Thermal Management Systems

New Driving Technologies Require an Advanced Heating and Cooling Strategy

Range anxiety is currently the main barrier to battery electric vehicles (BEV) ownership and operation. The driving range of a BEV is severely affected by limited battery capacity and the significant energy demand to run the heating and cooling system. A battery-powered electric bus, for example, uses up to 50% of its energy to provide appropriate heating/cooling to passengers, the traction battery as well as so called Power Electronics and Electric Motor systems (PEEM).

Webasto's goal is to accelerate the electrification of the commercial vehicles industry: We provide highly efficient heating and cooling solutions which positively impact a vehicle's availability, ensure overall TCO reductions and guarantee an increase in the driving range.

Plug & Play Battery Thermal Management

Our stand-alone Battery Thermal Management Unit ensures optimal functioning of the water-cooled battery packs used in electrical commercial vehicles. Furthermore, it also ensures ideal battery cell performance over the long term.

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Complete Thermal Management System

Webasto's unique holistic system approach: New technologies and components are integrated to guarantee consistent and optimum temperatures for the passengers, traction batteries, powertrain and power electronics of electric vehicles.

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Six Reasons Why EVs Need Efficient Thermal Management

Lack of Residue Heat

Electrical vehicles do not generate the abundant engine waste heat that is typically available in traditional vehicles. Therefore, EVs suffer from significant range loss when heating the cabin in cold weather conditions.

Reduced Electric Range while Heating

PTC resistance heaters decrease electrical range. Battery energy is basically “wasted” in order to warm up the cabin via electrical resistance heating. This results in range reductions of up to 50% under cold ambient conditions.

Poor Battery Performance When Cold

An adequate discharge power cannot be achieved during cold conditions.

Battery Damage When Hot

The optimal operational temperature range for battery packs is between 15°C and 35°C. Battery cells experience chemical degradation during hot ambient conditions or due to overheating.

PEEM Systems Overheating

Power Electronics and Electric Motor systems (PEEM) require additional cooling to remain below their maximum operating temperature limits of 125°C to prevent thermal damage or failure.

Additional Weight

There is no question that a lot of electrical vehicle components need to be cooled down in order to operate properly. Current manufacturers tend to set up an individual cooling circuit for each HVAC, traction battery and PEEM system – and this adds a lot of undesirable weight.

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