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Applied Energy
Article . 2025 . Peer-reviewed
License: CC BY NC ND
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image/svg+xml art designer at PLoS, modified by Wikipedia users Nina, Beao, JakobVoss, and AnonMoos Open Access logo, converted into svg, designed by PLoS. This version with transparent background. http://commons.wikimedia.org/wiki/File:Open_Access_logo_PLoS_white.svg art designer at PLoS, modified by Wikipedia users Nina, Beao, JakobVoss, and AnonMoos http://www.plos.org/
https://dx.doi.org/10.48550/ar...
Article . 2023
License: CC BY NC ND
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Concurrent design optimization of powertrain component modules in a family of electric vehicles

Authors: Maurizio Clemente; Mauro Salazar; Theo Hofman;

Concurrent design optimization of powertrain component modules in a family of electric vehicles

Abstract

We present a modeling and optimization framework to design powertrains for a family of electric vehicles, focusing on the concurrent sizing of their motors and batteries. Whilst tailoring these component modules to each individual vehicle type can minimize energy consumption, it can result in high production costs due to the variety of component modules to be realized for the family of vehicles, driving the Total Costs of Ownership (TCO) high. Against this backdrop, we explore modularity and standardization strategies whereby we jointly design unique motor and battery modules to be installed in all the vehicles in the family, using a different number of these modules when needed. Such an approach results in higher production volumes of the same component module, entailing significantly lower manufacturing costs due to Economy-of-Scale (EoS) effects, and hence a potentially lower TCO for the family of vehicles. To solve the resulting one-size-fits-all problem, we instantiate a nested framework consisting of an inner convex optimization routine which jointly optimizes the modules' sizes and the powertrain operation of the entire family, for given driving cycles and modules' multiplicities. Likewise, we devise an outer loop comparing each configuration to identify the minimum-TCO solution with global optimality guarantees. Finally, we showcase our framework on a case study for the Tesla vehicle family in a benchmark design problem, considering the Model S, Model 3, Model X, and Model Y. Our results show that, compared to an individually tailored design, the application of our concurrent design optimization framework achieves a significant reduction of the production costs for a minimal increase in operational costs, ultimately lowering the family TCO in the benchmark design problem by 3.5\%.

17 pages, 17 figures, 7 tables

Keywords

Optimization and Control (math.OC), FOS: Mathematics, FOS: Electrical engineering, electronic engineering, information engineering, Systems and Control (eess.SY), Mathematics - Optimization and Control, Electrical Engineering and Systems Science - Systems and Control

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citations
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
0
Average
Average
Average
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