Thermal management system for electric vehicles: benchmarking analysis, energy consumption strategies and future-oriented developments

The increasing adoption of Battery Electric Vehicles (BEVs) has highlighted the crucial role of Thermal Management Systems (TMS) in optimizing energy efficiency, performance, and component longevity. This thesis explores the impact of TMS on BEV performance, analyzing different cooling and heating strategies, energy consumption patterns, and future-oriented developments through a comprehensive benchmarking and simulation approach. The study employs a virtual testing methodology using Siemens Amesim to model and simulate a BEV thermal management system. By evaluating real-world data from highperformance electric vehicles, particularly the Porsche Taycan Turbo S, the research investigates various energy optimization techniques under different driving conditions. A detailed analysis of heat dissipation in lithium-ion batteries, electric motor cooling mechanisms, and HVAC efficiency provides insights into how thermal dynamics influence overall vehicle performance. The simulation results reveal how ambient temperature and driving cycles significantly affect energy consumption, with extreme climates leading to increased power demand for heating and cooling systems. The analysis highlights the effectiveness of integrated cooling circuits, heat recovery strategies, and predictive thermal management in improving vehicle efficiency. Additionally, the comparison between virtual models and real-world benchmarking data validates the accuracy of the proposed simulation framework while identifying areas for further refinement, particularly in auxiliary power consumption modeling. Findings from this study emphasize that a well-designed TMS can enhance driving range, reduce energy losses, and extend the lifespan of critical vehicle components. By implementing advanced control strategies and innovative cooling solutions, manufacturers can optimize energy distribution, ensuring BEVs operate efficiently under various climatic conditions.