EV Thermal Management System for Battery Electric Mining Trucks
For battery electric mining trucks, it’s critical to maintain the traction battery within an optimal temperature range to ensure both performance and safety. Given the high charge and discharge currents typical of mining operations, the EV thermal management system adopts a liquid cooling technology with superior heat dissipation efficiency.
How Does the EV Thermal Management System for Battery Electric Mining Trucks Work?
The EV thermal management system for battery electric mining trucks works by actively heating or cooling the coolant to keep the battery operating between 25°C and 35°C, which is considered the ideal thermal range for lithium battery performance. The system is also capable of maintaining the temperature difference between individual cells within 5°C, ensuring consistent operation and extending overall battery lifespan.
Operating Principle
The heat exchanger inside the EV thermal management system features two flow channels: one channel circulates coolant, the other circulates refrigerant.
These channels are alternately arranged:odd-numbered layers carry coolant, while even-numbered layers carry refrigerant. Heat is exchanged between the two media, reducing the temperature of the coolant before it is circulated into the battery pack to absorb and dissipate heat from the cells.
In cold environments, a PTC heater is activated to warm the coolant, which in turn heats the battery, ensuring safe operation and charging efficiency at low ambient temperatures.
Our Integrated EV Thermal Management System for Battery Electric Mining Trucks
Our integrated EV thermal management system for battery electric mining trucks is designed to address the following key challenges:
- Cabin climate control
- Maintain a comfortable temperature and airflow for the driver.
- Defrost and defog the windshield for clear visibility.
- Control cabin humidity and air outlet temperature to ensure a clear driving view.
- Battery temperature regulation
- Prevent extreme temperatures from affecting charging/discharging rates and battery lifespan.
- Motor cooling
- Maintain optimal coolant temperature for efficient motor operation.
- Limited space constraints
- Electric commercial vehicles require additional battery cooling, but lack waste heat from an engine.
- Complex vehicle layout with multiple components.
Solution Introduction
The integrated EV thermal management solution is engineered to manage both cabin and e-powertrain temperature needs. By sharing core components such as the condensers module and compressor module, the system supports both air conditioning and equipment cooling/heating, ensuring stable and efficient vehicle operation.
Solution Advantages
- High Efficiency & Energy Saving: Features variable-speed compressor, smart fan control, and motor waste heat recovery to minimize energy consumption.
- Reliable and Safe: Equipped with multiple layers of protection for pressure, temperature, current, and voltage to ensure system safety.
- Intelligent Control: Supports CAN bus vehicle communication, human-machine interface (HMI), and real-time display of temperature and airflow conditions.
- Highly Integrated Design: Combines heating and cooling modules into a single compact unit, with shared use of PTC heaters, fans, and other components to reduce footprint and simplify vehicle layout.
- Discover our BTMS Solutions here: https://brogenevsolution.com/battery-thermal-management-system-btms/
About Brogen
At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape.
Currently, our EV solutions for battery electric heavy trucks have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more.
- Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/
- Looking for an EV solution for your project? Reach out to us at contact@brogenevsolution.com
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