Abstract

Thermal management (TM) is a critical challenge in developing efficient, compact, and reliable electrified products in the automotive industry and beyond. TM encompasses strategies and technologies that maintain optimal operating temperatures for system components, ensuring safety and efficiency. This study explores TM in electrified products, focusing on the integration of hydraulic units, electric motors, and electronics, and the importance of system-level design from the pre-design phase.

Advances in modelling and simulation have transformed TM approaches, evolving from 1D analytical models to sophisticated 3D thermo-fluid dynamic simulations. Modern methods enable the creation of complex models with high-resolution thermal analysis, ensuring accurate predictions of temperature distributions and heat dissipation paths. These simulations, which use methods like conjugated heat transfer and coupled heat transfer, provide essential insights for verifying and improving designs.

The TM process involves multidisciplinary collaboration across fluid dynamics, mechanical analysis, and electronics to iterate thermal verification loops. Beyond technical considerations, TM reflects a cultural shift toward system-level thinking and interdepartmental synergy, driving faster time-to-market, cost efficiency, and enhanced product reliability.