Thermal Management in Electrified Transportation: A Comparative Study of Different Powertrain Technologies

2025-28-0412

10/30/2025

Authors Abstract
Content
The transition towards sustainable transportation necessitates the development of advanced thermal management systems (TMS) for electric vehicles (EVs), hybrid electric vehicles (HEVs), hydrogen fuel cell vehicles (FCVs), and hydrogen internal combustion engine vehicles (HICEVs). Effective thermal control is crucial for passenger comfort and the performance, longevity, and safety of critical vehicle components. This paper presents a rigorous and comparative analysis of TMS strategies across these diverse powertrain technologies. It systematically examines the unique thermal challenges associated with each subsystem, including cabin HVAC, battery packs, fuel cell stacks, traction motors, and power electronics. For cabin HVAC, the paper explores methods for minimizing energy consumption while maintaining thermal comfort, considering factors such as ambient temperature, humidity, and occupant load. The critical importance of battery thermal management is emphasized, with a focus on preventing thermal runaway and maximizing battery lifespan through precise temperature regulation. The complexities of fuel cell stack thermal management are addressed, considering the electrochemical reactions and the need for uniform temperature distribution for optimal performance and durability. Furthermore, the paper investigates the thermal behavior of high-power traction motors and power electronics, analyzing different cooling techniques and their impact on efficiency and reliability. A comparative assessment of various cooling technologies, including forced air convection, liquid cooling, and emerging two-phase cooling methods, is provided. The paper also delves into integrating these individual TMS components, exploring opportunities for waste heat recovery and holistic system optimization. Finally, the paper identifies critical research gaps and outlines future directions in the development of intelligent and adaptive thermal management systems for next-generation electrified vehicles, emphasizing the need for robust control algorithms, advanced materials, and innovative cooling architectures.
Meta TagsDetails
Pages
9
Citation
K, N., K, A., Ch, K., C, S. et al., "Thermal Management in Electrified Transportation: A Comparative Study of Different Powertrain Technologies," SAE Technical Paper 2025-28-0412, 2025, .
Additional Details
Publisher
Published
Oct 30
Product Code
2025-28-0412
Content Type
Technical Paper
Language
English