This paper proposes an integrated thermal management framework for battery electric vehicle (BEV) propulsion systems, combining five coordinated strategies into a unified control architecture. The approach includes thermal Model Predictive Control (TMPC), residual heat recovery from the motor and inverter, variable-speed actuation of the pump–fan–chiller, a “battery-first” thermal distribution logic, and HVAC-assisted thermal preconditioning. A coupled electro-thermal RC network model is developed for a liquid-cooled PMSM traction motor, automotive inverter, NCM battery pack, and cooling circuit, with thermal limits and derating laws aligned to OEM practice. Dynamic simulations on the WLTP Class 3b cycle are performed for four ambient temperatures (-10, 0, 25, 40 degrees C), capturing transient temperatures, temperature-dependent losses, heat flows, and auxiliary energy demand. Results show that all components remain well below their thermal limits, with no derating activation. The analysis demonstrates that range degradation in non-nominal climates is driven primarily by HVAC energy demand and battery charge-acceptance limitations, while propulsion losses remain nearly insensitive to ambient temperature. The proposed framework highlights the central role of intelligent, integrated thermal management in maximizing efficiency, safety, and real-world BEV range.
LUPU et al. (Thu,) studied this question.