Modular Thermal Management Framework for Electric Drive System Development

The automotive industry is undergoing a major shift from internal combustion engines (ICE) to hybrid (HEV) and battery-electric vehicles (BEV), which has led to significant advancements and increased complexity in drivetrain design and thermal management systems. This complexity reflects the growing need to optimize energy efficiency, extend vehicle range, and ensure system reliability in modern electric vehicles. At the Institute of Automotive Engineering, a specialized synthesis tool for drivetrain optimization is used to identify the best drivetrain configurations based on specific boundaries and requirements. Building up on this toolchain a modular and adaptable thermal management framework has been developed, addressing another critical aspect of vehicle and drive development: efficient thermal circuit layout and its impact on energy consumption and overall system reliability. The thermal framework emphasizes the dynamic interactions between key components, such as electric machines, power electronics and batteries, supporting early-stage evaluation of powertrain and thermal management configurations as well as cooling strategies. The modular design allows for systematic exploration of new topologies and parameter variations, providing insights into improving energy efficiency and addressing the unique challenges of electrified vehicle systems. By integrating this adaptable thermal framework with the drive synthesis tool, a holistic approach to drive system design is achieved. In this work, various BEV concepts were investigated through extensive parameter variations, including battery capacity, electric machine power, and transmission types. Both single-speed and two-speed transmissions were analyzed alongside different thermal management systems. The evaluations and benchmarks are carried out in legal cycles such as the WLTP as well as customer cycles for different ambient conditions, enabling a comprehensive system analysis.