Introduction to Thermal Management for electric vehicles (EV), hybrid electric vehicles (HEV) and hydrogen fuel cell electric vehicles (FCEVs)

Welcome to Technical Services’ series on vehicle level thermal management. In this video we are using a demonstration vehicle which is battery electric, with a fuel cell range extender. We explain simplified cooling circuits with a focus on key technologies and then progress onto integrated thermal management.

Hydrogen Fuel Cell Cooling Systems

In this video we demonstrate the basics of three different cooling loops through the use of various components and technologies.
why fuel cell loops require high coolant flowrate and protection of the fluid through DI Filters. Also, why in a winter drive cycle, waste heat recovery from a fuel cell enables high efficiency. We show how three way valves are utilised to maintain a constant inlet temperature to the fuel cell stack or bypass the heat exchanger for cabin heating. View video

EV Battery Thermal Management

Battery thermal management is key to safe operation, and long cell life. For example, in low ambient temperatures, batteries can be cooled passively at a low cost but in higher ambient temperatures or with higher C rates, active cooling is required. The video highlights that heating the battery packs is of equal importance and shows how it can be achieved through PTC heaters, or a waste heat recovery strategy coupled with a heat pump cycle for maximum efficiency. View video

Power Electronics for Electric Vehicles

Power electronics for electric vehicles are typically water glycol cooled, and often have many smaller sub systems within the main coolant loop. In this video we show why flow distribution is critical to ensure each sub system is thermally managed without excessive parasitic losses. You will discover why zoning the power electronics is a method of preventing unnecessary flow to systems that are offline in charging versus driving modes. We show how manifold, and valve technologies can enable dynamic cooling architecture. View video

Understanding the role of electric coolant pumps in Electric Vehicles

In this chapter, we delve into the critical function of electric coolant pumps, which are a fundamental component of the thermal architecture of electric vehicles (EVs). We also discuss high voltage coolant pumps for fuel cell vehicles which are a game changer for thermal management, in terms of power, efficiency, and packaging.

Expansion tanks for engine cooling

In this chapter, we discover more about the vital role that expansion tanks play in the thermal management systems of electric vehicles (EVs) and other applications. Cooling fluids expand but are considered 'incompressible.' Therefore, the architecture of a cooling system needs to integrate expansion tanks to accommodate the increase of fluid as it heats up with rising temperatures.

Coolant manifolds and why flow distribution is crucial on EV platforms

In this chapter, we focus on the role of coolant manifolds and why flow distribution is crucial on EV platforms. Within a cooling architecture of an EV, one pump services many components: these components can have different duty cycles, temperature and flow limits. Our video demonstrates how a coolant manifold is essential for precise flow distribution.