The fast spread of electric and hybrid-electric propulsion systems necessitates advanced liquid cooling systems for critical components like highperformance battery packs. While conventional centrifugal pumps are widely employed due to their simplicity, they often present limitations in efficiency and precise flow rate control, particularly under fluctuating pressure drops, leading to suboptimal cooling and increased energy consumption. This paper addresses these challenges by presenting the design, optimization, and experimental validation of a novel thermal management system for a high-performance electric vehicle, featuring an innovative volumetric ePump. A lumped parameter numerical model was developed, serving as a digital twin of the experimental test rig. The model accurately replicated the system hydraulic behaviour, including detailed component characteristics and the performance of the prototype screwtype volumetric pump, which was previously characterized through manufacturer data and 3D CFD analysis. The numerical simulation results demonstrated excellent agreement with the experimental data, confirming the model accuracy and reliability.
A Preliminary Design of a Thermal Management System for High-Performance Electric Vehicles: Numerical Simulation and Experimental Validation
Frosina, Emma;Li Veli, Stefano;Simeone, Antonio;Roselli, Carlo;
2025-01-01
Abstract
The fast spread of electric and hybrid-electric propulsion systems necessitates advanced liquid cooling systems for critical components like highperformance battery packs. While conventional centrifugal pumps are widely employed due to their simplicity, they often present limitations in efficiency and precise flow rate control, particularly under fluctuating pressure drops, leading to suboptimal cooling and increased energy consumption. This paper addresses these challenges by presenting the design, optimization, and experimental validation of a novel thermal management system for a high-performance electric vehicle, featuring an innovative volumetric ePump. A lumped parameter numerical model was developed, serving as a digital twin of the experimental test rig. The model accurately replicated the system hydraulic behaviour, including detailed component characteristics and the performance of the prototype screwtype volumetric pump, which was previously characterized through manufacturer data and 3D CFD analysis. The numerical simulation results demonstrated excellent agreement with the experimental data, confirming the model accuracy and reliability.I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
