Program Overview

Description:
This program focuses on the thermal behaviour of key electric vehicle subsystems and the engineering techniques used to manage temperature under varying operating conditions. Participants will explore thermal fundamentals, cooling technologies, heat exchanger design, thermal monitoring systems, and safety mechanisms that ensure optimal operation of batteries, motors, and power electronics throughout the vehicle lifecycle.

Key Topics Include:

Heat Generation in EV Systems: Understanding heat generation in battery packs, traction motors, chargers, charging ports, and power converters, along with the impact of temperature on performance, efficiency, and safety.
Battery Thermal Management: Analysis of internal resistance losses, cell balancing effects, thermal runaway phenomena, battery chemistry behaviour, and strategies for maintaining safe battery operating temperatures.
Motor Thermal Management: Exploring motor losses, heat dissipation requirements, thermal effects on magnetic performance, and cooling considerations for induction, permanent magnet, and switched reluctance motors.
Thermodynamics & Heat Transfer Fundamentals: Understanding heat transfer mechanisms, energy balance principles, thermodynamic laws, thermal properties of materials, and their applications in EV cooling system design.
Passive & Active Cooling Technologies: Introduction to air-cooled and liquid-cooled systems, heat exchangers, radiators, heat pipes, phase change materials, coolant selection, and thermal system sizing methodologies.
Cooling System Design & Controls: Development of cooling strategies, thermal control logic, system activation and deactivation, redundancy planning, hysteresis control, and performance optimisation.
Thermal Monitoring & Protection Systems: Thermal sensing, battery and motor load management, charger thermal protection, thermal event detection, warning systems, and operational safety controls.
Safety & Fire Protection: Thermal safety systems, pressure relief mechanisms, fire prevention strategies, battery fire management, and the selection and application of appropriate fire suppression methods.

This program equips learners with the knowledge required to design, analyse, and manage thermal systems that enhance the performance, reliability, efficiency, and safety of modern electric vehicles.

Skills You Will Gain

Battery Thermal Management

Motor Cooling Systems

Heat Transfer & Thermodynamics

Cooling System Design

Thermal Safety & Protection

EV Thermal System Integration

Program Curriculum

Course 01: Need of Thermal Management in Electric Vehicles

Module 01 - Heat generation in EV batteries - internal resistance, cell balancing, DC bus losses, thermal runaway, Li-Ion sub-chemistry thermal runaway temperature

Module 02 - Heat generation in Motors - various motor losses - copper losses, iron losses, frictional losses, brake resistor for regenerative braking, etc., heat production and impact on magnetic flux, impact on motor performance for various traction motor technologies - induction motors, permanent magnet motors, and switch reluctance motors

Module 03 - Heat generation in chargers, charging ports and power converters

Course 02: Basics of Thermal Management

Module 01 - Definition of heat, temperature, temperature scales, modes of heat transfer - conduction, convection & radiation, definition of thermal equilibrium and Zeroth law, First Law of Thermodynamics- concepts of internal energy, specific heat

Module 02 - capacities & enthalpy.

Module 03 - Energy balance for closed and open systems, energy balance for steady & unsteady flow systems.

Module 04 - Thermodynamic properties of pure substances in solid, liquid and vapour phases and phase rule

Course 03: Passive and Active Cooling Systems

Module 01 - Introduction to passive and active cooling, considerations for selection and sizing of cooling systems.

Module 02 - Types of heat exchangers - fins, radiators, heat tubes, phase change material, etc.

Module 03 - Analysis and design of heat exchangers applying specific cooling requirements of electric vehicles battery packs, motors, and power converters.

Module 04 - Coolant properties and specifications, coolant ageing and replacement

Module 05 - Design of cooling system control, activation & deactivation, hysteresis, redundancies.

Course 04: Other Thermal Management Methods in Electric Vehicles

Module 01 - Thermal monitoring systems, progressive battery load management systems & thermal cut-offs, motor load management systems, switching between peak and continuous power operations, charger thermal management & current throttling, thermal event detection, warning and control.

Module 02 - Design of air vents and ducts and their impact on vehicle aerodynamics

Module 03 - Safety systems: Breathers and pressure release valves, fire retardants and their use

Module 04 - Fire Extinguishing Methods: Dealing with electrical fires, dealing with battery fires, classes of extinguishers and their applicability.

Program Instructor

Mr. Vikrant Vaidya
24+ years’ experience in global automotive design and product development on multiple EVs and Hybrid vehicle platforms, specialising in model-based design, calibration, testing, and system integration; a Six-Sigma Green Belt with 3 inventions in battery & hybrid electric vehicles. He earned his Master's degree in Energy Systems Engineering from the University of Michigan and his Bachelor's in Mechanical Engineering from Nagpur University.

EV Thermal Management: Batteries & Motors

Program Overview

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