The automotive industry is racing toward a future defined by electrification, hydrogen power, and smarter engineering. With these advancements come new challenges—particularly in thermal management. As powertrains evolve, so do their cooling requirements. This article examines the critical differences in cooling systems for Fuel Cell Electric Vehicles (FCEVs), Battery Electric Vehicles (BEVs), and Internal Combustion Engines (ICEs), and explores how precision engineering is shaping the future of automotive reliability.
Understanding the Different Powertrains
The automotive industry’s shift toward electrification and alternative fuels has reshaped how we classify powertrains. While “EV” once broadly described any electric vehicle, advancements in hydrogen technology and hybrid systems now demand precise terminology. Let’s define the three primary powertrain types:
- FCEVs (Fuel Cell Electric Vehicles):
Often labeled as “hydrogen-powered cars,” FCEVs use fuel cells to generate electricity for the battery and motor. By eliminating sparking mechanisms—an important safety feature given hydrogen’s flammability—FCEVs achieve improved efficiency compared to ICE vehicles. However, maintaining optimal operating temperatures for the fuel cell system is crucial for both efficiency and durability, presenting unique thermal management challenges. - BEVs (Battery Electric Vehicles):
Renamed from the traditional “EVs” to reflect their unique energy storage and recharging requirements, BEVs operate solely on energy stored in rechargeable battery packs, requiring external charging sources like home outlets or dedicated stations. With efficiencies exceeding 75%, they generally produce less waste heat than ICE vehicles. Nevertheless, their batteries, like any high-energy device, generate significant heat underload. This necessitates compact yet robust cooling systems designed to protect battery integrity and performance. - ICEs (Internal Combustion Engines):
In ICE vehicles, a significant portion of engine energy—up to one-third—is lost as heat, with operating temperatures typically reaching around 120°C (248°F). Cooling systems in these vehicles must balance the need to maintain high engine performance with effective thermal safety measures.
Each powertrain not only defines how a vehicle is powered but also dictates its cooling strategy, making it critical to tailor thermal management systems to the specific challenges of each technology.
The Technical Challenges of Thermal Management
Every propulsion system dissipates energy as heat, but the approach to managing that heat varies:
- FCEVs:FCEVs require cooling systems that are two to three times larger than those in ICE vehicles. This is due to two key factors:
Heat Dissipation Pathways: Unlike ICEs, where a portion of the waste energy is removed via the exhaust, nearly all the energy in an FCEV must be managed by the cooling system.
Radiator Design and Operating Temperature: Radiators operate based on the equation
Q = w · Cp · ΔT
where Q is the cooling power, w is the airflow, Cp is the specific heat capacity of the fluid, and ΔT is the temperature difference between the system and ambient conditions. With FCEVs operating at a lower ΔT compared to ICEs, engineers must compensate with increased airflow or larger radiators, challenges that are compounded on vehicle weight and aerodynamic considerations. - BEVs:
Despite their higher overall efficiency, BEVs still produce considerable heat in their batteries. Their cooling systems are typically smaller and designed to rapidly dissipate heat to protect battery performance, operating at lower maximum temperatures (around 80°C or 176°F). - ICE Vehicles:
With roughly one-third of the energy input lost as heat and another third expelled through the exhaust, ICE vehicles rely on radiators that maintain high operating temperatures while efficiently removing excess heat.
Across all powertrain types, engineers are exploring new materials, digital thermal management systems, adaptive airflow controls, and novel coolant formulations to improve efficiency at higher operating temperatures. These advances are essential for optimizing performance and reliability in next-generation vehicles.
Bridging the Gap Between Cooling Challenges and Advanced Temperature Control
As automotive propulsion systems continue to evolve, accurately replicating real-world thermal environments is becoming increasingly critical. Engineers now require testing systems that not only simulate actual operating conditions but also account for the distinct cooling challenges presented by each technology from the oversized radiators required for FCEVs due to lower ΔT values, to the rapid heat dissipation demands of BEV batteries, and the high temperatures of ICE exhaust systems.
Drawing on decades of experience in automotive testing, LAUDA’s temperature control solutions are designed to meet these rigorous demands. Whether it’s UL 2267-compliant leak testing or high-temperature SOFC validation, our wide product range supports the development of innovative cooling strategies across ICE, BEV, and FCEV platforms.
We provide advanced temperature control solutions tailored to these challenges. Our INTEGRAL Process Thermostats ensure components withstand extreme temperature fluctuations, crucial for validating BEV battery resilience during fast charging and cold-weather operation. Additionally, the LAUDA MID 80 flow control unit, featuring a contactless magnetic inductive flow meter, enables precise flow-rate control even under fluctuating viscosities or pressures—an essential capability for maintaining stable coolant flow in FCEVs’ larger radiators.
Innovation thrives where precision meets performance. Let LAUDA power your next leap forward.
Contact us today to explore how our solutions can support your automotive projects—one precisely controlled degree at a time.
This post was authored by Justin Caruso, Inside Sales Manager at LAUDA-Brinkmann.