to optimize efficiency. To translate HVAC energy savings into vehicle range benefits, the authors coupled the HVAC model with a vehicle road load model based on the Worldwide Harmonised Light Vehicles Test Procedure (WLTP) drive cycle. The simulation accounted for vehicle parameters such as mass, aerodynamic drag, and rolling resistance, as well as the additional weight of the MVHR unit (estimated at 3 kg net). The model was validated against industry data, showing appropriate fit despite deviations at extreme temperatures due to simplified loss parameters. Results indicate that MVHR integration yields substantial HVAC energy consumption reductions, ranging from 74.3% to 94.9% compared to a baseline non-MVHR system, depending on ambient temperature and MVHR efficiency (tested between 70% and 100%). These energy savings translate to a mean average EV range increase of 8.8% to 11.0% over the baseline case. When compared to the industry sponsor’s certified vehicle range, the MVHR system provided a 0.5% to 2.5% range increase under certification conditions. The study found that MVHR systems provide more stable range performance across varying ambient temperatures, mitigating the severe range drops seen in baseline systems at extreme cold (e.g., -20°C). Sensitivity analysis revealed that smaller cabin volumes and fewer occupants yield higher percentage energy savings, suggesting that incorporating passenger detection sensors to minimize fresh air flow when unnecessary could further enhance efficiency. The study concludes that applying MVHR technology to automotive HVAC systems is beneficial, offering significant energy savings and improved range consistency without the complexity of heat pumps. An MVHR efficiency of at least 80% is recommended to ensure the mean range surpasses certified values. The findings suggest that MVHR can help alleviate range anxiety by stabilizing energy consumption across climates, particularly if paired with smart airflow control strategies. This approach presents a viable pathway for improving EV efficiency and extending range without increasing battery size.

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