Advanced thermal management strategies for electric vehicles: enhancing efficiency, reliability, and performance

Abstract

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, heatpipes, 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 tradeoffs 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.