2024NovDec-CJ - 18

NARSA NEWS
Thermal Management
Advancements for Off-Highway EVs
THE RISE OF ELECTRIC VEHICLES (EVS) on our roads is undeniable,
yet their off-highway counterparts remain a rarity. These rugged
workhorses, indispensable in construction and agriculture, face
unique challenges in their electrification journey. The demanding
workloads, intense duty cycles, confined vehicle spaces, and
harsh environments of off-highway vehicles require more than
just scaled-up passenger EV technology; they demand innovative,
purpose-built solutions.
At the heart of this challenge lies thermal management, a critical
hurdle in EV design that becomes even more formidable for electric
off-highway vehicles. Extreme temperatures can devastate EV
battery efficiency, range, and reliability, threatening performance
and longevity. The greater carrying capacities, higher torque
requirements, and extended operating times of off-highway EVs
necessitate cutting-edge thermal management systems for their
battery packs, power electronics, and operator comfort.
With heat waves intensifying nationwide, fleet operators must
understand how high temperatures affect electric off-highway
vehicles differently than their internal combustion engine
(ICE) counterparts. Built on solid scientific and manufacturing
foundations, current vehicular thermal management technology
offers robust solutions for these demanding electric applications.
This advanced technological foundation addresses the
unique challenges of electric off-highway vehicles, enabling
performance that matches or exceeds ICE vehicles across various
operating conditions.
Advanced Thermal Management in the EV Era
Vehicular thermal management has advanced dramatically over
the last hundred years. Today's EVs use advanced cooling systems
leagues ahead of their predecessors. These systems combine smart
heating and cooling circuits, temperature sensors, and complex
control software to keep everything running smoothly, even in the
most challenging environments.
Managing temperature isn't just a nice-to-have for electric
off-highway vehicles-it's crucial. EVs present distinct thermal
management challenges compared to traditional vehicles. While
ICE vehicles can operate effectively across a broad temperature
spectrum, EV components require more precise thermal control.
The primary heat-generating elements in EVs-the battery
pack and power electronics (traction motors, inverters, and
chargers)-demand careful temperature regulation. EV batteries, in
16 | THE COOLING JOURNAL | November/December 2024
particular, function optimally within a narrow range of 20°C to 45°C.
This specificity necessitates implementing a sophisticated battery
thermal management system (BTMS), especially for EVs operating
in diverse climate conditions like off-highway vehicles.
Thermal management systems in EVs serve dual critical
functions. In cold environments, they efficiently raise component
temperatures to optimal operating levels, ensuring prompt
vehicle readiness. Conversely, these systems act as crucial heat
dissipation mechanisms in high-temperature scenarios, preventing
overheating and maintaining peak performance. Advanced
thermal management systems are indispensable for electric
off-highway vehicles, which frequently operate in demanding
environments. These systems must keep all powertrain
components at optimal temperatures to prevent decreased
performance, shortened lifespan, or even component failure.
To preserve battery life and maintain range, off-highway EVs should
feature a comprehensive thermal management system, including an
active cooling circuit with a refrigerant loop that pre-conditions the
battery pack prior to use.
Smart Cooling to Beat the Heat
Battery pack temperatures can overheat in the hot summer
months. High temperatures pose significant challenges for battery
systems, accelerating chemical reactions, leading to higher internal
resistance and reducing capacity and power output. As such,
off-highway EVs like earthmovers or tractors require sophisticated
thermal management systems built into their design to handle
intense heat generation during demanding operations.
To preserve battery life and maintain range, off-highway EVs should
feature a comprehensive thermal management system, including
an active cooling circuit with a refrigerant loop that pre-conditions
the battery pack prior to use. When the ambient temperature
exceeds the battery pack temperature, the BTMS engages and
By: Gina Bonini,
Modine Manufacturing Company

2024NovDec-CJ

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