This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

The automotive industry's shift from internal combustion engines to electric vehicles (EVs) constitutes a critical move toward addressing environmental concerns and enhancing energy sustainability. This transition necessitates significant advancements in thermal management systems for EV drivetrains, especially under high-speed operational conditions. The substantial heat generated by electric motors and their mechanical components, such as gearboxes, demands sophisticated cooling strategies to ensure both efficiency and reliability. This paper presents a comprehensive investigation into the thermal management of EV drivetrains, utilizing an integrated approach that combines Computational Fluid Dynamics (CFD) and Multibody Dynamics (MBD). This dual-methodology enables an in-depth analysis of heat flow and fluid dynamics, while simultaneously considering the mechanical interactions that impact the thermal characteristics of the drivetrain. CFD serves to provide detailed insights into thermal distribution and flow patterns, identifying critical bottlenecks in heat dissipation. In contrast, MBD captures the dynamic mechanical behaviors, offering a holistic understanding of the system'™s overall thermal performance. Our research identifies key areas where cooling system designs can be optimized, focusing on improving heat dissipation efficiency to either maintain or enhance the drivetrain performance. By thoroughly evaluating both the electric motor and related mechanical systems, this study contributes substantially to the development of innovative and efficient thermal management solutions that are crucial for advancing EV technologies. The findings indicate considerable potential for improvements in cooling performance, emphasizing strategic approaches for optimizing thermal management while ensuring the drivetrain remains efficient. These developments are vital for supporting the efficient transition to electric mobility, providing sustainable, high-performance vehicle solutions that align with global environmental goals. In conclusion, the integration of CFD and MBD analyses in evaluating EV drivetrain cooling performance represents a significant advancement in sustainable automotive technology development. This research supports environmentally conscious transportation initiatives and addresses current technical challenges while laying a robust groundwork for future innovations in the EV industry. By doing so, it aligns with global efforts to promote sustainable and efficient transportation solutions.