Integrated Simulation Framework for Multi-Objective Electric Vehicle Powertrain Design: Energy, Cost and Environmental Impact Optimization

Eco-design represents a key challenge in vehicle development, as increasingly stringent regulations and rising customer performance expectations require the optimal combination of environmental considerations and efficiency. This work presents three integrated simulation tools for electric vehicle (EV) powertrain design, targeting energy consumption, cost optimization, and environmental impact assessment. Three complementary models were developed and validated: a dynamic energy consumption model, a comprehensive cost estimator, and a life cycle carbon footprint assessment tool. Validation against real-world data demonstrated residuals consistent with existing literature, with prediction errors under 9% for energy efficiency and cost models. This integrated approach enables designers to account for the complete life-cycle impact of the vehicle being designed while optimizing component sizing for specific behavioral usage patterns, thereby avoiding costly oversizing. As an example of application of the proposed methodology, a multi-objective optimization analysis in urban area was performed, which converged to a small electric vehicle with city-tailored propulsion power, resulting in lower cost (estimated at less than 20k€) and consumption (less than 13kWh/100km). This shows that the methodology successfully balances the trade-offs between performance, cost, and environmental impact based on a given usage. Key model limitations were identified and analyzed, providing clear directions for future improvements. The developed framework offers a practical tool for sustainable EV powertrain design that addresses current industry challenges.2 Keywords: Electric vehicles, eco-design, powertrain optimization, life cycle assessment, energy modeling