Fast Charging Thermal Considerations for Electric Vehicle Design

Electric vehicle battery technology is moving forward rapidly, but the fundamental principles of battery performance clash with the fundamental expectations of consumers: give me high energy density but charge quickly. Raising the rate of charging leads to higher temperatures across the battery cells. The effect of high temperatures means that battery performance will degrade over such cycles, which has been termed aging by industry.

Optimizing battery charge rates and coolant flow rates becomes an engineering imperative, but the charge controller and coolant controller must also prevent rapid aging. Fortunately, the ThermoAnalytics battery extension provides an accurate simulation of battery temperatures over time during both charge and utilization, enabling engineers to balance convenience with aging. In the consumer EV market, the fast charge wins the sale, but it’s avoiding aging that builds customer loyalty.

Maximizing Electric Vehicle (EV) Range in Cold Weather Environments

A critical aspect of engineering for complex systems is managing designs that must perform under a wide range of combined parameters. An example is designing an electric passenger vehicle’s climate control system. Here we illustrate a state-of-the-art simulation method that vehicle manufacturers employ to maximize their electric vehicle range while keeping customers satisfied with thermal comfort. We explore in this article the past benchmark convection methods of thermal management and challenge that approach with a radiant alternative and estimate the impact on EV range.

Izaak the Elf Solves Santa's Thermal Comfort with Expert Efficiency

“I want them back, Izaak!” cried Santa, blushing slightly at his own outburst and casting a glance at Sven, the electric reindeer. “I nearly froze behind that tin beast and could hardly hold the reins, my hands were so cold.”

Enabling Electric Vehicles to Last Their Lifetime

In many ways, an electric vehicle (EV) is mechanically simpler than a car with an internal combustion engine (ICE). There are fewer moving parts in an electric motor than an ICE and less maintenance required to keep it performing for the vehicle’s lifetime. However, consumers still carry concerns for the expected span of the electric car’s battery life. To be sure, replacing an electric vehicle’s battery is an expensive proposition. For example, a new battery pack for a Chevrolet Bolt EV is reportedly priced at more than $15,000, not including labor costs.

Solve for the Competing Priorities of Occupant Comfort and Electric Vehicle Range

With the cooler weather, many electric vehicle (EV) owners are preparing their best strategies to maintain a desirable range and keep warm. Sometimes EV owners must bundle up to mitigate HVAC usage to make it to their destination. These strategies are less than desirable, and so OEMs are working hard to minimize this issue with better cabin simulations for better designs.