Experimental Characterization and Numerical Modelling of an Electric Vehicle Thermal Management System Integrating a Screw-Type e-Pump

Nowadays, the adoption of electric and hybrid-electric propulsion systems has become a common solution for the stringent decarbonization requirements. These technologies require advanced thermal management solutions capable of ensuring effective cooling of critical components while limiting energy consumption. Although centrifugal pumps are commonly used in cooling circuits, their performance can be affected by variable pressure losses and changing operating conditions, reducing flow-control accuracy. This work presents the experimental characterization, numerical modelling, and validation of a thermal management system for a high-performance electric vehicle, integrating a prototype screwtype positive-displacement e-pump. Tests were carried out on a dedicated test rig to hydraulically characterize the main circuit’s components, including the electric motor and inverter, under different pump speeds and flow-rate distributions imposed by a needle-valve adjustment. The collected data were used to calibrate and validate a lumped-parameter model developed in Simcenter AMESim. The model accurately reproduced the measured pressure losses and the flow distribution across the different circuit branches, confirming the reliability of the numerical approach.