Integration and Evaluation of Different Thermal Loops through Simulation for Improved Defrost and Range of an Electric Truck

The rapid advancement in thermal management for electric vehicles (EVs) is driven by the need to reduce battery load and enhance EV range. Unlike conventional platforms, EV thermal management is complex due to temperature sensitivity and the numerous components involved. Powertrain components, such as the motor and transmission, operate at higher temperatures, while the battery and passenger cabin require distinct thermal conditions. This necessitates a carefully modelled thermal layouts that considers the diverse thermal needs of each component. The primary objective of this study is to improve the existing thermal layout of EVs, aiming for a more efficient design and evaluating its benefits through simulation. Utilizing the 1D commercial software GT-SUITE, the research integrates different layouts of EV’s and study the hydraulic and thermal feasibility. Integrations are based on operating temperatures, flow, and pressure requirements, while ensuring thermal comfort in the cabin and preventing deration. Design optimizations through thermal simulations demonstrate benefits in terms of battery power consumption under various environmental conditions. While integrating energy-saving loops is not new, their impact varies across different vehicles. Quantifying these benefits is vital for assessing the risk and potential advantages for end-users. Computational Fluid Dynamics (CFD) helps in identifying crucial design changes and provides quantifiable numbers in power consumption without the need for actual testing, saving time and cost during the initial design phase.