Battery & Electrification Technology - May/June 2024 - 19

Thermal Management
for Off-Highway
Electric Vehicles
Electrification of construction machinery poses new challenges in thermal management,
but they can be solved.
A
s demand increases for
electric and hybrid technology
advancements in
the North American market,
off-highway vehicles
are subject to many challenges.
These range from vibration and
shock impacts on the vehicles, to thermal
stress and adverse environmental conditions
such as water, ice, humidity, dust, and grime.
Like all power electronics, waste heat
in mobile applications must be dissipated
to avoid costly malfunctions and
shutdowns. The failure to disperse this
heat could result in the vehicle needing
to be switched off for a period, thereby
creating a disruption for the end user. For
construction machinery, any amount of
downtime is not good for business.
The good news is state-of-the-art component
technology continues to be developed
to meet the constantly rising power
requirements for today's off-highway
electric vehicles. The latest developments
in contact cooling and other options including
heatsink usage and cold plate
solutions for converters can solve the
thermal-management challenges.
Contact cooling is the most affordable
and convenient way to install high-performing
converters that manage thermal
stress challenges. Choosing the right cooling
system solution starts by looking at the
installation. Mounting the converters to
any heat-conducting surface is sufficient
for standard usage, but sometimes this
approach is not an option. A possible solution
is if the transducer can be attached in
a space with an approximate length and
width of 11.75-inches (300 x 300 mm).
There are other benefits that make contact
cooling attractive. In addition to an
easy installation process and being very
cost effective, there are the maintenance-free
aspects to consider. However,
there are times when this approach is not
an option. That's where using a heatsink
might be a viable and helpful option.
Heatsinks are especially valuable for their
passive cooling and space-saving capabilities,
and they also are maintenance-free.
In cases where there is insufficient surface
space available on the application for
contact cooling, a heatsink can be used if
there is good airflow available. An example
would be with a vehicle in motion where
the airflow is favorable, the converter
Battery & Electrification Technology, May/June 2024
19
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Battery & Electrification Technology - May/June 2024

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