Browse Topic: Thermal management

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Advanced Signal Domain Techniques for Real-Time Control and Prognostics in VTOL SystemsSM-2026-VLADA-52051/27/2026
Vertical Take-Off and Landing (VTOL) aircraft introduce complex monitoring challenges due to distributed propulsion, lightweight structures, and variable operating conditions. This paper presents advanced Frequency and Orders domain techniques that repurpose existing flight control, propulsion, and structural sensor data to enhance observability without additional instrumentation. By transforming vibration, acoustic, and electrical signals into frequency and order domains, the approach enables detection of harmonics, resonance, and fault signatures tied to rotor dynamics, supporting adaptive control and predictive maintenance. Beyond rotor systems, these techniques are equally effective for monitoring electric motor health, gearbox wear, bearing degradation, and structural coupling effects in composite airframes. They also provide insight into power electronics and thermal management systems by identifying spectral anomalies linked to electrical imbalance or cooling inefficiencies
LaRue, David
Innovative Preconditioning Solutions for Efficient High-Current Battery Charging2026-26-01671/16/2026
In high-performance charging systems, managing higher currents is crucial for efficient battery charging. However, elevated battery and charging gun pin temperatures pose significant challenges, limiting the duration and effectiveness of high-current charging. Our advanced control system addresses these barriers by optimizing charging time while maintaining optimal temperature ranges for both the battery and charging gun. This is achieved through innovative preconditioning solutions that incorporate both active and passive cooling configurations. Our system features a unique preconditioning approach with dedicated cooling circuits for the charging socket and battery. The passive liquid cooling system ensures effective temperature management without additional energy consumption, while the active liquid cooling system provides enhanced cooling capabilities for more demanding scenarios. By integrating these cooling configurations, our control system significantly reduces charging time
Badgujar, Pankaj Ravindra, Bhosale, Subhash, Dave, Rajeev
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-05791/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges-such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations-no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
PATRA, SOMNATH, HIBARE, NIKHIL, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Impact of density in simulation model for extreme cold ambient conditions2026-26-03881/16/2026
Battery Electric Vehicles (BEVs) necessitate highly efficient thermal management strategies, as cabin heating directly consumes energy from the finite traction battery, potentially reducing driving range significantly. Early-stage design evaluations of warmup performance commonly rely on one-dimensional (1D) simulations due to their computational speed and efficiency. The accuracy and predictive capability of these models are critically dependent on how well they represent blower operation and account for temperature-induced variations in air density. This fidelity is essential because engineers depend on warmup simulations to set HVAC targets that will deliver real‑world comfort and defrost performance within stringent range constraints. Earlier, warmup simulations employed a Constant Mass Flow (CMF) approach, which simplifies computations by assuming a fixed air density at a standard reference temperature. However, this approach contrasts with real-world blower behavior, where
Subramanian, Karthik, Mishra, Abhishek
Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger2026-26-01771/16/2026
Efficient thermal management in electric vehicle (EV) charging stations is critical for ensuring the reliability, safety, and longevity of power electronics. This study presents a comprehensive bench test analysis of three key parameters influencing charger cooling efficiency: filter resistance, louver airflow, and fan heat dissipation. A test bench was developed to measure pressure drop, temperature gradients, and air velocity variations across multiple filter types, louver orientations, and fan configurations. The results show that higher-efficiency filters (e.g., HEPA, MERV13) significantly reduce airflow, increasing thermal stress on electronic components, while optimized louver angles improve directional airflow, reduce turbulence, and enhance cooling performance. High-performance axial and centrifugal fans with adaptive control mechanisms further contribute to effective heat dissipation, maintaining stable operating temperatures under varying load conditions. This study provides
S, Sri Saran, chinnanna, Manjunath, Ajith, Arjun, B, Viswanathan, Kulkarni, Mukund, R, Vigneshwaran, Dhachinamoorthi, Sivanantham
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-03761/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
A comprehensive strategy for Diesel Particulate Filter calibration to address the diverse applications of Stage V Construction Equipment Vehicles.2026-26-01431/16/2026
The legislation of CEV Stage V emission norms has necessitated advanced Diesel Particulate Filter calibration strategies to ensure optimal performance across diverse construction equipment applications in the Indian market. Considering the various duty cycles of cranes, backhoe loaders, forklifts, compactors, graders, and other equipment, different load conditions and operational environments require a comprehensive strategy to enhance DPF efficiency, minimize regeneration frequency, and maintain compliance with emission standards. The DPF, as an after-treatment system in the exhaust layout, is essential for meeting emission standards, as it effectively traps particulate matter. Regeneration occurs periodically to burn the soot particles trapped inside the DPF through ECU management. Therefore, understanding soot loading and in-brick DPF temperature behavior across various applications is the key. This paper explores the challenges in DPF calibration for CEV Stage V and provides a
Mohanty, Subham, Patil, Lalit, Chaudhari, Kuldeepak Arun, Mahajan, Atish, Madhukar, Prahlad
Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries2026-26-01551/16/2026
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance
Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol
Enhanced Integrated Cooling-Protection Plate for Battery pack Underbody Impact Resistance in Electric Vehicles2026-26-01691/16/2026
In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members positioned at the bottom. The study aims to address the dual challenges of effective thermal management and enhanced crash protection in electric vehicles. Through a combination of Design iterations, Thermal performance evaluation and Crash simulations, the research evaluates the cooling efficiency and structural resilience of the proposed design. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. The paper concludes with the results of numerical simulations, rigorously validated against the robust design requirement globally accepted for series components to
DUSAD, SAGAR, Kummuru, Srikanth, Joshi, Amarja
Design and evaluation of Integrated Engine-Mounted Exhaust Aftertreatment and Air Intake Filtration System with CEV/TREM Stage-5 IC engine for off-highway applications2026-26-01441/16/2026
Conventional exhaust aftertreatment systems (ATS) and air intake filters are typically mounted separately on the vehicle chassis, leading to complex routing, significant packaging volume, thermal management challenges for the ATS, and increased assembly complexity. This paper presents a novel system integrating the air intake filter and the complete exhaust aftertreatment system (including DOC, DPF, SCR components as applicable) into a single unit mounted directly onto the engine. This engine-mounted integrated architecture significantly reduces system footprint, minimizes exhaust and intake piping lengths, potentially improves ATS thermal efficiency through close coupling, and simplifies vehicle assembly. Design considerations, including vibration isolation, serviceability, and potential performance benefits such as reduced pressure drop and faster catalyst light-off, are discussed. This integrated approach offers a compelling solution for optimizing packaging space and system
P U, Balaji, sivasankaran, Siva, Arputharaj, Jeba, Kumar, Lingesh, Pandian, Teja, Patil, Shankar
Advanced Thermal Management for High-Tonnage EVs: Increasing Coolant Flow and Reducing Energy Losses2026-26-01961/16/2026
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach to
DIXIT, SAMEER, Patil, Bhushan, Ghosh, Sandeep
Evaluating Thermal Control Strategies to Improve Electric Vehicle Range Using GT Suite2026-26-03621/16/2026
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating sub-systems such as the high-voltage battery (HVB), e-powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant-to-cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and e-powertrain thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, Abhijeet, Kumar, Dipesh, Gummadi, Gopakishore, Khan, Parvej, Thiyagarajan, Rajesh, Pandey, Rishabh, S, Ananth, Anugu, Anil, Mulamalla, Sarveshwar, Gangwar, Adarsh
Advanced Dual Dosing DeNOx System for Optimized NOx Reduction Under Future Emission Regulations2026-26-02301/16/2026
The evolution of global emission standards has imposed increasingly stringent limits on nitrogen oxide (NOx) emissions, particularly under Real Driving Emissions (RDE) testing protocols. These requirements demand effective NOx control across a wide range of operating conditions, posing a challenge for conventional single-injector Selective Catalytic Reduction (SCR) systems. This paper briefs about Dual Dosing SCR System designed to enhance NOx reduction performance by employing two Diesel Exhaust Fluid (DEF) injectors integrated within an advanced exhaust after-treatment system (EATS) configuration. The system features a close-coupled SCR on DPF (SDPF) followed by an underfloor SCR (UFSCR), enabling staged ammonia dosing. This layout promotes improved ammonia distribution and catalytic performance across both low-load and high-speed driving conditions. An Electronic Control Unit (ECU) governs the DEF injection using predefined dosing maps, with reference to real-time data from three
Hareesh, Sangaraju, Shanmugham, Balamurugan, V, Suryanarayanan
Optimizing System Design performance and its accuracy using Feature Importance2026-26-04211/16/2026
With continuous improvements in model accuracy and computational performance, system simulation can be seamless integrated into development tools and methodologies as a "virtual test bed" in synergy with experimental tests. However, virtual vehicle and powertrain thermal models still face significant obstacles in realizing their full benefits. One common challenge is modeling accuracy and its anomalies, particularly in models provided by internal automotive companies and external suppliers. The models developed for vehicle thermal management and its systems have been created using specific software, making it difficult to verify the accuracy of the models across different systems and their performance. Integrating different systems in a Co-simulation environment has affected the overall accuracy of the Vehicle Simulation Platform model. This situation significantly reduces the return on investment in model development. To address these issues, we propose deploying feature importance
Srinivasan, Rangarajan, SARAPALLI RAMACHANDRAN, Raghuveeran, ASHOK BHARDE, Pooja, SARAVANAN, Vivek
Strategic & Frugal technology approach meet the stringent CPCB-IV+ Emission norms2026-26-00591/16/2026
In CPCB-IV+ Emissions regulations NOx & PM are reduced by 90% from CPCB-II limits in the power band 56 <kW ≤ 560. Obvious technology approach adopted by industry to meet this requirement is, introduction of CRDI fuel injection system & DOC+SCR+ASC aftertreatment technology, leading to substantial modifications at both engine & genset level. It results into huge development expenditure as well as high incremental product cost, timelines and increased in the total cost of ownership. This paper describes the frugal technology approach to keep development cost, product cost, development time to the minimum using electronically governed, high pressure mechanical fuel injection equipment while comfortably achieving target CPCB-IV+ emission levels. 1D-thermodynamic & 3D-combustion simulation approach was adopted to predict the engine out emissions and to optimize combustion hardware. This was followed by Virtual Test Bench (VTB) or closed loop HiL system simulation to integrate the engine
Arde, Vasundhara, Juttu, Simachalam, Kadam, Atit, Kumar, Dinesh, Gothekar, Sanjeev, Karthick, K, Vandana, Suryanarayana, Thipse, S
Thermal Management Control strategy for Primary & Secondary Drive Cooling Hybrid Electric Tractor2026-26-00691/16/2026
Global emission norms are getting very strict due to combat the harmful pollutants from internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is
K, Sunil, Makana, Mohan, Natarajan, Saravanan, K, MALA
"Exploring the Effects of Oil Cooler Deletion on Tractor Engine Operation"2026-26-05471/16/2026
Cost reduction remains a significant challenge for engine manufacturers, particularly for off-highway application vehicles. An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the
Gupta, Deepak, Kumar, Pankaj, Singh, Manjinder, Singh, Gagandeep, Kumar, Munish, SINGH, HARPREET, Singh, Maninder
Quantifying the Energy Consumption of HVAC Operation and Its Impact on the Range of Electric Buses Across Diverse Climatic Conditions2026-26-02041/16/2026
Electric buses (e-buses) are essential to sustainable public transport, but their real-world efficiency and range are heavily affected by auxiliary systems, particularly the Heating, Ventilation, and Air Conditioning (HVAC) system. This study investigates how ambient temperature variations and HVAC loads influence energy consumption, range, and efficiency in e-buses operating under diverse climatic conditions. The methodology combines field data collection from urban e-buses across seasons—including extreme summer and winter—with controlled lab testing. Field measurements included ambient temperature, HVAC demand, vehicle speed, state of charge (SOC) variation, and energy consumption. These inputs were used to develop real-world duty cycles, replicating actual thermal loads, passenger profiles, idling periods, and driving patterns. In the lab, these cycles were simulated using a chassis dynamometer and environmental chamber, with HVAC systems tested at controlled ambient temperatures
Vishe, Prashant, Dalela, Saurabh, Joshi, Madhusudan, Saraswat, Shubham
A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides2026-26-03641/16/2026
An air guide in a car directs fresh air onto the Heat Exchangers (HXs) to facilitate efficient thermal management. It is of paramount importance that the air guide creates a proper sealing and prevents any leakage of the incoming fresh air. It is achieved in two ways – 1) In the design condition, the air guide is manufactured in a way so that it overlaps/intersects with the surrounding components 2) the air-guide is made flexible with a highly elastic rubber seal at the edge. When the air-guide is assembled, the rubber portion of the air-guide deforms to produce a proper fit leading to a sealed air-intake pathway. At high-speed condition as well as high airflow conditions by the radiator fan during idling/stationary, like DC charging – incase of BEV, etc., the air guide encounters high pressure. Being elastic and flexible, these conditions make the air guide susceptible to deformation with potential leakage of incoming air. Digital evaluation of the air guide deformation at different
GADASU, RAVISHASTRI, CHOUDHURY, SATYAJIT, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
Cabin modelling approach in 1D simulation for studying the impact of partial recirculation in warmup for BEV at extreme cold ambient conditions2026-26-04501/16/2026
The inclusion of the cabin in HVAC simulations gained more importance with the introduction of BEV’s. Thermal management and efficiency being in the forefront, exploration for the possible opportunities to reduce the energy consumption for meeting the comfort of passengers gained importance. The energy consumed by the Electric coolant or air heaters for heating the cabin at extreme cold ambient temperatures to deliver similar comfort to that of an ICE version is 2 to 3 times that of the energy required for cooling the cabin in a high ambient condition. Even during the sizing of HVAC system, if traditional method of ambient or fresh air conditions is considered for calculating the requirements, the result is we would require a product which will have unrealistic performance demand. Hence to explore different possibilities for studying the system, usage of recirculation air was considered as one of the options. This paper talks about the approach followed in creating the cabin model in
Veerla, Eswar, Subramanian, Karthik
System Level Temperature Distribution and Balancing in battery swapping stations2026-26-03611/16/2026
Battery charging systems generate heat during operation, which affects battery efficiency, discharge time, and overall lifespan. Effective thermal management is essential to prevent overheating, optimize heat dissipation, and ensure consistent performance. This study investigates testing methodologies to analyse thermal temperature distribution, detect imbalances, and implement effective balancings techniques. Testing was conducted in a controlled environmental chamber to evaluate heat dissipation behavior under varying conditions. Different dock-level temperatures were measured and optimized using multiple design configurations to assess their impact on thermal performance. The analysis identified thermal imbalances that contribute to uneven heat distribution and increased thermal stress, which can degrade battery performance over time. By refining system designs and incorporating optimized balancing strategies, the research demonstrated significant improvements in heat management
Kulkarni, Mukund, P, Hari Prasad Reddy, H, Manjunatha, Dash, Soumya
Thermal Management Techniques to Overcome Heating Challenges in Printed Circuit Boards2026-26-03771/16/2026
Nowadays, Printed Circuit Board (PCB) design is facing critical challenges like high heat dissipation, increased cost, densely populated components and reduced life span. In view of the above, present study is focused on temperature prediction, thermal management, and optimization of component allocation (e.g. mosfet) in PCB. Heat flow occurring from traces to different copper layers in the PCB can cause adverse effects such as thermal run away/PCB warpage. Here, transient thermal analysis is carried out in an in-house developed PCB which is placed inside a sheet metal enclosure. Initially, thermal prediction to explore thermal regimes in the PCB is performed with the help of a commercially available software Altair Simlab ElectroFlo 2024.1. Temperature across all the components of the PCB as well as at the enclosure is simulated which is found to be beneficial in identifying the critical hotspots. In addition to the above, thermal measurements are performed in the lab with the help of
Rajasekharan, Jayakrishnan, ML, SANKAR, prasad PhD, Suryanarayana
Multiphysics Analysis of Heat Sink Designs for Efficient Thermal Performance in Power Electronics Systems2026-26-04461/16/2026
The thermal management capability of power electronic (PE) systems has a critical impact on the performance and efficiency of electric, fuel cell, or hybrid vehicles. Bus bars, high resistance sensor devices, semiconductor switches, power capacitors are the primary components, which has major contribution in total heat generation in electrical drive unit. As PE packaging sizes are projected to become smaller, the challenge of managing increased heat dissipation becomes more critical. Hence, this paper numerically compares conventional and advanced cooling strategies to determine the best possible thermal management scenario. A multi-physics finite element model, integrating fluid, electrical, thermal, and structural fields, is employed to analyze heat generation within the PE system and the associated cooling mechanisms. Due to the significant impact of surface roughness and topology on electrical and thermal contact resistance, the Cooper-Mikic-Yovanovich (CMY) correlation is utilized
Singh, Praveen Kumar, Natarajan, Nesamani, Murali, Sariki
Thermal Management and Engine Calibration Strategies for Enhanced Passive DPF Regeneration in CEV Stage V CI Engines2026-26-01411/16/2026
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges. These stringent norms call for a highly efficient DPF. With the increasing demands for high-performance DPFs, the issue of soot accumulation and cleaning presents significant hurdles for DPF longevity. This paper explores the potential of passive DPF regeneration, which leverages naturally occurring exhaust gas conditions to oxidize accumulated soot, offering a promising approach to minimize fuel penalty and system complexity compared to active regeneration methods. The study investigates engine calibration techniques aimed at enhancing passive regeneration performance, emphasizing the optimization of thermal management strategies to sustain DPF temperatures within the passive regeneration range. Furthermore, the paper aims to expand the applicability of passive regeneration across diverse engine loads common in off-highway applications with effective passive
Saxena, Harshit, Gandhi, Naresh, Lokare, Prasad, Shinde, Prashant, Patil, Ajit, Raut, Ashish
Modelling and Analysis of Hypoid Gear Churning Loss in Rear Drive Axle: The Role of Oil Viscosity and Empirical Parameters2026-26-05081/16/2026
This definitive study investigates the variation of churning losses occurring with hypoid ring and pinion gear sets and puts primary importance to factors that determine energy dissipation in these mechanisms. A detailed investigation shows that viscosity is critical, particularly due to large temperature-dependent variations. Besides this, the study focuses on particular attention to experimental parameters derived from measured data to model churning losses. Churning Loss itself originates in the interaction between the rotation of the gears and the lubricating oil - a source of significant inefficiency within the overall drivetrain. A robust, comprehensive model has been formulated to take this into account. It does not only account for variable oil viscosity with temperature but integrates key empirical parameters that reflect observed behaviours in gear systems. The study adopts a multidimensional approach by considering the influence of various other factors. It investigates how
Khan, Aliya Javid, Praveen, Abhinav, Kanagaraj, Pothiraj, Jain, Saurabh Kumar, AP, Baaheedharan
Accelerating EV Thermal Controls Development: A Rapid controls prototyping framework using Speedgoat2026-26-06851/16/2026
In the era of software-defined vehicles, the complexity and requirements of automotive systems have increased significantly. Thermal management systems have become more complicated, incorporating multiple functions and strategies within software frameworks. This shift poses substantial challenges, increased development efforts and extending timelines in creating an efficient thermal management system for EVs. Fulfilling them in the early stages of design makes it more challenging due to the unavailability of key components such as fully developed ECU hardware, the battery pack, and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation, enabling the testing and validation of thermal control strategies without fully matured system and ECU hardware. The framework uses the Speedgoat platform as the central controller which hosts the control and thermal models developed in Simulink and Simscape. Speedgoat is physically
Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh
Thermal Management of High-Voltage Connectors using double-layered Phase-Change Materials (PCM)2026-26-02791/16/2026
Abstract: High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with
Neogi, Angshuman, Shinde, Shardul
1D Thermo-Fluid Model for Electric Vehicle Traction Inverter2025-01-50629/19/2025
Thermal management solutions in power electronics applications are of prime importance to meet the needs of the ever-increasing demands on higher power and torque density of the traction motor and controller. Traction inverters are essential power electronic devices that convert direct current (DC) supply from the battery pack of the vehicle to three-phase alternating current (AC) output and vice versa. Estimation of die junction temperatures and cooling system pressure drop is necessary for assessing the maximum heat load capacity of the traction inverter system and coolant pump capacity requirements. The system comprises of a power module and a water–glycol–based cooling domain with heat sink. This article proposes a 1D model for accurate predictions of junction temperatures on the SiC die, temperature rise of the cooling medium, and pressure drop across a custom heat sink fluid domain. The model is built to handle steady-state and transient conditions for varying heat loads on the
Ravindra, Vidyasagar, Prasad, Praveen, Singh, Ishan, Sureka, Sumit
EDITORIAL: Farewell and thanks, Mr. Birch21AUTP06_041/27/2025
“We pay close attention to the SAE magazines because your guy in Europe writes interesting articles,” a BMW engineering executive told me one year at the Frankfurt Motor Show. He was referring to Stuart Birch, our veteran European Editor, who has recently decided - after nearly 37 years of outstanding reporting for SAE International - to hang up his keyboard and spend more time with his wife, Kim, their family and friends in the British countryside, and his classic Porsche 911. Our staff had been dreading the day that Stuart would announce his retirement, foremost because he's been a great friend as well as a colleague. And because journalists with his qualities - professionalism, perspective, a powerful work ethic and great wit - are increasingly rare in the mobility-technology space. As SAE's global audience knew, Stuart Birch delivered compelling technical and business information. He covered product, processes and people with equal poise. And he thrived on the R&D beat: Virtual
Brooke, Lindsay
SAE TOMORROW TODAY BRIEFS: EV Batteries That Run on Sunshine--Or in the Cold134606/12/2024
It's no secret that installing EV charging stations can be time-consuming. But what if you could use the power of the sun? Beam Global is doing just that -- not only on land, but in the water and sky as well. Beam's research and work in thermal management enables EV batteries to charge in a hot or cold environments. Using clean energy solutions like solar power, Beam deploys EV charging infrastructure in minutes not months -- with no permitting, no construction, and no electrical work. Listen in as Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sits down with Said Al-Hallaj, Chief Battery Scientist, Beam Global, to discuss the rapidly deployed and scalable EV charging solutions, the challenges of electrification in the air and water, and the importance of thermal management. For more information on the evolution of sustainability, head on over to sustainablecareers.sae.org. There you can read about how GM is pushing back on media coverage that growth in the
Hineman, Marcie
Predictive Underhood Thermal Management Model2024-26-02721/16/2024
In the automotive industry, thermal management is a very important way to solve the problems of energy saving and emission. The underhood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts the
P V, NAVANEETH, Prasad, Suryanarayana A N, ML, SANKAR
The effect of different Air Path based ATS thermal management strategy on a Non- EGR Medium Duty Diesel Engine’s performance and emissions.2024-26-00381/16/2024
The effect of different Air Path based ATS thermal management strategy on a Non- EGR Medium Duty Diesel Engine’s performance and emissions. Ajeet Kumar Sharma AVL Technical Center Pvt. Ltd. Abstract: In view of BS6.2 emission norms implementation for medium duty diesel engine, the tail pipe emissions are not only confirmed in test bed conditions but also in real driving condition including different combinations of ambient temperature and pressure. In modern non-EGR engine the Engine out emissions especially NOx emission is higher compared to EGR engine, therefore the tail pipe emissions are solely depending on conversion efficiency of After Treatment System (ATS). Hence meeting the stringent tail pipe emission, quick heating of ATS required. It became more challenging with a WHTC Cycle, where beginning of the cycle is not only having low load engine operations, but also cold ATS system followed by cold soaking. Further addition of DOC (Diesel oxidation Catalyst), DPF (Diesel
Sharma, Ajeet Kumar, Kreuzig, Gerhard, Gupta, Ayush, Goyal, Dinesh, Garg, Varun
Cost Effective Pathways Toward Highly Efficient and Ultra-Clean Diesel Engines, Part II: Air-handling and Exhaust Aftertreatment2024-26-00441/16/2024
Following global trends of increasingly stringent greenhouse gas (GHG) and criteria pollutant regulations, India will likely introduce within the next decade equivalent Bharat Stage (BS) regulations for Diesel engines requiring simultaneous reduction in CO2 emissions and up to 90% reduction in NOx emission from current BS-VI levels. Consequently, automakers are likely to face tremendous challenges in meeting such emission reduction requirements while maintaining performance and vehicle total cost of ownership (TCO), especially in the Indian market which has experienced significant tightening of emission regulation during the past decade. Therefore, it is conceivable that cost effective approaches for improving existing diesel engines platforms for future regulations would be of high strategic importance for automakers. In this second of a two-part article, several component levels advancements are discussed including both engine and the aftertreatment system (ATS). For engine, role of
Kumar, Praveen, Shah, Ashish, Lago, Rafael, Echeverri Marquez, Manuel, Cleary, David, Gothekar, Sanjeev, Thipse, Sukrut S
Gasoline Particulate Filter Calibration approach for BS6 market2024-26-01561/16/2024
With the implementation of BS6 standards, there is an increased focus on reducing particulate matter and particulate number emissions from gasoline Direct Injection (GDI) engines. The direct injection process can lead to increased soot formation, which poses environmental concerns. GPFs are effective in capturing particulate matter (PM) and Particulate number (PN) but their calibration is critical to ensure optimal performance and emissions compliance. This paper presents a study on the calibration of Gasoline Particulate Filters (GPF) to comply with Bharat Stage-6 (BS6) emissions norms. The main focus is on thermal management, soot loading, ash loading and the unique challenges faced in the Indian market. Thermal management strategies include active and passive methods to optimize GPF regeneration and prevent thermal degradation. Active RGN mechanism involves advanced control on engine to achieve target temperature and sufficient oxygen to react with soot. Passive RGN occurs during
Arale, Shrikant, B G, Sharath, Chaudhari, Kuldeepak, Madhukar, Prahlad, MY, Raghu
Design methodology for avoiding condensation in automotive head lamps2024-26-00831/16/2024
One of the important aspect to consider at the design stage is the condensation of water vapor inside the lighting system, under particular weather conditions of temperature and humidity, which may compromise the device functionality. Condensation of water vapor is an issue affecting functional and aesthetics of Head Lamp. The current paper analyses the process of water vapor condensation inside an automotive LED head lamp. This paper also discusses the design methodology to avoid condensation under particular conditions. Design methodology includes design considerations for better air movement for heat management, material selection, ease of moisture exchange, breather or vent selection, placement. Additionally, this paper would also discuss about effective use of simulations tools, test methods and assembly process guidelines to avoid impact due to condensation. This paper would consist of one example with application of above methodology, its test and field results.
RANE, SANDEEP BALU, Pawar, Nishant
A mechanism to maintain negative crankcase pressure in a turbocharged gas engine to meet Euro-VI emission regulation and to reduce oil consumption.2024-26-01451/16/2024
Emissions regulation continually drives the automotive industry to innovate and develop. This pushes to introduce mechanism to maintain negative crankcase pressure in gas engine to meet this changing regulation. The way a turbocharger is used, to meet engine performance, can impact the pressure balance over the compressor and turbine end seals. This pressure difference can allow oil to leak through turbocharger seals. In normal engine operating condition, the pressure in the turbocharger end housings is higher than the bearing housing and oil/gas flows into the bearing housing, through the oil drain to the crankcase. Under certain operating conditions, such as low idle and thermal management, this pressure difference can be reversed with a higher bearing housing pressure than the pressure behind the turbine compressor wheel. Under this condition oil/gas will flow out of the bearing housing to the recess behind the compressor wheel. The bearing housing pressure will always track the
R, MAHESH BHARATHI
Effect of Busbar Design on the Thermal Performance of Battery Packs2024-26-01351/16/2024
Li-ion batteries face challenges which is not usually present with other chemistries is cell balancing. If a high imbalance occurs within a parallel circuit, possibly because of the poor cell -grading or due to temperature localization, the other cells will charge the unbalanced cell and it may be possible that the imbalance never completely fades away and the other cells also end up unbalanced, One of the key solutions to maintaining cell balance is to ensure that all cells within a battery pack are kept at a uniform temperature. This requires careful thermal management, which can be achieved through a combination of conduction and convection circuits. In this paper, a 1D-3D simulation study has been performed on a 12 V 4s4p pack by varying the thickness of HV busbars and temperature localization effects and temperature uniformity has been observed. The holder has 16 cells with a 4*4 grid pattern, each cell has a diameter of 18 mm and a length of 65mm. The cells are connected in
Jagtap, Aditya, Khan, Faiz, Shah, Harsh, Malani, Shekhar
A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack2024-26-01091/16/2024
EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of
Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar
Advanced Thermal Management System for Electric Vehicles – An Indian Case study2024-26-01261/16/2024
Climate change and global warming is one of the major challenges faced by the world today. A significant number of Indian cities rank among the most polluted globally, with vehicular emissions being a primary contributor. To address this issue, Government of India is actively advocating for the adoption of zero-emission vehicles, such as electric vehicles, through policies and initiatives like FAME II, PMP, and the National Mission for Transformative Mobility and Storage. The acceptance of electric vehicles is growing in the Indian market seeing more than 200 % increased sales with large shares of 2-wheelers, 3-wheelers & compact cars getting electrified. One of the major inhibitors to EV sales being the high overall electric vehicle cost compared to conventional vehicles with HV battery is the most costly system on the present day electric vehicles . An electric vehicle having high energy efficiency can meet it's driving range requirements with a relatively smaller battery size
Emran, Ashraf, Chavan, Sagar, Franke, Kai, Sharma, Vijay, Garg, Shivam, Pawar, Bhushan, Hemkemeyer, David
Cost-effective techniques for SCEV to improve performance & life of battery and motor by using efficient thermal systems2024-26-02751/16/2024
The automotive world is moving towards electric powertrain systems. The performance of an electric powertrain and its electric components majorly depends on the operating temperature of the components. In the small commercial vehicle segment overall vehicle cost is a very sensitive parameter while competing in the market. This paper presents advanced efficient cost-effective thermal techniques for small commercial electric vehicles (SCEV) to improve the performance & life of major electric components. It is observed that from the literature survey, this technology is a novel technology for small commercial electric vehicle applications. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the battery and traction cooling system during battery charging and vehicle driving scenario for different ambient conditions. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which help
Chormule, Suhas Rangrao, Warule, Prasad, Jadhav, Vaibhav, Nagpure, Rahul
Thermal Management of An Automotive Headlamp2024-26-02861/16/2024
These days, the use of virtual simulations through Computation Fluid Dynamics (CFD) methodology is increasing exponentially during the development phase of an automotive headlamp. Thereupon, the automotive industries are becoming competent enough to build an ingenious and creative design with optimal performance within the coherent time. Considerable amount of heat is generated inside the headlamp when it is switched on for a longer time. Hence it becomes vital to reduce the risks if any during the development phase by providing an adequate thermal management strategy within the headlamp. The present study conducted an experimental analysis on an automotive headlamp to determine its thermal characteristics and behavior. Numerical analysis was also performed to determine the airflow and temperature distributions within a headlamp. This study also focuses on finding the main hotspot regions over the headlamp through virtual simulations. The methodology shows a consensus with the
Kolhe, Shailesh Madhukar
A Novel Approach to Make an Efficient Thermal Management of a Solar Electric Four-Wheeler Through Model-Based System Simulation2024-26-01301/16/2024
The objective of this paper is to determine and design an optimized thermal management system for a solar electric four-wheeler while considering system influence. The major systems that will be analyzed and optimized include the HVAC, solar system, and battery. The HVAC system imposes a challenge to the designers to fulfill the passenger's comfort and to operate it efficiently under a wide range of external loads from solar radiation, ambient temperature & humidity, human metabolic activity, and also other loads like the propulsion system temperature on the cabin. From the literature, it is found that the air conditioning system reduces on average 14% of the total battery capacity whereas the heating system reduces it by 18%, which makes the HVAC system design a crucial aspect to consider for the system influence. The battery car voltage changes significantly to meet the power demand and because of this, the battery system produces a large amount of heat while discharging which will
Karthikeyan, Vikram Raj, Gumma, Muralidhar
Study of Critical Vias Design Parameters for Power Electronics Thermal Management2024-26-03171/16/2024
With the advent of wide band gap semiconductor devices like SiC based MOSFETs/Diodes, there is a growing demand for utilizing electrical power instead of the conventional fuel-based power generation in both automotive and aerospace industry. In automotive/aerospace industry the focus on electrification has resulted in a need for sub-systems like inverters, power distribution units, motor controllers, DC-DC converters that actively utilize SiC based power electronics devices. To address the growing power density requirements for electronics in next generation product families, more efficient & reliable thermal management solution plays a critical role. The effective thermal management of the power electronics is also critical aspect to ensure overall system reliability. The conventional thermal management system (TMS) optimization targets heat sink/ cold plate design parameters like fin spacing, thickness, height etc. or sizing of the required cooling pump/fan. This paper focuses on
Bhardwaj, Divyanshu, Patil, Sachin, Datta, Sauradeep, Pawar, Sunny, Dougherty, Derek
Research on Cold Start Strategy of Vehicle Multi-Stack Fuel Cell System2023-01-703610/30/2023
To study the cold start of muti-stack fuel cell system (MFCS), a novel thermal management subsystem structure and corresponding cold start strategies are proposed. Firstly, leveraging the distinctive configuration of the MFCS that can be sequentially initiated, we augmented the existing thermal management subsystem with the incorporation of two additional collection valves and two bypass diverter valves, which affords an increased degree of flexibility in the formulation of cold-start strategies. Secondly, we innovatively propose a hierarchical auxiliary heating cold start strategy and an average auxiliary heating cold start tailored for MFCS consisting of power levels of 20 kW, 70 kW, and 120 kW. Furthermore, we have developed a controller to address temperature control challenges during the start-up process. The results demonstrate that the multi-stack hierarchical auxiliary heating cold start strategy yields a significant reduction in energy consumption and startup time during the
Jin, Yapeng, Yuan, Tanghu, Fan, Lei, Zhou, Su
Backend-based State-of-Charge Control as an Operating Strategy for a Serial PHEV2023-01-12016/26/2023
In previous work, a serial hybrid powertrain concept with a phlegmatised ICE has been described. Drivability is to be ensured through an innovative predictive operating strategy. Battery State-of-Charge (SoC) is controlled using a backend-based prediction of energy consumption on a given route based on road map and traffic data. In this paper, a spotlight is thrown on the proposed control architecture. On the top level of the controller, a Dynamic Programming algorithm finds an optimal reference trajectory for the SoC over a known route with the goal of avoiding certain Worst-Case scenarios commonly associated with the serial hybrid powertrain topology. Close adherence to the reference trajectory is ensured on a lower level through Model Predictive Control, taking into account additional factors such as battery stress. These control layers closely represent the map data distributed on the on-board bus network of state-of-the-art road vehicles under the current ADASIS standard. The
Böhme, Maximilian, Gerdts, Matthias, Trapp, Christian
Noise analysis and optimization of thermal management integrated module2025-01-00815/5/2023
Abstract：The thermal management integration module is a multifunctional integrated component. The thermal management integration module includes water pumps, flow channel plates, brackets, sensors, etc. However, due to the large range of speed changes, the water pump will generate a wide range of frequency excitation. This excitation will cause the integrated module to vibrate and generate noise. This article studies and analyzes an integrated module that generates noise. An integrated module of a certain new energy vehicle is used as an example. Firstly, a vehicle experiment was conducted. It was found that the noise came from the integrated module. And then use finite element method to analyze the causes of noise generation. Based on the characteristics of multiple integrated module components, high integration degree, and complex structure. This article simplifies components such as brackets, heat exchangers, sensors, etc. And they are replaced by centralized quality points
XU, shenao
Electric compressor integration noise influence in Battery Electric Vehicles2025-01-00755/5/2023
Within the automotive industry’s shift to Battery Electric Vehicles, in order to meet the global zero emission target, thermal management systems are key aspects to address. For instance, vehicle cooling requirements are reinforced to take into account the cabin comfort as well as battery management performances. Consequently to the increased cooling requirements, the critical component that is the Electric Drive Compressor, must operate at higher speeds and refrigerant pressures to achieve these targets. This trend results in increased noise levels which might occur inside the car cabin and outside. In this paper, noise investigations were performed on different Battery Electric Vehicles to assess the behavior of the electric compressor within a temperature controlled environment. Then, the electric compressors alone were investigated on specific test benches with compressor load units. The vehicle level assessment highlighted significant noise differences between vehicles. Further
Bennouna, Saad, Yamayoshi, Itsukyo, Del Valle, Edward
Immersion Cooling for Power Electronics2022-28-044611/9/2022
The ability to precisely control electrical voltages on a large scale has made possible many efficient, powerful innovations, from high-speed electric trains to wind turbines to electric drive motors for everything from heavy earthmoving equipment to personal electric vehicles (EVs). But the equipment that manages this process — including power inverters, thyristors and variable-speed drives — requires high-performance power electronics cooling. As temperatures rise, the efficiency, reliability, and life spans of these devices drop, and the power electronics inside HEVs and EVs are no exception. Advancements in power electronic thermal management technologies will enable next generation automotive to fulfill increasingly demanding mission objectives. DC-DC converter and inverter systems slated for higher performances, reliable and sustainable applications. Even with very high efficiencies, the components of these systems produce kilowatts of power loss in the form of heat. The current
Sahoo, Pranati
Carbon-Neutral Powertrains for Future Mobility and its Impact on Thermal Management2022-28-041511/9/2022
In this article we summarize the main classification of hybrid powertrains for automotive sector and quantify the scope and benefit these powertrains using gasoline and diesel as mono fuel or dual fuel with CNG, Flex fuel (Ethanol blended). Such power trains have high potential to achieve lower carbon emissions for the near future usage and implementation, until the carbon-neutral powertrain reaches its majority in the market. The major focus is on the H2 combustion engine powertrain as it is one of the potential solutions to achieve carbon-neutral powertrain solution using the optimized IC engine. We highlight the benefits and challenges involved to commercialize H2 combustion engine powertrain against the e-fuel based carbon-neutral powertrain for the new-energy vehicles such as Battery powered electric vehicles (BEVs) and Fuel Cell powered electric vehicle (FCVs). Finally we discuss about the link between the capacity and size of the thermal cooling system of the automotive vehicle
Muthu, Selvaraji, N, Sekarapandian, KANNAIYAN, Ashok
Faster Cool-Down of a Reefer Unit by Optimizing the System Losses through Experimental Investigation2022-28-044211/9/2022
Refrigerated shipping containers are one of the four segments of the cold chain; cooling and storage; refrigerated transport; distribution centre and refrigerated display in super markets. The term reefer has become an established term to refer refrigerated shipping containers. It is one of the emerging areas in transport segments. With the onset of ongoing pandemic this area has further drawn global attention recently and due focus is being given to the development and improvement of reefer unit Hence with the growing demand in this field the energy consumption is also leapfrogging day by day. Primary energy sources (fossil fuel) are depleting and their environmental impact is raising anxiety around the world. In order to minimize unnecessary energy waste in refrigerated shipping container system, it needs to be designed to be energy efficient and provide high cooling capacity to ensure rapid pull down to carriage temperature and to maintain product quality at idle. Improper operation
Sen, Somnath
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