Advanced thermal management strategies for electric vehicles: enhancing efficiency, reliability, and performance
Corresponding Author(s) : Amin Mahmoudzadeh Andwari
Future Energy,
Vol. 4 No. 1 (2025): February 2025 Issue
Abstract
Thermal management plays a crucial role in enhancing electric vehicles' performance, reliability, and lifespan (EVs) by effectively dissipating heat from key components, including electric traction motors, power electronic components (PECs), and batteries. This paper explores various thermal management strategies tailored for these systems, highlighting their advantages, limitations, and technological advancements. In electric traction motors, heat dissipation is primarily addressed through active and passive cooling techniques such as forced convection, heat pipes, and phase change materials (PCMs), with recent advancements like direct slot cooling (DSC) improving efficiency. Similarly, PECs and electronic chips face thermal challenges due to electrical resistance, requiring innovative solid-state, air, liquid, and two-phase cooling methods to prevent performance degradation and component failure. Battery thermal management systems (BTMS) are equally critical, as temperature variations directly impact efficiency, safety, and cycle life. Active, passive, and hybrid BTMS technologies—including liquid cooling, thermoelectric systems, PCMs, and heat pipes—are evaluated based on their effectiveness in maintaining optimal operating temperatures. This paper comprehensively analyzes emerging cooling solutions, addressing key trade-offs between efficiency, cost, and design complexity. By integrating advanced thermal management techniques, the EV industry can achieve improved energy efficiency, enhanced safety, and prolonged component durability, paving the way for more reliable and sustainable electric mobility.
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- A. Maiorino, C. Cilenti, F. Petruzziello, and C. Aprea, “A review on thermal management of battery packs for electric vehicles,” Appl Therm Eng, vol. 238, p. 122035, Feb. 2024, doi: 10.1016/J.APPLTHERMALENG.2023.122035.
- Andwari, A.M.; Pesiridis, A.; Esfahanian, V.; Muhamad Said, M.F. Combustion and emission enhancement of a spark ignition two-stroke cycle engine utilizing internal and external exhaust gas recirculation approach at low-load operation. Energies 2019, 12, 609, https://doi.org/10.3390/en12040609
- Y. Sheikh, M. O. Hamdan, and S. Sakhi, “A review on micro-encapsulated phase change materials (EPCM) used for thermal management and energy storage systems: Fundamentals, materials, synthesis and applications,” J Energy Storage, vol. 72, p. 108472, Nov. 2023, doi: 10.1016/J.EST.2023.108472.
- Mahmoudzadeh Andwari A, Azhar AA. Homogenous charge compression ignition (HCCI) technique: a review for application in two-stroke gasoline engines. Appl. Mech. Mater. 2012;165:53-57, https://doi.org/10.4028/www.scientific.net/AMM.165.53.
- Z. Zhang, X. Wang, and Y. Yan, “A review of the state-of-the-art in electronic cooling,” e-Prime - Advances in Electrical Engineering, Electronics and Energy, vol. 1, p. 100009, Jan. 2021, doi: 10.1016/J.PRIME.2021.100009.
- M. A. Abdelkareem et al., “Prospects of Thermoelectric Generators with Nanofluid,” Thermal Science and Engineering Progress, vol. 29, p. 101207, Mar. 2022, doi: 10.1016/J.TSEP.2022.101207.
- A. G. Olabi et al., “Battery thermal management systems: Recent progress and challenges,” International Journal of Thermofluids, vol. 15, p. 100171, Aug. 2022, doi: 10.1016/J.IJFT.2022.100171.
- J. A. P. Selvin Raj et al., “Thermal management strategies and power ratings of electric vehicle motors,” Renewable and Sustainable Energy Reviews, vol. 189, p. 113874, Jan. 2024, doi: 10.1016/J.RSER.2023.113874.
- B. H. Huang, C. Mi, L. Gong, C. Y. Zhu, and K. Li, “Thermal management for multi-cores chips through microchannels completely or incompletely filled with ribs,” Case Studies in Thermal Engineering, vol. 54, p. 103977, Feb. 2024, doi: 10.1016/J.CSITE.2024.103977.
- Y. Wang, W. Li, C. Qi, and J. Yu, “Thermal management of electronic components based on hierarchical microchannels and nanofluids,” Thermal Science and Engineering Progress, vol. 42, p. 101910, Jul. 2023, doi: 10.1016/J.TSEP.2023.101910.
- M. R. Cosley and M. P. Garcia, “Battery thermal management systems,” INTELEC, International Telecommunications Energy Conference (Proceedings), pp. 119–160, Jan. 2023, doi: 10.1016/B978-0-443-18862-6.00003-3.
References
A. Maiorino, C. Cilenti, F. Petruzziello, and C. Aprea, “A review on thermal management of battery packs for electric vehicles,” Appl Therm Eng, vol. 238, p. 122035, Feb. 2024, doi: 10.1016/J.APPLTHERMALENG.2023.122035.
Andwari, A.M.; Pesiridis, A.; Esfahanian, V.; Muhamad Said, M.F. Combustion and emission enhancement of a spark ignition two-stroke cycle engine utilizing internal and external exhaust gas recirculation approach at low-load operation. Energies 2019, 12, 609, https://doi.org/10.3390/en12040609
Y. Sheikh, M. O. Hamdan, and S. Sakhi, “A review on micro-encapsulated phase change materials (EPCM) used for thermal management and energy storage systems: Fundamentals, materials, synthesis and applications,” J Energy Storage, vol. 72, p. 108472, Nov. 2023, doi: 10.1016/J.EST.2023.108472.
Mahmoudzadeh Andwari A, Azhar AA. Homogenous charge compression ignition (HCCI) technique: a review for application in two-stroke gasoline engines. Appl. Mech. Mater. 2012;165:53-57, https://doi.org/10.4028/www.scientific.net/AMM.165.53.
Z. Zhang, X. Wang, and Y. Yan, “A review of the state-of-the-art in electronic cooling,” e-Prime - Advances in Electrical Engineering, Electronics and Energy, vol. 1, p. 100009, Jan. 2021, doi: 10.1016/J.PRIME.2021.100009.
M. A. Abdelkareem et al., “Prospects of Thermoelectric Generators with Nanofluid,” Thermal Science and Engineering Progress, vol. 29, p. 101207, Mar. 2022, doi: 10.1016/J.TSEP.2022.101207.
A. G. Olabi et al., “Battery thermal management systems: Recent progress and challenges,” International Journal of Thermofluids, vol. 15, p. 100171, Aug. 2022, doi: 10.1016/J.IJFT.2022.100171.
J. A. P. Selvin Raj et al., “Thermal management strategies and power ratings of electric vehicle motors,” Renewable and Sustainable Energy Reviews, vol. 189, p. 113874, Jan. 2024, doi: 10.1016/J.RSER.2023.113874.
B. H. Huang, C. Mi, L. Gong, C. Y. Zhu, and K. Li, “Thermal management for multi-cores chips through microchannels completely or incompletely filled with ribs,” Case Studies in Thermal Engineering, vol. 54, p. 103977, Feb. 2024, doi: 10.1016/J.CSITE.2024.103977.
Y. Wang, W. Li, C. Qi, and J. Yu, “Thermal management of electronic components based on hierarchical microchannels and nanofluids,” Thermal Science and Engineering Progress, vol. 42, p. 101910, Jul. 2023, doi: 10.1016/J.TSEP.2023.101910.
M. R. Cosley and M. P. Garcia, “Battery thermal management systems,” INTELEC, International Telecommunications Energy Conference (Proceedings), pp. 119–160, Jan. 2023, doi: 10.1016/B978-0-443-18862-6.00003-3.