Thermal management may be one of the most important design factors in electric vehicle systems. Sustaining excellent temperature control in the cabin is essential for comfortable travel as well as the proper functioning of critical systems within the vehicle. Design engineers are also under pressure to overcome energy losses through proper friction management. Here are 4 top thermal management design challenges and how you can solve them!

 

Understand your surface materials and how they interact. Utilize materials that offer a very low coefficient of friction and excellent wear resistance in compressor applications. Reducing friction will lead to extended lifetime and reduce the loss of range impact cabin heating and cooling has on the battery’s capacity.

 

Batteries and electric vehicle components can be big and heavy. The more the vehicle weighs the more energy it takes to operate. Incorporate lighter weight, compact bearing materials to reduce weight and size. Consider coating options in compressor designs that could also increase efficiency and allow a more compact design.

 

Nothing is more frustrating than loud or repetitive noises while operating a quiet electric vehicle. Plain bearings offer low NVH components compared to roller bearings and can significantly reduce size and weight. Using polymer-based bearings, coatings and material surfaces can offer a noise free operation for the lifetime of the vehicle in many auxiliary systems. The result is a peaceful, pleasant passenger cabin experience.

 

Compared to traditional combustion vehicles, environmental conditions have more impact on electric vehicles. It is critical to keep cabin temperatures just right (cool in summer, warm in winter) and regulate battery temperatures both during operation AND charging times. Use increased wear resistant materials that offer extended service life, cost savings, and reduced maintenance intervals.