New components and systems for thermal management of electrical vehicles

The Next-TMS project will develop innovative components and systems for the thermal management (TM) of electric vehicles (EVs), both battery EVs and fuel cell EVs. Furthermore, the project will establish an R&D based framework for such developments. The role of the thermal management system is to ensure that the battery, power electronics, motors, transmissions etc have the right temperature during charging and driving. Li-ion batteries is the state-of-the-art energy storage for EVs. For such batteries, temperature control is a key factor for the performance (charging rate, driving range), lifetime and security. The project is aimed at commercial electrical vehicles (trucks and buses). Project owner Kongsberg Automotive has established a new business area for automotive TM systems, and is developing a new product portfolio for this market. The project will demonstrate new concepts for flow control (dynamic flow restrictors) with lower cost and weight compared to conventional valves. The project will also develop new R&D methodologies, and new material and manufacturing solutions with improved sustainability. There is a need for research on topics such as materials science, sustainability, and "multiphysics" (for improved understanding and simulation of flow, heat transfer and mechanical behaviour). The R&D framework established in this project will contribute to products with optimised flow (lower pressure drop), better thermal and mechanical performance, and long and predictable lifetime (e.g. compatibility with coolants). Another objective is to develop simpler and more serviceable systems with fewer parts by smart integration and system control. Last, but not least, sustainability is an important aspect of the project. The project will assess the sustainability of material alternatives including recycled materials, and pave the way for components and systems with low weight and low energy usage.

The project will develop innovative components and systems for the thermal management (TM) of of electric vehicles (EVs), and establish an R&D based framework for such developments. The project is mainly aimed at commercial vehicles (trucks, buses etc), and battery EVs, but it is also relevant for fuel cell EVs. Li-ion batteries is the state-of-the-art energy storage for EVs. For such batteries, temperature control is a key factor for the performance (charging rate, driving range) and lifetime. The TM system also has an important role in hindering fire due to thermal runaway in battery cells. Project owner Kongsberg Automotive has established a new business area for this market, and is developing a new product portfolio which will include components such as couplings, pipes, valves and restrictors, as well as control units, sensorics, power electronics and integrated thermal management systems. The project will demonstrate new dynamic flow restrictor concepts with lower cost and weight compared to conventional valves. The project will also develop new R&D methodologies, and new material and manufacturing solutions with improved sustainability. There is a need for research on materials science, solid state mechanics, circular economy, simulation of flow and heat transfer, instrumentation and sensorics. The R&D framework established in this project will be used to develop products with following characteristics: - Better flow, thermal and mechanical performance (including fire safety) via optimal material combinations and part designs optimised by numerical simulations - Simpler and more serviceable systems with fewer parts by smart integration and system control - Improved sustainability by material selection and the use of recycled materials - Reduced cost, weight and volume via material selection, product design and manufacturing methods. Reduced energy consumption, e.g. via flow-optimised couplings and valves, and optimised thermal insulation.