Figure 1: manufacturers are increasingly focused on integrating advanced technologies that optimize thermal management and powertrain efficiency. Source: The Lee Company

As the demand for sustainable mobility solutions grows, manufacturers are increasingly focused on integrating advanced technologies that optimize thermal management and powertrain efficiency. This requires collaboration with suppliers who offer innovative, high-quality components that can be seamlessly integrated into next-generation electric vehicles (EVs). By partnering with experienced suppliers, manufacturers can ensure their vehicles meet the stringent performance and sustainability standards required in today’s competitive market, ultimately contributing to the broader adoption and success of EVs worldwide.

Energy efficiency

Enhancing energy efficiency is critical for extending the driving range of EVs and reducing the need for frequent recharging. One innovative approach is the use of digital twin technology, which allows for the modeling of thermodynamic systems within EVs to optimize energy consumption and flow. This technology can simulate various driving conditions and identify inefficiencies, enabling adjustments in control logic without hardware changes. For example, optimizing heating and cooling systems can significantly reduce energy consumption, with studies showing potential energy savings of up to 540 W, which translates to an increased driving range.

Powertrain optimization

Depending on the design goals of a particular manufacturer, the ideal electric powertrain for an EV may be an electric drive unit (EDU), electric drive module (EDM), or one or multiple electric axles (eAxles). While these systems differ in the specific components involved and the level of integration required, the engineers designing them are facing similar challenges.

• Maximizing miles: A primary focus of powertrain system engineers is improving how the motor, power electronics and transmission work together to optimize performance and increase vehicle range. Electric powertrain designers are experimenting with various system architectures and levels of integration. Depending on a specific EV’s need for performance and efficiency, a single-motor and or multi-motor powertrain may be an ideal solution.
• Losing weight: While reducing weight is always desirable in the automotive industry, the need for lightweight components is even more pressing in EVs and HEVs. By shedding any unnecessary weight that may be associated with fluids, materials or components in the powertrain, designers can increase a vehicle’s range. In some cases, a 10% reduction in vehicle weight can result in a 13.7% improvement in range.
• Staying cool: The amount of heat generated by electric powertrains has been growing continuously alongside increasing HEV and EV performance requirements. Managing the cooling and lubrication needs of the motor, stator, gear train, end coils and windings is central to efficient system operation. Using The Lee Company’s targeting orifices, designers can minimize fluid use, downsize electric oil pumps, reduce total system weight, and enhance overall energy efficiency. This contributes to an extended vehicle range and a more sustainable driving experience.

Click here to learn more about strategies for powertrain optimization in EVs.

Thermal management

Effective thermal management is vital for maintaining the efficiency and safety of EV components. It involves managing the cooling and heating needs of the battery, motor and power electronics:

• Batteries: Batteries generate significant heat, especially during fast charging. Additionally, the chemical reaction that stores and releases energy in an EV battery slows down in freezing temperatures. This makes the battery less efficient and reduces the EV’s range. Efficient heating and cooling systems, such as liquid cooling or phase-change materials, help maintain optimal battery temperatures, preventing performance drops and extending battery life.
• Heat pump systems: These systems are more energy-efficient than traditional resistive heaters, as they transfer heat rather than generate it. Optimized heat pump systems can improve heating efficiency in cold weather, reducing the energy required for cabin heating. The Lee Company’s components ensure the reliable and efficient operation of heat pump systems in EVs.
• Thermal management control: Advanced control systems can dynamically adjust cooling and heating operations based on real-time conditions, optimizing energy use without compromising comfort. For instance, optimizing the timing of positive temperature coefficient (PTC) heaters can save significant power and extend range.

How The Lee Company can help

The Lee Company, renowned for its precision fluid control components, offers invaluable support to automotive manufacturers in selecting the right component supplier. With decades of experience in microhydraulic technology, The Lee Company provides a comprehensive range of high-quality, reliable components that enhance the performance and efficiency of EVs.

Their expertise in fluid control solutions ensures optimal thermal management and powertrain efficiency, crucial for the advancement of EV technology. Furthermore, The Lee Company collaborates closely with manufacturers to tailor solutions that meet specific design and performance requirements, ensuring seamless integration into next-generation vehicles. With The Lee Company, manufacturers benefit from innovative solutions that drive sustainable mobility and improve overall vehicle performance.