The performance of an electric vehicle (EV) heavily depends on the efficiency of its integrated e-Drive system, which includes the electric motor (e-Motor), inverter, and reducer. Under extreme load conditions, e-Motor windings generate heat, reducing efficiency. Similarly, inverters produce heat during power conversion, suffering power losses and potential damage at high temperatures.
An effective cooling system is therefore essential not only for EV battery packs but also for the e-Drive system. A well-designed cooling strategy ensures efficient operation, improves overall vehicle performance, and extends the lifetime of electrical components. Additionally, e-Motor sizing and vehicle weight optimization depend on the cooling capability, which directly impacts energy efficiency.
This paper investigates the design of a highly efficient e-Drive system featuring a fully integrated liquid cooling system and advanced cybersecurity features using a Plug-and-Play approach. The Gearbox Motor Generator (GMG) is mounted directly to the reducer, maximizing powertrain efficiency and optimizing NVH performance.
The cooling control system is embedded within the inverter, managing the liquid coolant flow based on data from seven temperature sensors located on the e-Motor, inverter, and heatsink. The system uses a water-glycol mixture, which provides superior continuous torque compared to oil- and air-cooled systems. The cooling box, consisting of a heatsink and pump, is connected in series to the inverter and e-Motor.
To reduce costs, the design reuses benchmarked components such as the PMSM machine, inverter, reducer, heatsink, and water pumps. 1-D simulation in Modelon confirmed that the cooling system effectively compensates for e-Drive thermal losses of 1000 W at 40°C ambient temperature and 1.5 m/s air mass flow during the WMTC2 driving cycle.
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